xpsmcwin configuration software for xpsmc€¦ · · 2010-12-03document scope this manual...

3300

3281

.03

XPSMCWINConfiguration Software for XPSMC11/2007

Table of Contents

Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

About the Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Chapter 1 System Requirements and Software Installation . . . . . . . . . .11At a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11System Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Chapter 2 XPSMCWIN User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15At a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Window Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Elements of a Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Chapter 3 Menu Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19At a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Edit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Help. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Chapter 4 Device Library . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31At a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4.1 Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33At a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Creating a Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Setting the Safety Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Connecting a Device to a Safety Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Modifying the Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

3

4.2 Monitoring Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51At a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Overview of all Control Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Safety Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Light Curtains (Electro Sensitive Protective Equipment (ESPE)) of Category 4 without Muting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Light Curtain with Muting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Magnetic Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Two-Hand Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Safety Mat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Zero Speed Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Injection Molding Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76Hydraulic Press Valve Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Hydraulic Press 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Eccentric Press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84Eccentric Press 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88Shaft/Chain Break Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94Seat Valve Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

4.3 EDM Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97EDM Device (External Device Monitoring). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

4.4 Start Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98Start Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

4.5 Enabling Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100Two-Channel or Three-Channel Enabling Device . . . . . . . . . . . . . . . . . . . . . . . 100

4.6 Miscellaneous Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103At a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104OR Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106Foot Switch Control Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109Closed Tool Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

4.7 State of Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113Applying Output States to Other Safety Outputs . . . . . . . . . . . . . . . . . . . . . . . . 113

4

Chapter 5 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115At a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

5.1 General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117Generals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

5.2 Application Scheme Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119At a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119Creating a New Configuration / Selecting a Controller Type. . . . . . . . . . . . . . . 120Assigning the Switch Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124Assigning the Protective Guard Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125Assigning the Starting Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126Assigning the Enabling Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127EDM Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128Assign a Name and a Stop Category to a Safety Output . . . . . . . . . . . . . . . . . 129Copying the State of One Safety Output onto another Safety Output. . . . . . . . 130

5.3 Configuring the Emergency Stop Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131At a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132Master E-Stop Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

5.4 Save the Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137Save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

5.5 Requesting/Changing the Password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139Password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

5.6 Sending a Configuration from the PC to the XPSMC and Performing a Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141Sending a Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

5.7 Loading a Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

5.8 Creation/Transfer of a Validated Configuration Copy . . . . . . . . . . . . . . . . . . . . 151At a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151Copy/Saving of a Validated Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152Transfer of a Validated Configuration Copy . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

5.9 Read Protocol from Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155Read Protocol from Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Chapter 6 Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157XPSMC Safety Controller Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

5

Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161At a glance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Appendix A Wiring (Examples) and Functional Diagrams . . . . . . . . . . . . 163At a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163Electrical Diagram for the XPSMC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165Three One-Channel Emergency Stops, with Automatic Start . . . . . . . . . . . . . . 167Two Two-Channel Emergency Stop, with Start Button . . . . . . . . . . . . . . . . . . . 169Safety Guard with One Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171Two Channel Safety Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174Two Channels Safety Guard with Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178Light Curtain with Relay Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182Light Curtain with Transistor Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186Muting for Light Curtains Type 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190Magnetic Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192Two-Hand Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196Safety Mat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198Zero Speed Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200Injection Molding Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204Hydraulic Press Valve Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207Hydraulic Press 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209Eccentric Press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215Eccentric Press 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226Shaft/Chain-Break Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229Seat Valve Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231Enabling Device 2 Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233Enabling Device 3 Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235Foot Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

6

§
Safety Information
Important Information

NOTICE Read these instructions carefully, and look at the equipment to become familiar with the device before trying to install, operate, or maintain it. The following special messages may appear throughout this documentation or on the equipment to warn of potential hazards or to call attention to information that clarifies or simplifies a procedure.

The addition of this symbol to a Danger or Warning safety label indicatesthat an electrical hazard exists, which will result in personal injury if theinstructions are not followed.

This is the safety alert symbol. It is used to alert you to potential personalinjury hazards. Obey all safety messages that follow this symbol to avoidpossible injury or death.

DANGER indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury.

DANGER

WARNING indicates a potentially hazardous situation, which, if not avoided, can result in death, serious injury, or equipment damage.

WARNING

CAUTION indicates a potentially hazardous situation, which, if not avoided, can result in injury or equipment damage.

CAUTION

33003281 7

Safety Information

PLEASE NOTE Electrical equipment should be installed, operated, serviced, and maintained only by qualified personnel. No responsibility is assumed by Schneider Electric for any consequences arising out of the use of this material.

© 2006 Schneider Electric. All Rights Reserved.

8 33003281

About the Book

At a Glance

Document Scope This manual contains the XPSMCWIN software description.

This program allows you to start, set up and diagnose the XPSMC safety controller from a PC.

The simple user interface lets you set up the XPSMC for a multitude of applications for the protection of hazardous areas near mechanical machines.

The XPSMCWIN software is used for the installation, documentation and fault diagnostics of your safety application.

Validity Note Eight versions of the safety controller are available:

Type Characteristics

XPSMC16Z 8 control outputs and 16 safety inputs6 safety transistor outputs2 x 2 safety relay outputsadd-in functionsModbus (RTU) communication and configuration port

XPSMC16ZP 8 control outputs and 16 safety inputs6 safety transistor outputs2 x 2 safety relay outputsadd-in functionsProfibus DP communication portModbus (RTU) communication and configuration port

XPSMC16ZC 8 control outputs and 16 safety inputs6 safety transistor outputs2 x 2 safety relay outputsadd-in functionsCANopen communication portModbus (RTU) communication and configuration port

33003281 9

About the Book

This documentation is valid for XPSMCWIN under Microsoft Windows 2000/XP.

Related Documents

You can download these technical publications and other technical information from our website at www.telemecanique.com

User Comments We welcome your comments about this document. You can reach us by e-mail at [email protected]

XPSMC16X 8 control outputs and 16 safety inputs6 safety transistor outputs2 x 2 safety relay outputsModbus (RTU) communication and configuration port

XPSMC32Z 8 control outputs and 32 safety inputs6 safety transistor outputs2 x 2 safety relay outputsadd-in functionsModbus (RTU) communication and configuration port

XPSMC32ZP 8 control outputs and 32 safety inputs6 safety transistor outputs2 x 2 safety relay outputsadd-in functionsProfibus DP communication portModbus (RTU) communication and configuration port

XPSMC32ZC 8 control outputs and 32 safety inputs6 safety transistor outputs2 x 2 safety relay outputsadd-in functionsCANopen communication portModbus (RTU) communication and configuration port

XPSMC32X 8 control outputs for 32 safety inputs6 safety transistor outputs2 x 2 safety relay outputsModbus (RTU) communication and configuration port

Type Characteristics

Title of Documentation Reference Number

XPSMC - Hardware Manual 33003275

10 33003281

33003281

1
System Requirements and Software Installation
At a Glance

Overview This chapter contains the system requirements for the software and hardware.

What's in this Chapter?

This chapter contains the following topics:

Topic Page

System Requirements 12

Installation 14

11


System Requirements

Hardware The following is required for configuring the XPSMC safety controller:� XPSMC safety controller� PC with the following capabilities at least

� Pentium® processor, or equivalent� CD-ROM drive for the installation� mouse� free RS232 serial port with a 9-pin subD connector or USB-Port� 20 MB free hard disk space

� display: 800 x 600, 256 colors (1024 x 768 recommended)� configuration cable

� serialXPSMCCPC adaptorTSXPCX1031 serial adaptor

or� USB

standard (1:1) RJ45/RJ45 twisted pair Category 5D Ethernet cable Ref: 490NTW00002TSXCUSB485 USB adaptor

Connection between the PC and the XPSMC Safety Controller

To set up and diagnose the XPSMC for faults with the XPSMCWIN software, you must establish either

� a serial connection from the PC to the XPSMC safety controller.The following 2 cabling components are required to set up the connection� XPSMCCPC adaptor� TSXPCX1031 serial adaptoror

� an USB connection from the PC to the XPSMC safety controller.The following 2 cabling components are required to set up the connection� Standard (1:1) RJ45/RJ45 twisted pair Category 5D Ethernet cable Ref:

490NTW00002� TSXCUSB485 USB adaptor

Software The following are system requirements for the XPSMCWIN software:� Operating system: Microsoft® Windows 2000/XP®

12 33003281


Installing the USB Driver for the TSXCUSB485 Cable

The following table describes steps to install the USB driver for the TSXCUSB485 cable:

Step Action

1 Download the driver from the Web site http://www.telemecanique.com and search for USB Driver.Note: Additionally, the driver pack can be found on the Safety Suite V2 installation CD, within the ...XPSMC Safety Controller\XPSMC Drivers for cable folder.

2 Double click on ...Driver Pack V2.3.

3 Run the Communication_Drivers_Pack_V23.exe.file.

4 Plug in the cable.

5 Select Look for an adequate driver.

6 Select Other sources.

7 Select the location of the driver on the hard disk.

8 The driver is installed.

33003281 13


Installation

Installation Procedure

To install the XPSMCWIN software, you need the installation CD-ROM (included). If your PC does not have a CD-ROM drive, you can also copy the installation files on floppy disks and perform the installation. Proceed as follows:

Step Action

1 Insert the CD with the current version of the Safety Suite (included) into the drive. Follow the installation wizard instructions to install the software.

2 In case installation does not start automatically, run the setup.exe file in the CD-ROM default directory, for example:D:\setup.exe (if D: is the letter corresponding to your CD-ROM drive).

3 The program is ready to be started for the first time

14 33003281

33003281

2
XPSMCWIN User Interface
At a Glance

Overview This chapter contains the description of the software user interface.



Topic Page

Window Types 16

Elements of a Window 18

15


Window Types

Introduction Typical XPSMCWIN user interface window

The items 1 to 5 have the following meanings:

Item Meaning

1 Menu bar

2 Tool bar

3 Device library window

4 Configuration window

5 Status bar

File Edit Mode Check Controller Options Help

XPSMCWIN

Device Library: Configuration:

i i

Configuration Mode Configuration changed. Com1

Configuration

C1 (XPSMC16 X): ’Controller1’i16

o1

o2

o3

o4

o5

o6

R1

R2

Telemecanique

Inputs: left: 16 I Load: 0 %

i

16

XPSMC16 ZC - CANopen Extension

EDM Devices

Start Devices

Miscellaneous Devices

Enabling Devices

Controller

State of Outputs

XPSMC16 Z

XPSMC16 ZP - Profibus Extension

XPSMC16 X

XPSMC32 Z32

XPSMC32 ZC - CANopen Extension32

XPSMC32 ZP - Profibus Extension32

XPSMC32 X32

16

16

16

Monitoring Devices

1

5

3 42

i

i

i

i

i

i

i

i

16 33003281


Device Library Window

This window contains the eight possible types of controllers (XPSMC16Z, XPSMC16ZC, XPSMC16ZP, XPSMC16X, XPSMC32Z, XPSMC32ZC, XPSMC32ZP, and XPSMC32X) and the library of all devices available.

A device is copied from this library into the Configuration window by pressing and holding down the left mouse button and simultaneously dragging the mouse.

Configuration Window

This is the working window in XPSMCWIN. The configuration is defined and modified in this window.

All devices are configured by the following similar procedure.

If a device is moved in the Configuration window, a window appears in which the parameters of this device are selected. On the subject of these parameters, reference should also be made to chapter Device Library, p. 31.

The following commands can also be called by clicking the right mouse button on the symbol in the Configuration window:

Note: If this window does not open automatically, this means that this device is not active in the Options editor menu option. In this case, open the window by clicking with the right mouse button on the symbol and selecting the Properties option.

Command Description

Properties Open the Properties window of the selected device.

Copy Using this command, a device can be copied with the properties assigned to it and pasted elsewhere in the configuration tree.

Cut Cut the selected device.

Paste Paste a copied or cut device as a copy or as a new device into the selected location.

Delete Delete the selected object.

Delete incl. copies Delete the selected object and its copies.

Mark copies Mark all the copies of the selected device.

Unmark copies Clear all the copies of the selected device.

Expand all Expand the entire configuration tree.

Expand controller Expand the selected controller tree (only visible when more than one controller are in the current configuration).

Collapse all Collapse the entire configuration tree. Only controller will be shown.

33003281 17


Elements of a Window

Menu Bar The menu bar contains all the commands of the XPSMCWIN software as shown in the structure overview below.

Menu bar for Configuration mode

Menu bar for Configuration mode (continued)

Menu bar for Diagnostics mode

File

New

Open...

Save

Print Tree

as you see it

all nodes expanded

Exit

Edit

Undo

Redo

Copy

Paste

Delete

Mode

Configuration

Diagnostics

Check

CheckConfiguration

Save As... Cut

Controller

Stop Controller

Run Controller

Change Password

Download Configuration to Controller

Upload Configuration from Controller

Get Validated Copy from Controller

Transfer Validated Copy to Controller

Read Validation

Read Protocol from Controller

Controller Setup (Bus Configuration)

Modbus...

Download Setup to Controller

COM Settings...

Options

Editor...

Language

Deutsch

English

Français

Italiano

Español

Português

Help

Contents....

About...Library...

Show all devices

Show only devices applicable for

CANopen...

Profibus...

Open Protocol

Controller Info

Validated Copy

MC16ZC - CANopen Extension

MC16ZP - Profibus Extension

MC16X

MC32Z

MC32ZC - CANopen Extension

MC32ZP - Profibus Extension

MC16Z

MC32X

File

Print Tree

as you see it

all nodes expanded

Diagnostics

Start diagnostics

Pause diagnostics

Mode

Configuration

Diagnostics

Options

Editor...

Language

Deutsch

English

Français

Italiano

Español

Português

Help

Contents...

About...

Exit

18 33003281

33003281

3
Menu Commands
At a Glance

Overview This chapter contains the description of the menu commands.



Topic Page

File 20

Edit 21

Mode 22

Check 23

Controller 24

Options 27

Help 28

Diagnostics 29

19

Menu Commands

File

New Click New to create a new configuration. When this command is called, a new window appears in which the name and the author of this configuration can be indicated. A message box appears for saving an existing configuration if a configuration is already opened.

To enable opening the Properties dialog window automatically, after you drag and drop a device onto the Configuration window, select option automatically open properties dialog if a new device is dropped onto configuration in Editor on the Options menu.

Open Click Open to open a file selection popup menu. Here you can select an existing configuration. Additionally a backup file is created in the same directory with .mcb extension.

Save Click Save to save the current configuration under the current name.

Save As... Click Save As... to save the current configuration under a new name.

Print Tree Click Print Tree to print the configuration, and choose one of the following options:

Exit Click Exit to quit the XPSMCWIN software. If changes have been made to the configuration, you will be asked whether you want to save changes before quitting the program.

Option Meaning

as you see it The configuration tree will be printed as you see it in the configuration window.

all the nodes expanded The configuration tree will be printed with all the nodes expanded.

20 33003281

Menu Commands

Edit

Undo Click Undo to cancel the last action. You can repeat the step up to 10 times in a row.

Redo Click Redo to restore a cancelled action. You can repeat the step up to 10 times in a row.

Copy Click Copy to copy the selected item to the internal clipboard.

Cut Click Cut to cut the selected device.

Paste Click Paste to paste an item from the internal clipboard to the selected location, and choose one of the following options.

Delete Click Delete to delete the selected item.

Option Meaning

as a copy of the device The device will be copied with the properties of the source device (e.g., the same input and output) if the same hardware is connected to different inputs and outputs of the XPSMC.

as a device The device will be copied with its default properties. Alternatively, you can drag the device to the selected location.

33003281 21

Menu Commands

Mode

Configuration The Configuration mode is the software’s working mode. All the commands can be executed in this mode. In the Configuration mode, a configuration is created, modified, and sent to or reloaded from XPSMC. When the program is started, this is the default mode of the software.

Diagnostics The Diagnostics mode is used exclusively for diagnosing the XPSMC connected to the PC. The configuration cannot be modified. In the Diagnostic mode, the software working windows are grey in color.

In this mode, the connected XPSMC safety controller continues to operate without being affected.

22 33003281

Menu Commands

Check

Check Configuration

Use this command to check if the configuration is correct, before you download it into the XPSMC.

33003281 23

Menu Commands

Controller

Stop Controller Click Stop Controller to stop the XPSMC. Its safety outputs are de-activated in accordance with their stop category, (either immediately or with a delay). The password must be entered.

Run Controller Click Run Controller to change the XPSMC to Run mode.

Change Password

Click Change Password to open a window in which you can change the password. Beforehand, you will receive a message saying the controller has been stopped


Click Download Configuration to Controller to send the current configuration to the selected controller. Prior to it, you will receive a message that the controller has been stopped. The password must be entered.

Note: Please bear in mind that when the configuration is downloaded, all outputs will be deactivated.


Click Upload Configuration from Controller to load the configuration to the PC and display the current configuration of the connected XPSMC. The XPSMC is still running at the same time.

Create Validated Copy from Controller

Click Create Validated Copy from Controller to create a file as safety copy of a validated configuration.

Transfer Validated Copy to Controller

Click Transfer Validated Copy to Controller to transfers a validated configuration to a controller.

Read Validation Click Read Validation to provide the date of validation and the name of the person who performed the validation of the connected XPSMC configuration.


Click Read Protocol from Controller to upload the protocol of the current configuration and present it in a text (not ASCII) format. It allows you to store the protocol on your PC or to print it out. Before you use the command, stop the XPSMC and enter your password. Restart the XPSMC after you have closed the protocol.

Note: As the protocol is read from the Controller, all outputs are deactivated.

24 33003281

Menu Commands

Open Protocol Click Open Protocol to open a locally stored copy of the protocol and print it out. The file is read-only, and you cannot modify it.


Click Controller Setup (Bus Configuration), and choose one of the following options:


Click Download Setup to Controller to send the parameters set (for all communication protocols, i.e. Modbus (RTU), CANopen, Profibus DP) to the selected controller of this configuration. The XPSMC must also be stopped. The password must be entered.

Option Meaning

Modbus (RTU)

Opens a window for adjusting the settings required for the operation of all the XPSMCs (up to 8) of this configuration with a MODBUS system. Operation with different MODBUS systems is also possible. By clicking the Download button, the Send the settings to the controller command is executed. The settings are applicable to all controllers.

CANopen Opens a window with address and baud rate.

Profibus DP Opens a window with address only.

Note: This command causes only the bus communication parameters to be sent and not the configuration!

33003281 25

Menu Commands

Controller Info Click Controller Info to display the information about the type of controller, the firmware version, and the controller status.

To view information about the current firmware version of the Controller 1, Controller 2, and the fieldbus, click Details:

COM Selection... Choose COM Selection... to select the COM port (1...16) of the PC to which the XPSMC is connected.

Controller Info

Controller

Type: XPS-MC32 ZC

Firmware version: 2.30

Extension: CANopen Details...

Communication parameters

Modbus: Addr. 1, 19200 bit/s, 8 E

CANopen: Addr. 2, 1 Mbit/s

State

The controller is in RUN mode.

Configuration

The controller contains a validated configuration.Configuration validated by TESTLAB on ***ERROR: validation date corrupted***.

OKRefresh

26 33003281

Menu Commands

Options

Editor... Click Editor... to open the Editor Options dialog box, which allows you to check the automatically open properties dialog if a new device is dropped to configuration function.

Library Click Library , and select one of the following options:

Language Click Language to select the XPSMCWIN software language.

The software switches automatically to the selected language.

Option Meaning

Show all devices All devices are shown.

Show only devices applicable for Only the applicable devices of the XPSMC model are shown.

33003281 27

Menu Commands

Help

Contents... Click Contents... to view an overview of the online help.

About... Click About... to view information about the present version of the software.

28 33003281

Menu Commands

Diagnostics

Start Diagnostics The transmission of the diagnostics data from the XPSMC to the PC will be started.

Stop Diagnostics The transmission of the diagnostics data from the XPSMC to the PC will be stopped.

Note Switching into the diagnostic mode, with menu command Mode → Diagnostics, the menu bar will be modified like described in the chapter Elements of a Window, p. 18.

33003281 29

Menu Commands

30 33003281

33003281

4
Device Library
At a Glance

Overview This chapter contains the description of all the functionalities of the XPSMC. These functionalities are contained in the Device Library window in the configuration software.


This chapter contains the following sections:

Section Topic Page

4.1 Controller 33

4.2 Monitoring Devices 51

4.3 EDM Devices 97

4.4 Start Device 98

4.5 Enabling Devices 100

4.6 Miscellaneous Devices 103

4.7 State of Outputs 113

31

Device Library

32 33003281

Device Library

4.1 Controller

At a Glance

Overview The folder Controller contains the 8 types of controllers: XPSMC16Z, XPSMC16ZC, XPSMC16ZP, XPSMC16X, XPSMC32Z, XPSMC32ZC, XPSMC32ZP, and XPSMC32X.

What's in this Section?

This section contains the following topics:

Topic Page

Creating a Configuration 34

Setting the Safety Outputs 47

Connecting a Device to a Safety Output 49

Modifying the Properties 50

33003281 33

Device Library

Creating a Configuration

Introduction To create a configuration, click File → New.

Response Time You have the possibility to select a reponse time for the XPSMC16Z, XPSMC16ZC, XPSMC16ZC, XPSMC32Z, XPSMC32ZC, XPSMC32ZC devices. You can select 20 or 30 ms for the response times. With the longer response time you can configure more functionality in the device.

In the XPSMC16X and the XPSMC32X this possibility does not exist. Here the reponse time is always 20 ms.

Note: The following examples are for 16 input controllers only. The procedure for 32 input controllers is the same, if it is not otherwise stated.

34 33003281

Device Library

Procedure for XPSMC ••X Using Modbus

Proceed as follows:

Step Action

1 To create a new configuration, click File → New.Result: A window which contains the Title and the Author of this configuration opens.The following figure shows the Configuration dialog box:

2 Fill out the fields and click OK.Note: If this window does not open automatically, this function is not active in the Options → Editor... menu option.

3 Drag-and-drop the controller symbol onto the Configuration window. Note: Because the X version does not support all the devices, the following window appears:

Configuration

| (max. 16 char.)Title:

Author:

last modified: 15.12.03 11:23:22

OK Cancel

Yes No

This Controller does not support all devices included in the library.

XPSMCWIN

Do you want to hide the unsupported devices in the library?

33003281 35

Device Library

4 Select No to see all devices in the library. You can also make this selection in the Options menu.Result: A dialog box with Modbus marking appears.The following figure shows the Controller C1 (XPSMC16 X) dialog box:

5 Click change... to modify bus parameters.Result: The Modbus parameters dialog box appears.The following figure shows the Modbus Parameters dialog box:

This window also opens when all the other controllers in this configuration are added. Enter all necessary parameters.Note: This window can also be accessed by clicking with the right mouse button on the controller symbol and then selecting the Properties option or Controller → Controller Setup (Bus Configuration) if the Modbus option is available.

Step Action

Controller C1 (XPSMC16 X)

Name:

XPSMC16 XType:

OK Cancel

i16

Response Time

all outputs <= 20 ms(Function Safety Mat <= 30 ms)

Modbus

[not used] change...

Controller C1

Modbus Parameters

Controller 1:

Cancel OK

Address Bitrate Parity

(1-247)

19200 even

Controller 2:

Controller 3:

Controller 4:

Controller 5:

Controller 6:

Controller 7:

Controller 8:

different Modbuses

Download i

connect

36 33003281

Device Library

6 Select the Download button.Result: You must select the controller that your configuration corresponds to. Only the bus parameters for this controller will be transmitted.Note: To download the whole configuration including the bus parameters, click Controller → Download Configuration to Controller.

7 After having closed the properties window of the controller, the controller will be represented in a tree structure.Example: All devices of the XPSMCWIN application:

Step Action


XPSMCWIN


i i


Configuration

C1 (XPSMC16 X): ’Controller1’i 16

o1

o2

o3

o4

o5

o6

R1

R2

Telemecanique


i

i16

XPSMC16 ZC - CANopen Extensioni

EDM Devices

Start Devices


Enabling Devices

Controller

State of Outputs

XPSMC16 Z

XPSMC16 ZP - Profibus Extensioni

XPSMC16 Xi

XPSMC32 Zi32

XPSMC32 ZC - CANopen Extensioni32

XPSMC32 ZP - Profibus Extensioni32

XPSMC32 Xi32

16

16

16

Monitoring Devices

33003281 37

Device Library

Procedure for XPSMC ••Z Using Modbus

Proceed as follows:

Step Action


2 Fill out the fields and click OK.Note: If this window does not open automatically, this function is then not active in the Options → Editor... menu option.

3 Drag-and-drop the controller symbol onto the Configuration window. Result: A dialog box with Modbus marking appears.The following figure shows the Controller C1 (XPSMC16 Z) dialog box:

4 Select OK.Note: By selecting the response time, you have a possibility to reduce the load of the CPU (not available for the XPSMC16X and XPSMC32X, where the response time is always ≤ 20 ms.) Note that when you change the response time in the current configuration, all configured timers are set to 0 and must be modified again. The limit ranges are then also changed.

Configuration


Author:

OK Cancel

Controller C1 (XPSMC16 Z)

Name:

XPSMC16 ZType:

OK Cancel

i16

Response Time

all outputs(Function Safety Mat <= 30 ms)

Modbus


Controller1

<= 20 ms <= 30 ms

38 33003281

Device Library

5 To modify bus parameters click change....Result: The Modbus parameters dialog box appears.The following figure shows the Modbus Parameters dialog box:

This window also opens when all the other controllers in this configuration are added. Enter all necessary parameters.Note: This window can also be accessed by clicking with the right mouse button on the controller symbol and then selecting the Properties option or Controller → Controller Setup (Bus Configuration) if the Modbus option is available.

6 Select the Download button.Result: You will be asked to select the controller that your configuration corresponds to. Only the bus parameters for this controller will be transmitted.Note: To download the whole configuration including the bus parameters, click Controller → Download Configuration to Controller.

Step Action

Modbus Parameters

Controller 1:

Cancel OK

Address Bitrate Parity

(1-247)

19200 even

Controller 2:

Controller 3:

Controller 4:

Controller 5:

Controller 6:

Controller 7:

Controller 8:

different Modbuses

Download i

connect

33003281 39

Device Library

7 After having closed the properties window of the controller, the controller will be represented in a tree structure.The following figure shows the XPSMCWIN application:

Step Action


XPSMCWIN


i i


Configuration

C1 (XPSMC16 Z): ’Controller1’i 16

o1

o2

o3

o4

o5

o6

R1

R2

Telemecanique


i

i16


EDM Devices

Start Devices


Enabling Devices

Controller

State of Outputs

XPSMC16 Z


XPSMC16 Xi

XPSMC32 Zi32



XPSMC32 Xi32

16

16

16

Monitoring Devices

40 33003281

Device Library

Procedure for CANopen

Proceed as follows:

Step Action


2 Fill out the fields and click OK.Note: If this window does not open automatically, this function is not active in the Options → Editor... menu option.

3 Drag-and-drop the controller symbol onto the Configuration window.Result: A dialog box with CANopen and Modbus markings appears.The following figure shows the Controller C1 (XPSMC16 z) dialog box:

Configuration


Author:

OK Cancel

Controller C1 (XPSMC16ZC)

Name:

XPSMC16 ZC - CANopen ExtensionType:

OK Cancel

i16

Response Time

all outputs

Modbus


Controller1

<= 20 ms <= 30 ms

(Function Safety Mat <= 30 ms)

CANopen


33003281 41

Device Library


5 To modify bus parameters, click change... under CANopen.Result: The CANopen parameters dialog box appears. The following figure shows the CANopen Parameters dialog box:

This window also opens when all the other controllers in this configuration are added. Enter all necessary parameters.Note: This window can also be accessed by clicking the controller symbol with the right mouse button and then selecting the Properties option or Controller → Controller Setup (BusConfiguration) if the CANopen option is available.

6 Select the Download button.Result: If you have more than one controller in the configuration, you will be asked to select the controller that your configuration corresponds to. Only the bus parameters for this controller will be transmitted.Note: To download the entire configuration including the bus parameters, click Controller → Download Configuration to Controller.

Step Action

CANopen Parameters

IController 1:

OK Cancel

Address (1-127)

Baud Rate: 250 k

Controller 2:

Controller 3:

Controller 4:

Controller 5:

Controller 6:

Controller 7:

Controller 8:

Download i

connect

42 33003281

Device Library

7 After the Properties window of the controller has been closed, the controller will be represented in a tree structure.The following figure shows the XPSMCWIN application:

Step Action


XPSMCWIN


i i


Configuration

C1 (XPSMC16 ZC): ’Controller1’i 16

o1

o2

o3

o4

o5

o6

R1

R2

Telemecanique


i

i16

i

EDM Devices

Start Devices


Enabling Devices

Controller

State of Outputs

XPSMC16 Z


i

XPSMC32 Zi32



XPSMC32 Xi32

16

16

16

Monitoring Devices


XPSMC16MC16 X

33003281 43

Device Library

Procedure for Profibus

Proceed as follows:

Step Action


2 Fill out the fields and click OK.Note: If this window does not open automatically, this function is then not active in the Options → Editor... menu option.

3 Drag-and-drop the controller symbol onto the Configuration window.Result: A dialog box with Profibus and Modbus marking appears.The following figure shows the Controller dialog box:

Configuration


Author:

last modified: 15.12.03 11:23:22

OK Cancel

Controller C1 (XPSMC16ZP)

Name:

XPSMC16 ZP - Profibus ExtensionType:

OK Cancel

i16

Response Time

all outputs

Modbus


Controller1

<= 20 ms <= 30 ms


Profibus


44 33003281

Device Library


5 To modify bus parameters click change.. under the Profibus marking.Result: The Profibus parameters dialog box appears.The following figure shows the Profibus Parameters dialog box:

This window also opens when all the other controllers in this configuration are added.Note: This window can also be accessed by clicking with the right mouse button on the controller symbol and then selecting the Properties option or Controller → Controller setup, where Profibus option is available.

6 Click the Download button.Result: If you have more than 1 controller in the configuration, you will be asked to select the controller that your configuration corresponds to. Only the bus parameters will be transmitted.Note: To download the entire configuration including the bus parameters, click Controller → Download Configuration to Controller.

Step Action

Profibus Parameters

Controller 1:

OK Cancel

Address

(1-125)

Controller 2:

Controller 3:

Controller 4:

Controller 5:

Controller 6:

Controller 7:

Controller 8:

Download i

connect

33003281 45

Device Library

7 After having closed the properties window of the controller, the controller will be represented in a tree structure.The following figure shows the XPSMCWIN application:

Step Action


XPSMCWIN


i i


Configuration

C1 (XPSMC16 ZP): ’Controller1’i16

o1

o2

o3

o4

o5

o6

R1

R2

Telemecanique


i

i16

i

EDM Devices

Start Devices


Enabling Devices

Controller

State of Outputs

XPSMC16 Z


i

XPSMC32 Zi32



XPSMC32 Xi32

16

16

16

Monitoring Devices


XPSMC16MC16 X

46 33003281

Device Library

Setting the Safety Outputs

Introduction The following information shows you how to set the safety outputs.

Procedure Set the safety outputs as follows:

Step Action

1 Click the right mouse button, and select Properties.The following dialog box appears:

2 Set the properties of the output.

3 Confirm your settings by clicking OK.

Configuration

Configuration: ’Robot 1’

C1 (XPSMC16 ZP): ’Controller 1’i 16o1

o2

Output with delay time

Output without delay time

Output o1

Delay Off Input:

CancelOK

i01

Name:

Stop Category 0

Stop Category 1

2.5Delay Time: s

(0.1 ... 300 s)

Interruption of Delay Time:

Control Output: c01

? ?

33003281 47

Device Library

Dialog Settings The parameter setting window provides the following setting possibilities:

These functions are available for all devices where the block diagram and help icons appear.

Option Description

Name A specific Name can be assigned to the output.

Stop Category 0/1 A choice can be made between Stop Category (stop not delayed) and Stop Category 1 (stop delayed).

Delay Time Delay Time is defined between 0.1 s and 300 s for the Response Time of 20 ms and between 0.15 s and 300 s for the Response Time of 30 ms for Stop Category 1

Interruption of Delays Time An interrupt input can also be defined for an interruption of the delay. If the connection between the assigned control output and the safety input is opened, the safety output is immediately deactivated.

Icon for Block Diagram A window opens in which the block diagram of the concerned component is represented.

Icon for Help (?) The instruction sheet will be opened at the corresponding chapter of the component from which help is required.

48 33003281

Device Library

Connecting a Device to a Safety Output

Procedure To assign a device to the desired safety outputs proceed as follows:

This procedure is the same for all the functionalities of the XPSMC.

Step Action

1 Open one of the device folder.

2 Click the symbol of the device you wish to connect, and drag it to the appropriate safety output symbol in the Configuration window.Result: When the mouse button is released, the device is connected to the safety output, as represented in a tree structure.

Note: The connection of several devices to a safety output is automatically a logical AND.

LOSS OF SAFETY INPUT CROSS-CONNECTION DETECTION

Ensure that no more than one critical safety input is connected to each of the control outputs.

Failure to follow these instructions can result in death, serious injury, or equipment damage.

WARNING

33003281 49

Device Library

Modifying the Properties

Introduction By dropping a component onto an output, the properties window of this component will be automatically opened. This function can be activated or deactivated in the menu Options → Editor....

Procedure For additional modifications of the properties proceed as follows:

Step Action

1 Right-click and select Properties... in the shortcut menu.Result: In this window, the adjustable parameters of this function can be modified.Note: If this window does not open automatically, this function is not active in the Options → Editor... menu option. In this case, open the window by clicking the symbol with the right mouse button and selecting the Properties... menu option.

2 Indicate the switching item of this function (for example, the Emergency Stop button, the Limit Switch, etc.), the control outputs and the safety inputs with which it is connected to the XPSMC.Note: If a control output c1...c8 has been used, a * follows the name, for example c2*, appears when this output is already in use.The user must guarantee that no dangerous fault can occur when this control output is used more then once, as a dangerous short-circuit, for example, is no longer detected.Note: If a safety input is occupied, it no longer appears in the list of safety inputs currently available. An incorrect double occupation is therefore eliminated.Note: The already used control outputs cannot be used in the Properties window of the device Safety mats.

3 Confirm the defined inputs with OK.

Note: This procedure is the same for all the functionalities of the XPSMC.

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Device Library

4.2 Monitoring Devices

At a Glance

Overview This section contains the description of the folder Monitoring Devices.



Topic Page

Overview of all Control Devices 52

Emergency Stop 54

Safety Guards 55

Light Curtains (Electro Sensitive Protective Equipment (ESPE)) of Category 4 without Muting

58

Light Curtain with Muting 60

Magnetic Switch 65

Two-Hand Control 66

Safety Mat 67

Zero Speed Detection 69

Injection Molding Machine 76

Hydraulic Press Valve Monitoring 78

Hydraulic Press 2 80

Eccentric Press 84

Eccentric Press 2 88

Shaft/Chain Break Monitoring 94

Seat Valve Monitoring 95

33003281 51

Device Library

Overview of all Control Devices

Introduction This information is about the Monitoring Devices folder. It contains all the control devices of the XPSMC.

The response time in the following pictures have the basis of 20 ms. When you use the basis of 30 ms the ranges are changing a little bit. See also Response Time, p. 34.

The figure below gives an overview of Monitoring Devices:

MC16 ZC - CANopen Extensioni16MC16 ZP - Profibus Extensioni

i Monitoring Devicesi

1-channel2-channel

Emergency Stop

i1-channel2-channel

Safety Guards

with locki

with Transistor Outputswith Relay Outputs

Light Curtains

with Transistor Output and Mutingwith Relay Output and Muting

Magnetic SwitchTwo Hand Control

Safety MatZero Speed Detection

i Specific Functions

MC16 Zi16

MC32 ZiMC32 ZC - CANopen Extensioni32

MC16 Xi16

MC32 ZP - Profibus ExtensioniMC32 Xi32

16

32

32

i Light Curtain with Muting

Injection Molding Machine

Eccentric Press 2

Seat Valve Monitoring

Shaft/Chain Break Monitoring

Eccentric Press

Hydraulic Press 2

?2

2

Hydraulic Press Valve Monitoring

52 33003281

Device Library

Monitoring Devices (continued):

iEDM

EDM Devices

iAutomatic StartNon-Monitored Start

Start Devices

Monitored Starti

Enabling Device 2-channelEnabling Devices

iTimerOR

Miscellaneous DevicesEnabling Device 3-channel

ii

o1o2

’Controller1’

o3o4o5o6R1R2

1

Selector SwitchClosed Tool

State of Outputs

Foot Switch Control

33003281 53

Device Library

Emergency Stop

Introduction The Emergency Stop folder contains the two device symbols for the one channel and two-channel emergency stop.

Dialog Box Settings

You can make the following settings in the Emergency Stop dialog box:

The table describes the following setting possibilities:

Option Description

Name A specific Name can be assigned to this device.

Function You can choose between a one channel switch and a two channel switch. The device symbol in the configuration tree is adapted automatically.

Inputs The control outputs and the safety inputs with which the emergency stop button is connected to the XPSMC must be indicated in the Inputs group box.

Emergency Stop

Control Output:

OKCancel

Name:

one channel switch

two channel switch

Control Output:

?

Function

Inputs

Ch 1:

Ch 2:

54 33003281

Device Library

Safety Guards

Introduction

The Safety Guards folder contains 3 device symbols: protection door with 1-channel , protection door with 2-channels and protection door with lock (3 channels).

Note: One of the 3 starting devices: automatic starting, non monitored starting or monitored starting must be assigned to each safety guard device. The corresponding safety output cannot be activated without this assignment.

33003281 55

Device Library

Dialog Box Settings

The Safety Guard dialog box allows you to make the following settings:

The table describes the settings you can make setting possibilities:

Option Description

Name A specific Name can be assigned to the device.

Function A choice can be made between a protection barrier with 1 limit switch one channel, w/o lock, 2 limit switches two channel, w/o lock or 2 limit switches with lock two channel, with lock. The device symbol is adapted to the choice made.

Safety Guard with 1 channel, w/o lock

In the Options field, you can define whether a Start Interlock is to be carried out. During the Start Interlock, the protection door must be opened once before the machine is started and then closed again, to guarantee that the connected contact ch.1 also operates.In the Inputs group box, the control output and the safety input to which ch.1 is connected must be indicated.

Safety Guard

Control Output:

CancelOK

Name:

one channel, w/o lock

two channel, w/o lock

Control Output:

?

Function

Inputs

Ch 1:

Ch 2:

Sync Time: s

(0.5 .. 2.5 s)

Start Interlock

two channel, with lock

Options

Sync Time Monitoring Ch. 1 - Ch. 2:

Control Output:Lock:

Safety Guard

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Safety Guard with 2 Channel, w/o Lock

In the Options field, you can define whether a start interlock is to be carried out. During the start interlock, the protection door must be opened once before the machine is started and then closed again, to guarantee that the connected contacts ch.1 and ch.2 also operate. A synchronization time, during which contacts ch.1 and ch.2 must close, can also be entered. If this time is exceeded, the assigned safety outputs are not activated. For the response time of 20 ms, the range is 0.5...2.5 s; for the response time of 30 ms, the range is 0.45...2.4 s (synchronization time).The control outputs and the safety inputs used must be indicated in the Inputs group box.

Safety Guard with 2 Channels, with Lock

In the Options field, you can define whether a start interlock is to be carried out. During the start interlock, the protection door must be opened once before the machine is started and then closed again, to guarantee that the connected contacts ch.1, ch.2 and lock also operate. A synchronization time, during which contacts ch.1 and ch.2 must close, can also be entered. If this time is exceeded, the assigned safety outputs are not activated. For the response time of 20 ms, the range is 0.5...2.5 s; for the response time of 30 ms, the range is 0.45...2.4 s (synchronization time).The control outputs and the safety inputs used must be indicated in the Inputs group box.

Option Description

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Light Curtains (Electro Sensitive Protective Equipment (ESPE)) of Category 4 without Muting

Introduction The Light Curtains folder contains two device symbols:

Light curtain (ESPE = Electro Sensitive Protective Equipment) with Transistor Outputs and with Relay Outputs with and without muting.

For the light curtain with transistor outputs, the light curtain checks its safety outputs itself (OSSD = Output Safety Switching Device) by a short interruption. The light curtain safety outputs must be connected to different XPSMC safety inputs.

This output test is not, however, possible for the output and is thus performed by the XPSMC. To guarantee complete short-circuit monitoring, the light curtain safety outputs must be connected to different XPSMC safety inputs and control outputs.

For the light curtain safety outputs the following synchronization time must be entered:

If the time difference between the tripping of the two safety outputs (OSSD) is greater, the safety outputs affected are not activated.

Note: One of the three starting devices: automatic starting, non monitored starting or monitored starting must be assigned to each light curtain device. The corresponding safety output cannot be activated without this assignment.

Response Time Synchronization Time

20 ms 0.5...2.5 s

30 ms 0.45...2.4 s

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Dialog Box Settings

The parameter setting window provides the following setting possibilities:


Option Description


Function A choice can be made between the light curtain with a Transistor Output and Relay Output. The device symbol is adapted to the choice made.

Options You can define whether a Start Interlock is to be carried out. During the start interlock, the light curtain protection field must be interrupted once and validated again, before activating the XPSMC safety outputs. A synchronization time during which contacts ch.1 and ch.2 must close can also be entered. If this time period is exceeded, the assigned safety outputs are not activated. The response time period of 20 ms can be defined in the range between 0.5 s and 2.5 s, and a response time of 30 ms - in the range of 0.45...2.4 s (for the synchronization time).

Inputs The Control Outputs (by outputs alone) and the safety inputs to which the light curtain safety outputs (OSSD 1 and OSSD 2) are connected are activated.

Light Curtain

Control Output:

CancelOK

Name:

Transistor Output

Relay Output

Control Output:

?

Function

Inputs

OSSD 1:

OSSD 2:

Start Interlock

Options

Light Curtain

0.5Sync Time OSSD 1 - OSSD 2: s

(0.5 ... 2.5 s)

Sync Time

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Light Curtain with Muting

Introduction The Light Curtain with Muting folder contains two device symbols:

Light curtain (ESPE = Electro Sensitive Protective Equipment) with transistor outputs or relay outputs, and with muting function.

The muting function can be used to bypass the protection field of a light curtain (ESPE) in order, for example, to bring a part to be worked into and/or leave the hazardous area.

Show a muting example:

The muting function is controlled by four additional sensors belonging to two groups (A and B), and can only be activated when the safety outputs have already been activated (the protection field is then free). If not, the activation of the muting function produces an error message and the safety outputs remain deactivated. Muting operates according to a suitable order of the muting sensors in both directions of transport, and thus inside and outside the hazardous area again.

The muting sensors of groups A and B must be activated during a variable synchronization time tsyn (0.5...3 s with the response time of 20 ms or 0.6...3 s with a response time of 30 ms or to infinity), in order to trigger the muting function. A muting time tM can also be adjusted from 0.5...10 min or to infinity. During this time, the conveyed goods can pass through the activated protection field, without the XPSMC safety outputs switching off the machine. If this time is exceeded, an error message appears and the safety outputs are deactivated.

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The override button is used to bypass the protection field manually. This is necessary, for example, when the muting function is activated and when conveyed goods have entered and stuck in the light curtain protection field (ESPE). Through this option, the goods can be withdrawn from the machine, in spite of the light curtain (ESPE). To prevent inappropriate use, the override function can only be activated for up to 10 min.

To create the muting signal, sensors with relays output, or mechanical limit switches are suitable for making sure that a distinction is made between individuals and goods. At the same time, all easy defeating must be prevented (stickers or photoelectric sensors for example).

On entering the hazardous area, light signal is recommended to announce the muting status for muting operation; this signal must be connected between terminal H1 and the XPSMC supply voltage (terminal A1). If a fault occurs at the level of this light signal (short-circuit, interruption), the muting function is immediately de-activated and an error message appears. The safety outputs are then deactivated.

Sources of white light with an illumination surface of 1 cm2 and a brightness of at least 200 lm/m are used as a light signal. The current of this light source could vary from 20...350 mA.

The light signal always comes on when the muting signals are generated correctly and announces the bypassing of the light curtain protection function (ESPE):� A new cycle is only initiated with the starting control when no muting signal is

required and when the protection field is free.� During the time a muting signal is produced correctly, no one must be allowed to

enter the hazardous area.

IMPROPER ACCESS TO A PROTECTED AREA

Ensure opening sizes are as small as possible and comply with EN60294.Ensure photo-sensors are clean and free from obstructions.


DETECTOR INTERFERENCE HAZARD WITH THRU-BEAM SENSORS

Reciprocal mount transmitters and receivers.Mount adjacent receivers at distance greater than minimum separation distance.


WARNING

WARNING

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� A guide less means of transport must create the muting signal before it enters the protection field, and may only leave this field when it no longer interrupts the light curtains beams of the protection field.

The muting function meets the requirements of category 4 according to EN 954-1. To ensure the correct monitoring of the muting lamp, a minimum duration of 500 ms for muting is necessary.

Photoelectric muting sensors must operate in dark switching mode, in order to produce the output signal when a light ray is interrupted.

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Dialog Box Settings



Press the Muting button you get the following Muting Parameters window.

Option Description

Name A specific name can be assigned to this device.

Function A choice can be made between the light curtain with a transistor or relay output. The device symbol is adapted to the choice made.

Options You can define whether a start interlock is to be carried out. During the start interlock, the light curtain protection field must be interrupted once and validated again, before activating the XPSMC safety outputs.

Inputs Both the Control Outputs (by relay outputs only) and the safety inputs to which the light curtain safety relay outputs (OSSD 1 and OSSD 2) are connected are activated.

Light Curtain with Muting

Control Output:

CancelOK

Name:

Transistor Output

Relay Output

Control Output:

?

Function

Inputs

OSSD 1:

OSSD 2:

Start Interlock

Options

Light Curtains

0.5Sync Time OSSD 1 - OSSD 2: s

(0.5 ... 2.5 s, increment 0.1 s)

Muting ...

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The Muting Parameters window offers the following options:

The following table describes the parameters of the dialog box:

Option Description

Options Muting Time Monitoring:The optional Muting Time indicates the maximum time the muting function is allowed to operate. Exceeding this time with the muting function still activated causes an error message. The Muting Time have the range of 0.5...10 min.Override Time: The Override Time indicates the maximum time during which the relieve time function can be activated. The default value set is 10 min. The Override Time has the range of 0.5...10 minSynchronization Time Monitoring:The optional Sync Time is the time during which the muting sensors of groups A and B must be activated before muting is started. If this time is exceeded, the muting function is not activated. For a response time of 20 ms, the range is 0.5...2.5 s, and for a response time of 30 ms, the range is 0.45...2.4 s for the Sync Time.

Inputs The override input, the 2 groups A and B of muting sensors and the control outputs to which the XPSMC are connected to the light curtain, must be indicated in the Inputs group box. The 2 groups A and B of muting sensors must be necessarily connected to different control outputs.

Muting Parameters

Control Output:

CancelOK

Control Output:

?

Inputs

A 1:

B 1:

Options

Muting Time: min

(0.5 ... 10 min)

Muting Time Monitoring

10Override Time: min

(0.5 ... 10 min)

Sync Time: s

(0.5 ... 3.0 s)

Sync Time Monitoring A1-B1/A2-B2:Control Output:

Override:

A 2:

B 2:

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Magnetic Switch

Introduction The Monitoring Devices folder contains the Magnetic Switch control device symbol.

The Magnetic Switch consists of an opening contact and a closing contact, which must be actuated within the Synchronization Time, otherwise the Safety Outputs affected are not activated.

Dialog Box Settings

The parameter setting window offers the following settings:


Option Description


Options You can define whether a Start Interlock is to be carried out. During the Start Interlock, the magnetic switch must be actuated once before the machine is started and then de-activated again to guarantee that the connected contacts are also operating. For the response time of 20 ms, the range is 0.5...2.5 ms, and for the response time of 30 ms, the range is 0.45...2.4 s for the Synchronization Time.

Inputs The control outputs and the safety inputs must be indicated in the Inputs group box.

Magnetic Switch

Control Output:

CancelOK

Name:

Control Output:

?

Inputs

NC:

NO:

Start Interlock

Options

NC

NO

0.5Sync Time: s

(0.5 ... 2.5 s)

Sync Time

Magnetic Switch

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Two-Hand Control

Introduction The Monitoring Devices folder contains the Two-Hand Control device symbol.

The control panel of the two-hand control consists of two buttons each having an opening contact and a closing contact. These buttons must be actuated within the synchronization time space of 0.5 s, to obtain switching of the safety outputs. If this time is exceeded, the assigned safety outputs are not activated.

To ensure complete short-circuit monitoring, the 2 buttons must be connected to different control outputs. If a button produces an unexpected signal, such as a short-circuit for example, the safety outputs affected are deactivated or are not activated and an error message appears.

Dialog Box Settings



Option Description


Inputs The control outputs and the safety inputs to which the two-hand control buttons are connected, must be indicated in the Inputs field.

Two Hand Control

Control Output:

OKCancel

Name:

?

Inputs

Button 1:

Button 1:

NO

NC

Control Output:Button 2:

Button 2:

NO

NC

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Safety Mat

Introduction

The Monitoring Devices folder contains the Safety Mat function symbol.

The switching mat consists of two pairs of metal leads that are short-circuited when the mat is walked on. The XPSMC safety outputs are then immediately deactivated. To be able to detect this short-circuit, the four connection leads must be connected to different safety inputs and control outputs.

Types: see Technical Specifications, Hardware Manual.

Note: 1 of the 3 starting devices: automatic starting, non monitored starting or monitored starting must be assigned to each switching mat function. The corresponding safety output cannot be activated without this assignment.

Note: The control outputs used for this device cannot be used for any other device!

LOSS OF SAFETY INPUT-CROSS CONNECTION DETECTION

In Safety Mat applications, ensure that all four connection leads are connected to different safety inputs and control outputs.


WARNING

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Dialog Box Settings



Option Description


Inputs The control outputs and the safety inputs to which the safety switching mat is connected must be indicated in the Inputs group box.

Safety Mat

Control Output:

OKCancel

Name:

?

Inputs

Input 1:

Control Output:Input 2:

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Zero Speed Detection

Introduction The Monitoring Devices folder contains the symbol Zero Speed Detection device symbol.

This device detects the zero speed of a motor or a shaft. To enter the motor rotational speed, an encoder wheel and two PNP sensors are required as indicated in figure Functional Diagram, p. 200. These sensors can only be connected to XPSMC safety inputs i1 and i2. If these inputs are already taken, a warning appears automatically.

Points to be Complied

The following points should be complied with for this device:� The sensors must be arranged so that only 1 sensor is activated at any given time

(= HIGH-Signal).� If both sensors are in the LOW state, a cable break error message is indicated

and the corresponding outputs are deactivated.� If both sensors are in the HIGH state after power on of the XPSMC, a notification

is send via Modbus and the corresponding outputs are deactivated. After a zero speed detection and a subsequent motion the notification is reset.

� If zero speed is already detected and both sensors are in HIGH state, a notification is send via Modbus and the corresponding outputs are activated.

� If only 1 sensor produces a dynamic signal after a zero speed, an error message appears after 30 s and the corresponding outputs are deactivated.

� If, after the XPSMC has started, both sensors are in the LOW state, an error message appears.

Note: You cannot use the Zero Speed Detection device simultaneously with the Shift/Chain Break Monitoring device on the XPSMC safety controller, because there are only two counter inputs (i1 and i2) per controller.

Note: The output will be activated if the sensors detect no motion.

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Sensor States and Behavior

Switch-on Sequence

Operation

* If the state of the sensors is inverse (0/1, 1/0), the behavior is identical.

** If the firmware version is earlier than 2.34 an error message (short circuit between inputs) appears instead of a notification. This error message must be acknowledged with the reset button.

Error Message External error messages must be acknowledged with the reset button.

Notification A notification, sent via Modbus, does not need to be acknowledged. As soon as the sensor states change, it will be acknowledged automatically.

State of Sensor 1 0 0 (*) 1


Behavior Error Message Zero Speed Notification (**)

Output 0 1 0



Behavior Error Message Zero Speed Notification

Output 0 1 1

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Calculation Both sensors give a frequency depending on the numbers of cogs and the revolution per minute:

or

where

f = Pulse frequency of the sensors in Hertz

n = Rotational speed of the encoder wheel in revolutions per minute

z = Encoder wheel number of cogs

Examples Example 1: Machine with 3000 rpm and an encoder wheel with 26 cogs:

1300 Hz is not authorized, because it is greater than 450 Hz.

Example 2: The same machine (3000 rpm) and an encoder wheel with 8 cogs:

400 Hz is authorized, because it is smaller than 450 Hz.

IMPROPER OPERATON

Do not use the XPSMC in applications where the pulse frequency requirement for detection of cogs on a rotary machine exceeds 450 Hz.


f Hz[ ] n rpm[ ]60

------------------ z×=

n rpm[ ] f Hz ] 60×[ ]z

-----------------------------=

WARNING

fmax300060

------------ 26× 1300Hz==

fmax300060

------------ 8× 400Hz==

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Switching Frequency

The frequency limit, below which the zero speed is detected and the safety outputs activated, can be adjusted by the user within a range of 0.05...20 Hz.

Example: A 8-cog encoder wheel is located above a shaft. A zero speed is detected when the speed is less than 10 rpm.

A switching frequency of 1.33 Hz must be indicated to detect a zero speed.

The switching from Motor Operation to Zero Speed (= activation of safety outputs) only occurs when1. 1 safety input contains a HIGH signal and2. the other input contains a LOW signal and3. the frequency on the two inputs is lower than the value entered.

Note: A frequency calculator is included in the properties determination menu. Enter the number of cogs and the zero speed limit in rpm, and the frequency limit to be set is calculated automatically.

fSwitchingfrequency10 rpm[ ]

60--------------------- 8× 1.33Hz= =

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Dialog Box Settings



Option Description


Zero Speed Frequency

The frequency limit, below which the zero speed must be detected and the safety outputs activated, must be indicated in this field, as indicated above. For the response time of 20 ms, the range is 0.05...20 Hz, and for the response time of 30 ms, the range is 0.05...16.7 Hz for the Zero Speed Frequency.

Frequency Calculator

A dialogue field opens when you click here.

Inputs (Fixed) i1 and i2


Sensor 2:

CancelOK

i02

Zero Speed DetectionName:

?

Inputs (fixed)

Sensor 1: i01

Zero Speed Frequency: Hz

(0.05 ... 20 Hz)

Frequency Calculator:

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Option Description

Rotational Speed Limit

The desired rotational speed limit (in rpm) to detect a zero speed.

Cogs on Encoder Wheel

The number of cogs.

Frequency Limit The frequency limit to be set is calculated automatically; it can be adjusted using the Apply button in the Properties menu.

Frequency Calculator

ApplyCancel

0.10Frequency Limit: Hz

With this setting the actual limit is1.00rpm.

Rotational Speed Limit: rpm

6Cogs on Encoder Wheel:

1

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Safety inputs i1 and i2 are already automatically indicated in the Inputs field. This device cannot operate with other inputs. If inputs i1 and/or i2 are already used, the following window appears to resolve the conflict:


Option Description

Manually or As a user, you assign other safety inputs manually to the function using i1 and/or i2. When OK is clicked, the Properties window of all concerned devices will be opened.

Automatically The software automatically assigns other safety inputs to the function using i1 and/or i2 according to 1 of 3 options:1. shift all inputs

All the safety inputs are shifted as a block. Inputs that are not used and are available may also be shifted.For example, i1 becomes i3, i2 becomes i4 and i4 becomes i6.

2. move up inputsAll the safety inputs are shifted as a block. Inputs that are not used and are available may also be shifted, and spaces thus filled.For example, i1 becomes i3, i2 becomes i4 and i4 becomes i5.

3. replace only concerned inputsOnly the inputs that are used (i1 and/or i2) are shifted to the next free safety inputs. This is the standard option.

Input Selection

OKCancel

manually or

automatically

Do you want to rearrange the inputs

This function needs to use inputs 1 and 2 which are already used elsewhere (See the yellow warning mark(s)).

You need to rearrange your input selection to free these inputs.

shift all inputs (incl. unused)

replace only concerned inputs

Automatic Mode:

move up inputs (use unused)

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Introduction

The Specific Functions folder contains the Injection Molding Machine device symbol for monitoring an injection molding machine with a protection door, as indicated in figure Wiring Diagram, p. 206.

The 3 limit switches Ch.1, Ch.2 and Valve must then be connected to various control outputs and safety inputs, to ensure complete short-circuit monitoring. The injection molding machine is activated according to the switching states of limit switches Ch.1, Ch.2 and Valve, in accordance with the function diagram in figure Functional Diagram, p. 204. A Start Interlock is, in this case, mandatory, i.e. the protection door must be opened once and then closed again, to make starting possible.

Note: 1 of the 3 starting devices: automatic starting, non monitored starting or monitored starting must be assigned to each injection molding machine device. The corresponding safety output cannot be activated without this assignment.

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Dialog Box Settings



Option Description


Sync Time A synchronization time, during which contacts ch.1 and ch.2 must close, must be entered in this field. If this time is exceeded, the assigned safety outputs are not activated. For the response time of 20 ms, the range is 0.5...2.5 s, and for the response time of 30 ms, the range is 0.45...2.4 s for the Synchronization Time.

Inputs The safety inputs and control outputs used must be indicated in this field.


Control Output:

CancelOK

Injection Molding MachineName:

?

Inputs

Ch.1:

Control Output:Ch.2:

Sync Time: s

(0.5 ... 2.5 s)

Control Output:Valve:

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Introduction The Specific Functions folder contains the Hydraulic Press Valve Monitoring device symbol for monitoring a hydraulic press valve, as indicated in figure Wiring Diagram, p. 208.

Using this device, a hydraulic press with safety valves with three position switches or with PNP sensors Valve C to Valve C+O can be connected to the XPSMC, as shown in the figure Wiring Diagram, p. 208. The press control delivers the press opening and closing signals. Each time the leading edge of the two press control signals, OPEN PRESS and CLOSE PRESS goes positive, a configurable internal time window is generated, during which the XPSMC waits for a response from the appropriate valve position switch (Valve C and Valve C+O for press closing, Valve O for press opening). If this time window is exceeded, the corresponding safety outputs are deactivated.

If signals Valve C to Valve C+O appear in an order other than the one shown in figure Functional Diagram, p. 207, the affected safety outputs of this function are then deactivated and an error message appears.

This function thus delivers the CLOSING AUTHORIZATION signal to a safety output, if the CLOSE PRESS signal is active and if Valve C and Valve C+O are closed correctly in the time window.

The OPENING AUTHORIZATION signal will also be activated on a safety output, if the OPEN PRESS signal is active and if Valve O is closed correctly in the time window.

When this device is selected, it is first necessary to assign the OPENING AUTHORIZATION function to a safety output and the CLOSING AUTHORIZATION function to another safety output.

This takes place in the window which appears automatically:

Output Selection

CancelOK

Enable CLOSING

Enable OPENING

The selected output o6 shall be used for:

This function has two outputs: one for the opening and one for the closing of the press.

Please select the other output:

Enable OPENING:

o6:

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Dialog Box Settings



Option Description


Options A synchronization time, during which the respective contacts Valve C/Valve C+O and Valve O/Valve C+O must close, can be entered in this field. If this time is exceeded, the corresponding safety outputs are deactivated. For the response time of 20 ms, the range is 0.1...1.5 s, and for the response time of 30 ms, the range is 0.15...1.5 s for the Synchronization Time.

Inputs The safety inputs and the control output used must be indicated here. Switches Valve C to Valve C+O must be connected directly to the +24 V supply voltage. The two contacts for OPEN PRESS and CLOSE PRESS can operate with the same control output.Optional, an input to bypass the monitoring of the valves can be chosen.If the bypass is used, Valve C, Valve O and Valve C+O will not be monitored and have no influence on the position of the press. The safety outputs are dependant only on the situation of the OPEN and CLOSE contacts.

Hydraulic Press

CancelOK

Hydraulic Press Valve MonitoringName:

?

Inputs

Valve C:

Valve O:

Control Output:Close:

Open:

Sync Time: s

(0.1 ... 1.5 s)

Enable bypassing of valve monitoring by:

Options

Valve C+O:

Control Output:Input:

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Hydraulic Press 2

Introduction The Specific Functions folder contains the Hydraulic Press 2 Functions device symbol for a hydraulic press with valve monitoring and optional overtravel monitoring, as indicated on the Wiring Diagram, p. 208.

This device provides an internal mode selector switch function for the operation modes OFF / INCHING / SINGLE STROKE / AUTOMATIC of the hydraulic press. The use of the overtravel monitoring functionality is optional. The press control delivers the press opening and closing signal; the use of these inputs is mandatory when Automatic mode is selected. The use of the input for the Open command is also mandatory when mode Inching is selected. In Inching mode, valve monitoring is not active.

When you drag-and-drop the Hydraulic Press 2 device onto an output, the following window appears. Here you can select the output you need and enable either the opening or the closing movement of the machine.

Output Selection

CancelOK

Enable CLOSING

Enable OPENING

The selected output o5 shall be used for:

This function has two outputs: one for the opening and one for the closing of the press.

Please select the other output:

Enable OPENING:

o5:

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The following image shows the output selection options:

Hydraulic Press 2

CancelOK

Name:

?

Inputs

Close:

Open:

Control Output

2 - Single Stroke:

1 - Inching:

3 - Automatic:

Sync Time: s

(0.1 ... 1.5 s)

Mode Selector Switch

0 - Off

* contact position ofdeactivated valve

Hydraulic Press 2

Valve O:

Valve C:

on

on *

*

Valve C + O: off *

Use Open/Close Signals from PLC

NWK:

Kx:

Control Output

Use Overtravel Monitoring used

OTS:

UT:

Control Output

Control Output

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Dialog Box Settings

The following table describes dialog settings of the Hydraulic Press 2:

Option Description


Options Here you can enter synchronization time in which respective contacts Valve C / Valve C+O and Valve O / Valve C+O must be moved (opened or closed). If the time is exceeded, corresponding Safety Outputs are deactivated. For the response time of 20 ms, the range is 0.1...1.5 s; for the response time, the range is 0.15...1.5 s for the Synchronization Time.

Inputs The safety inputs and the control output used must be indicated here. Switches Valve C to Valve C+O must be connected directly to +24 V supply voltage.NWK and Kx are an own control output. The close and opening contact use also only 1 control output.

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The following operation modes are available:� Mode Off

The press is deactivated and all safety outputs connected to the press are turned off.

� Mode InchingPosition switches OTS and UN as well as the switches of the valves PSV1 and PSV2 will not be monitored, and have no influence on the movement of the press. The safety outputs are dependant only on the situation of the Safety Means and Start.

� Mode Single StrokeWith each releasing of the start device, for instance Two-Hand Control, one stroke of the press is implemented. The safety stopping at the top dead centre is realized by the limit switches OTS and UN. The automatic upstroke is controlled by the closing of the limit switch UN. In addition, with selected valve monitoring, the synchronous time of the two halves of the press safety valve (PSV) are monitored with the switches PSV1 and PSV2 when switching on and off.

� Mode ContinuousThe functions of monitoring correspond in theory to those of the mode Single Stroke, however the press does not stop after one cycle. The continued operation starts with the input Safety Means and Start, and the press runs until the Safety Means and Start input is released or the Continuous Off switch is switched off. Dynamic monitoring of the valve and the monitoring of overtravel will only be performed one time in the continuous cycle.

� Mode Continuous AutomaticThe function of monitoring corresponds to those of the mode Single Stroke, however the press does not stop after one cycle. Continued operation starts with the input Safety Means and Start (after the start, the device can be deactivated), and the press runs until the Continuous Off switch is actuated or the Safety Means for Continuous Automatic input is switched off. Dynamic monitoring of the valve and monitoring of overtravel will only be performed one time in the continuous cycle.

Note: In the following situations, reoperate all safety means:� The E-Stop has been pressed.� The operation mode has been changed.� The opening has been finished in single stroke or inching.� Safety means for presses that are not to be operated each stroke should be

dragged and dropped onto the press output and not on the press itself.

Option Description

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Eccentric Press

Introduction The Specific Functions folder contains the Eccentric Press symbol to control the safety stopping of an eccentric press at top dead center (OTS) with over-travel monitoring and optional valve monitoring.

The press must be operated with a two-hand control device. The XPSMC safety outputs are activated as long as the start signal is active at the beginning of the cycle and the position switches OTS, UN,PSV1, and PSV2 deliver the correct signals throughout the cycle. To enable short-circuit detection, the position switches must be connected to different safety inputs and control outputs.

The function detailed operation differs according to the selected operating method.

Position switches OTS and UN detect the press movement and in particular safety stopping at the top of the dead center OTS.

The control cams are shown on the following functional diagram:

Position switches PSV1 and PSV2 monitor the status of the press safety valve. For the response time of 20 ms, the range is 0.1...1.5 s, and for the response time of 30 ms, the range is 0.15...1.5 s for the Synchronization Time. If this time is exceeded, an error message appears, and the corresponding safety outputs are deactivated until the Reset input is activated.

OTS

UN

Hazardousmotion

Braking angle

Cam

OTS

CamUN

approx. 150°

approx. 300°

approx. 10°

OTS

UN

Positionswitch

Position

switch

Maintain=Automatic opening

Acceptableovertravel

0° = Top dead center OTS

Representation at OTS

Normallyopen"NO"

Normally

closed"NC"

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To delete an overtravel error or an error at the UN or OTS position switches, the Reset input must be actuated. The errors on the press safety valves, the UN or OTS position switches, and overtravel will not be cleared by switching off the controller.

If one of the safety inputs delivers an incorrect signal, an error message appears, and the corresponding safety outputs are deactivated.

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Dialog Box Settings

The parameter settings window provides the following setting possibilities:

Description of the settings window:

Setting Description


Options The valve monitoring can be activated, and the Synchronization Time for the switch ON and Off of the press safety valves PSV1 and PSV2 can be adjusted. For the response time of 20 ms, the range is 0.1...1.5 s, and for the response time of 30 ms, the range is 0.15...1.5 s for the Synchronization Time.

Inputs Relation between inputs and control outputs can be selected.

Eccentric Press

OKCancel

Eccentric PressName:

?

Inputs

OTS:

UN:

Control Output:

PSV2:

ContinousOff:

Sync Time PSV1-PSV2 (s): (0.1 ... 1.5 s)

Valve Monitoring

Options

PSV1:

Control Output:

Control Output:

Control Output:

Reset:

Inching:

Off:

Continuous Autim.:

Single Stroke:

Mode Selector Switch:

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Mode Selector Switch The following operation modes are available:� Mode Off






Setting Description

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Eccentric Press 2

Introduction The Specific Functions folder contains the Eccentric Press 2 device symbol to control the safety stopping of an eccentric press at top dead center (OTS) with over-travel monitoring and optional valve monitoring. The valve monitoring shown in the Wiring Diagram, p. 218 is optional. The press must be operated with the minimum of 1 device, such as Light Curtains without Muting, Safety Guard, Magnetic Switch, Two-Hand Control, Foot Switch, and Selector Switch.

The XPSMC safety outputs are activated as described for the different operation modes and the position switches OTS, UN, PSV1 and PSV2 deliver correct signals throughout the cycle. To enable short-circuit detection, the position switches must be connected to different safety inputs and control outputs. The function-specific operations differ according to the selected operation mode. Position switches OTS and UN detect the press movement and ensure safety stopping at the top dead center OTS.

The control cams are shown on the following functional diagram:

OTS

UN

Hazardous

motionBraking angle

Cam

OTS

CamUN

approx. 150°

approx. 300°

approx. 10°

OTS

UN

Positionswitch

Position

switch

Maintain=Automatic opening

Acceptable

overtravel

0° = Top dead center OTS

Representation at OTS

Normally

open"NO"

Normallyclosed

"NC"

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Two more switches PSV1 and PSV2 monitor the status of the press safety valve. For the response time of 20 ms, the range is 0.1...1.5 s, and for the response time of 30 ms, the range is 0.15...1.5 s for the Synchronization Time. If this time is exceeded, an error message appears, and corresponding safety outputs are deactivated until the reset input is activated.

To delete an overtravel error or an error at the UN or OTS position switches, the reset input has to be actuated. The errors on the press safety valves, the UN or OTS position switches and overtravel will not be cleared by switching off the controller.

If one of the safety inputs delivers an incorrect signal, an error message appears and the corresponding safety outputs are deactivated.

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Dialog Box Settings


The following image shows the safety means displayed on the output tree:


Option Description


Valve Monitoring For the response time of 20 ms, the range is 0.1...1.5 s, and for the response time of 30 ms, the range is 0.15...1.5 s for the Synchronization Time.

Eccentric Press 2

CancelOK

Name:

?

Inputs

OTS:

UN:

Control Output:

PSV2:

ContinuousOff:

PSV1:

Control Output:

Control Output:

Control Output:

Reset:

2 - Single Stroke:

1 - Inching:

4 - Continuous Automatic:

3 - Continuous:

Sync Time PSV1-PSV2: s

(0.1 .. 1.5 s)

Enable Valve Monitoring

Dead Time: s

(0.05 .. 0.50 s)

Shaft Monitoring

Enable shaft Monitoring


on

on *

*

0 - Off

* contact position ofdeactivated valve

Eccentric Press 2

Valve Monitoring

used

continue stroke until OTS on’Continuous Off’ signal in ’Continuous Automatic’ mode

’Eccentric Press’

i Configuration: ’wer’

i C1 (XPSMC16 ZP): ’Controller1’i16

R1

R2

o1

o2

o3

o4

o6

[Safety Means + Start]

[Safety Means for Continuous Auto.]

o5

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Shaft Monitoring For the response time of 20 ms, the range is 0.05...0.50 s, and for the response time of 30 ms, the range is 0.06...0.48 s for the Synchronization Time.

Inputs The used inputs and the control output must be indicated in this field (see the Wiring Diagram, p. 206. The stopping functionality of the Continuous Off signal can be defined. The Reset Switch and Mode Selector Switch must be connected directly to the +24 V supply voltage.


The following operation modes are available:� Mode Off






Option Description

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Depending on whether Enable Shaft Monitoring is selected or not, the corresponding device will or will not appear in the Configuration window immediately under Eccentric Press.

Without shaft monitoring

With shaft monitoring

When devices have been moved to the safety means, the safety means to be started in the Continuous Automatic mode appear underneath the corresponding small circles, as shown in the example below.


i Configuration:


R1

R2

o1

o2

o3

o4

o5

o6




i Configuration:


R1

R2

o1

o2

o3

o4

o5

o6




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Two-hand control and a light curtain

Note: The Selector Switch device can be used to provide the signals for Safety Means and Start and/or Safety Means and Continuous Automatic to the press device. The Selector Switch devices permit a great deal of flexibility regarding various safety means for the different operation modes (see Selector Switch, p. 109).Safety means for presses that are not to be operated each stroke should be dragged and dropped onto the press output and not on the press itself.


i Configuration:


R1

R2

o1

o2

o3

o4

o5

o6




’Light Curtain’

’Two Hand Control’

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Introduction The Specific Functions folder contains the Shaft/Chain Break Monitoring icon. The device is used to monitor the movement of a cam switch mechanism of an eccentric press, as shown in the Shaft/Chain-Break Monitoring, p. 229. This device is directly linked to the OTS and UN position switches by a cogwheel sensor and can only be connected either to input i1 or i2. You can drag and drop the device from the library onto any output of the controller. For theEccentric Press 2 device, you can only enable the Shaft Monitoring device inside the Properties window.

Dialog Box Settings

The parameter setting window provides the following possibilities:


Option Description


Options For the response time of 20 ms, the range is 0.02...0.10 s, and for the response time of 30 ms, the range is 0.03...0.9 s for the Pulse cycle.

Inputs Only i01 or i02 are selectable.

Note: You can only use 2 different Shaft/Chain Break Monitoring devices in 1 XPSMC, because there are only 2 counter inputs (i1 and i2) available, see also Zero Speed Detection, p. 69.


CancelOK

Name:

IPulse Cycle: s

(0.02 .. 0.10 s)

Sensor:

? ?

Options


Input

Only input i01 or i02 can be used to connect the sensor.

Pulse Cycle Calculator:

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Introduction The Specific Functions folder contains the device symbol for monitoring of a seat valve as shown in figure Wiring Diagram, p. 232.

The device senses the start signal for operating the valve with the first input and the answer signal of the concerned valve contact with the second input.

Dialog Box Settings



Option Description


Options The function of the valve contact can be selected as either NO or NC. For the response time of 20 ms, the range is 0.1...3.0 s, and for the response time of 30 ms, the range is 0.15...3.0 s for the Synchronization Time.

Inputs After the start signal is given and the valve contact is not operating, the output of the device is immediately activated and remains activated until the synchronisation time is exceeded. The output only remains activated if the valve contact is operating during the synchronisation time. After this, the valve contact may open and close without disrupting the output as long as the start signal is maintained. If the start command disappears, the output will always be deactivated.


Seat Valve MonitoringName:

NO

NC

Control Output:

CancelOK?

Inputs

Start:

Control Output:Valve:

Sync Time: s

(0.1 ... 3.0 s)

Sync Time Monitoring Start - Valve:

Valve Contact:

Options

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4.3 EDM Devices

EDM Device (External Device Monitoring)

Introduction The EDM Device folder contains the device symbol for monitoring a feedback loop. This device is used to monitor external devices such as subsequent contactors or relays.

If, for example, external contactors K1 / K2 are activated, the EDM input to which opening contacts K1 and K2 are assigned must then be opened, by the end of the adjustable synchronization time at the latest. If this is not the case, an error message appears and the safety outputs concerning K1 and K2 are deactivated.

Before activating the safety output, ensure that the EDM input is activated. If it is not, an error message appears, and the safety output gets deactivated.

Dialog Box Settings



Option Description


Options A synchronization time, during which the return circuit must open, can be entered in this field. If this time is exceeded, the corresponding safety output is deactivated. For the response time of 20 ms, the range is 0.1...0.5 s, and or the response time of 30 ms, the range is 0.15...0.5 s for the Synchronization Time. If the Synchronization Time is not activated, only check whether the EDM input is closed immediately before activating the safety outputs.

Inputs The safety input and the control output must be indicated in this field.

EDM

Name:

Control Output:

OKCancel?

Inputs

Input:

EDM Time (s):

(0.15 .. 0.50 s)

Options

EDM Time Monitoring:

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4.4 Start Device

Start Device

Introduction The Start Devices folder contains 3 device symbols for

� Automatic Start,� Non-Monitored Start,� Monitored Start.

The functional diagram for these devices is shown, as an example, in figure Functional Diagram, p. 174.

Dialog Box Settings



Option Description


Start

Name:

Automatic Start

Non monitored Start

Control Output:

OKCancel?

Input

Start:

Function

positiv

negativ

Trigger Edge:

Options

Monitored Start

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Function You can then select one of the starting devices again in this field. The device symbol in the configuration tree is adapted automatically.The following options are available:� Automatic Start

The safety outputs are activated as soon as all the starting conditions are fulfilled. A start button is not necessary.

� Non monitored StartThe safety outputs are activated as soon as all the starting conditions are fulfilled and starting is initiated by the start button being pressed. The Start button must not re-activated to launch the Start device, and the non monitored start then operates in the same way as the automatic start.

� Monitored StartIn this case, the safety outputs are only activated when all the starting conditions are fulfilled and starting is initiated when the start button is pressed (automatic start on a positive trigger edge) or when the start button is pressed and released (automatic start on a negative trigger edge). It is possible to define whether starting should take place on the positive-going edge or negative-going edge of the starting signal. Unlike non monitored starting, the safety output cannot be activated when the start button is actuated by an XPSMC Power-Up or when the start button is maintains status 1 for some time after the operation. This will cause an error message.

Options During monitored starting, a selection can be made in this field between automatic start on a positive trigger edge (= starting when the start button is pressed) or automatic start on a negative trigger edge(= starting when the start button is released).

Inputs The safety input and the control output must be indicated here.

Option Description

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4.5 Enabling Devices

Two-Channel or Three-Channel Enabling Device

Introduction The Enabling Devices folder contains 2 device symbols for the enabling switch. This device can be used alone on a safety output, with a safety guard or together with a safety guard on the OR device.

With an enabling switch, a safety guard can be bypassed and a hazardous movement can consequently be started, even with a protection door open, during the fitting out of a machine for example. The enabling switch does not activate the dangerous movement but gives a validation for the dangerous movement to be actuated.

This function works with a two or three channel enabling switch (Wiring Diagram, p. 234 or figure Wiring Diagram, p. 236). Category 4 is only achieved when using the 3 position enabling switch. For the types of enabling switches that can be used, see the Technical Data chapter of the Hardware instruction manual.

To produce the confirmation signal, the enabling switch must first be set to position 0 and then to position 1. The authorization is thus activated, as are the XPSMC safety outputs. If the enabling switch reaches position 2, the safety outputs are again deactivated. When the enabling switch is set back to position 0, no further enabling is authorized, even if the switch is returned to position 1.

Note: The enabling device can be dragged and dropped together with a safety guard onto the OR device. An external switch (preferably a key switch) should be used to enable the input of the enabling device.

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Dialog Box Settings



Option Description


Function You can select one of the enabling switches in this field. The device symbol in the configuration tree is adapted automatically. The switching diagram needed for the contact switch is also schematically illustrated here.

Options Here a max. enable time can be given. If the enabling switch is active longer than the enable time, the corresponding safety outputs will be deactivated and a fault message will be given. The time is adjustable from 0.5...10 min.

Inputs The safety inputs and control outputs used must be indicated in this field. To ensure reliable short-circuit detection, all the contacts must be set into service on different control outputs.

Enabling Device

Control Output:

CancelOK

Enabling DeviceName:

two channels

Control Output:

?

Function

Inputs

Ch 1:

Ch 2:

Enable Time: min

(0.5 ... 10 min)

Enable Time Monitoring:

Three channels

Options

Control Output:Ch 3:

NO

NC

NO

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4.6 Miscellaneous Devices

At a Glance

Overview This section contains the description of the Miscellaneous Devices folder, which contains all the logic devices.



Topic Page

Timer 104

OR Device 106

Foot Switch Control Device 107

Selector Switch 109

Closed Tool Device 112

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Timer

Introduction The Miscellaneous Devices folder contains the Timer device symbol. Figure Functional Diagram, p. 226 indicates the corresponding functional diagrams.

This device enables the safety output(s) with the timer function.

Dialog Box Settings



Option Description


Timer

Control Output:

CancelOK

TimerName:

switch ON delay

?

Function

Input

Input:

Time: s

(0.1 ... 300 s)

switch OFF delay

switch ON pulse

switch OFF pulse

Input:

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Function You can select one of the four operating modes: 1. Switch ON delay

If the safety input changes its status from 0 to 1 and stays at 1, the adjustable time delay starts, and the time delay has reached its setpoint, the safety output is set to 1. If the control output is set to 0, the safety output is simultaneously set to 0. If the safety input status changes to 0, and the time delay has not expired, the safety output remains at 0.

2. Switch OFF delayIf the safety input changes its status from 0 to 1, the safety output is immediately set to 1. If the safety input changes its status from 1 to 0 and stays at 0, the adjustable time delay starts, and the time delay has reached its setpoint, then the safety output is set to 0. If the safety input status changes to 1, and the time delay has not reached its setpoint, the safety output remains at 1.

3. Switch ON pulseIf the safety input changes its status from 0 to 1 and stays at 1, the adjustable time delay starts, and the safety output is simultaneously set to 1. The safety output is set to 0, if the time delay has reached its setpoint, or the safety input changes to 0.

4. Switch OFF pulseIf the safety input changes its status from 1 to 0, then the adjustable time delay starts, and the safety output is set to 1. The safety output is set to 0, if the time delay has reached its setpoint.

The function is presented by an explanatory schematic diagram.

Time For a response time of 20 ms the range is 0.1 to 300 s and for a response time of 30 ms the range is 0.15...300 s.

Inputs The safety input and the control output used for the control signal must be indicated here.

Option Description

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OR Device

Introduction The Miscellaneous Devices folder contains the symbol of the OR Device.

The result of an OR connection between several devices is validation of an output.

There are no properties available for this device.

The OR component cannot be used with an E-Stop device.

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Foot Switch Control Device

Introduction The Miscellaneous Devices folder contains the Foot Switch Control device symbol. The device monitors a NO and NC contact from 1 control output.

Dialog Box Settings



Option Description


Options � Start Interlock: Foot switch must be released before starting the foot switch function.

� Sync Time Monitoring: for the response time of 20 ms, the range is 0.5...2.5 s, and for the response time of 30 ms, the range is 0.45...2.4 s for the Synchronization Time, required for the 2 inputs, NO and NC.

Inputs The Inputs must be supplied from a control output.

HAZARDOUS APPLICATIONS

Do not use foot switches on machines without point-of-operation protection.

Failure to follow these instructions will result in death or serious injury.

Foot Switch Control

CancelOK

Name:

?

Inputs

Control Output:Contact NO:

Contact NC:

Sync Time: s

(0.5 ... 2.5 s)

Start Interlock

Options

Foot Switch Control

Sync Time Monitoring:

NO

NC

DANGER

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Note: The use of the Foot Switch requires additional safety measures! The Foot switch does not provide technical safety for a press control. Example: In order to control the continuous mode of a press with the Foot Switch, additional safety means are necessary (e.g., Safety Guard, Light Curtain).

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Selector Switch

Introduction The Miscellaneous Devices folder contains the Selector Switch device symbol.

You can drag the selector switch device symbol to either the Eccentric Press 2, the Hydraulic Press 2, or directly to an output.

The selector switch device helps you to select the devices to be used as safety means and start means. When you drag and drop the selector switch symbol onto an output or a press, no dilaog box will appear, because you should first drag and drop all relevant devices onto the switch and configure them, before you define your selection.

The following is a list of devices that can be dragged and dropped onto the Selector Switch device (their number is limited by the number of inputs of the controller).

For the Hydraulic Press 2 and Eccentric Press 2 (Safety Means + Start / Safety Means for Continuous Automatic):

� Safety Guards� Light Curtains without Muting� Magnetic Switches� Two-Hand Control� Foot Switch� Enabling Device� Closed Tool device

For an output:

� Safety Guards� Light Curtains� Magnetic Switches� Two-Hand Control� Foot Switch Control� Safety Mat� Zero Speed Detection� Hydraulic Press� Eccentric Press� Shaft / Chain Break Monitoring� Seat Valve Monitoring� Start devices� Enabling devices� Timer

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The following image shows the selector switch on a safety means and start of the Eccentric Press 2 with three related devices:

’Foot Switch Control’


’Magnetic Switch’

’Two Hand Control’

i Configuration:

i C1 (XPSMC32 ZC): ’Controller1’i32

’Selector Switch’

R1

R2

o1

o2

o3

o4

o5

o6


[Safety Means for Continuous Automatic]

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Dialog Box Settings

The following image shows the selector switch with related devices. Here you can allocate the devices to the relevant input.



For the safety means and start it is active in� Position 1: Two-Hand Control � Position 2: Magnetic Switch � Position 3: Foot Switch Control and Magnetic Switch

Option Description


Device Declaration Selector Switch position: Select the relevant input to the selector switch position.

Selector Switch

CancelOK

Name:

?

Device Declaration

Input: i01

Selector Switch Position: 1

Selector Switch

i02

2

i03

3 4 5 6

used:

’Two Hand Control’:

’Foot Switch Control’:

’Magnetic Switch’:

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Closed Tool Device

Introduction The Miscellaneous Devices folder contains the Closed Tool symbol. You can use this device with a Selector Switch and an additional start device (e.g., Foot Switch Control) on Hydraulic Press 2 or Eccentric Press 2. You can also move it directly to the safety means for continuous automatic operation of the Eccentric Press 2.

When you configure the Closed Tool device directly to the Safety Means for continuous automatic operation of the Eccentric Press 2, you also need an external key switch to enable the continuous automatic operation as well as a signal lamp.

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4.7 State of Outputs

Applying Output States to Other Safety Outputs

Introduction The Output states folder contains the symbol of the safety outputs for each controller.

By moving the output X symbol on the output Y in the Configuration window, the safety output Y will have the same behavior as the safety output X. Other components can be assigned to the output Y.

The same result will be achieved by moving the output X symbol with the left mouse button onto the output Y.

Example

In this example, safety output o1 is associated with Non monitored Start, Safety Guard and two channel Emergency Stop. Safety output o2 represents the 2nd channel of this safety function and will behave exactly like o1.

No adjustment is provided for in this function. Modifications can only be performed in the original safety function (in this case, safety output o1); they are then taken into account automatically in the corresponding safety output.

i

C1: ’Controller1’i16

Configuration:

i

o1

’Emergency Stop’

’Safety Guard’

o1 (C1)

o2

’Non monitored Start’

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5
Configuration
At a Glance

Overview This chapter contains the description to create a configuration.


This chapter contains the following sections:

Section Topic Page

5.1 General Information 117

5.2 Application Scheme Configuration 119

5.3 Configuring the Emergency Stop Function 131

5.4 Save the Configuration 137

5.5 Requesting/Changing the Password 139

5.6 Sending a Configuration from the PC to the XPSMC and Performing a Check

141

5.7 Loading a Configuration 149

5.8 Creation/Transfer of a Validated Configuration Copy 151

5.9 Read Protocol from Controller 155

115

Configuration

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5.1 General Information

Generals

Introduction

By way of example, the creation of a configuration is explained by means of the following application:

The entry of personnel into the hazardous zone of the robot arm is prevented by the guard/protection door with 2 limit switches. For adjustment and maintenance purposes, the robot arm may also be controlled when the door is open by using an enabling switch. The choice of using the guard or enabling switch for personnel safety is done by an external selector switch mounted near the guard. The safety of any personnel inside or around this cell is further enhanced with a two-channel emergency stop.

Note: The configuration can be created with the PC offline, i.e. without being connected with an XPSMC, and later sent to the XPSMC.

Robot

openProtection door

Limit switch Limit switch

Enablingswitch

StartE-Stop Selectorswitch

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Configuration

The corresponding wiring diagram could be as follows:

ESC External Start Conditions(1) See Technical Data for maximum fuse size, Hardware manual

Enable switch contact:

A complete overview of all the functions and their configurations is given in chapter Wiring (Examples) and Functional Diagrams, p. 163.

Maximum Response Time

You can select the response time for all XPSMC••Z versions. For the XPSMC••X versions, the response time is always ≤ 20 ms. By selecting the response time, you can reduce the load of the CPU. Note that when you change the response time in a current configuration, all configurable timers are set to zero and must be modified again. The limit ranges for the timers is also changed.

LOGIC Channel 1

Channel 2

XPSMC16

safety controller

Channel 1

Release safety gate

E-Stop

open

Enabling

switch

Start

(NC)(NO)

(1)(1)

Channel 2 Channel 1

Emergency stop

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

ESC ESC

Enable

highspeed

Selector switch S6:

0 - OFF

1 - Guard

2 - Enable switch

Note: XPSMC32 with 32 inputs i1...i32, otherwise identical

On

Off

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5.2 Application Scheme Configuration

At a Glance

Overview This section contains the application scheme of configuration.



Topic Page

Creating a New Configuration / Selecting a Controller Type 120

Assigning the Switch Position 124

Assigning the Protective Guard Function 125

Assigning the Starting Function 126

Assigning the Enabling Device 127

EDM Adjustment 128

Assign a Name and a Stop Category to a Safety Output 129

Copying the State of One Safety Output onto another Safety Output 130

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Configuration

Creating a New Configuration / Selecting a Controller Type

Procedure Proceed as follows:

Step Action

1 Start the XPSMCWIN configuration software.Result: The program user interface appears.

2 Drag the symbol of the desired controller from the Device Library window into the still empty Configuration window.

3 Release the left mouse button and a new configuration is automatically created.Result: Fill in the window which has opened.Note: If the window does not open automatically, you are prompted to activate automatic opening in the Options editor menu option.The following figure shows the Configuration dialog box:

Configuration

Robot 1 (max. 16 char.)Title:

Your name|Author:

last modified: 15.12.03 11:23:22

OK Cancel

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4 Click on the relevant change... button to provide for adjustments for the future Modbus and Profibus communication.The following figure shows the Controller dialog box:

5 Click on the change... button of Modbus or Profibus.

Step Action

Controller C1 (XPSMC32 ZP)

Name:

XPSMC32 ZP-Profibus ExtensionType:

OK Cancel

i32

Modbus

not used change...

Controller1

Profibus

not used change...

<= 30 ms<= 20 ms

Response Time

all outputs


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Configuration

6 Fill in the window which has opened.The following figure shows the Modbus Parameters dialog box:

The following figure shows the Profibus Parameters dialog box:

As the PC is not yet connected to controller 1, the Modbus settings cannot yet be sent at this level to controller 1.You can download only the parameters (no configuration) for the Modbus and Profibus by clicking on the Download button when your PC is connected to the safety controller.

Step Action

Modbus Parameters

Controller 1:

OK Cancel

Address Bit Rate Parity

(1-247)

19200 even

Controller 2:

Controller 3:

Controller 4:

Controller 5:

Controller 6:

Controller 7:

Controller 8:

different Modbuses

Download i

connect

1

Profibus Parameters

Controller 1:

OK Cancel

Address

(1-125)

Controller 2:

Controller 3:

Controller 4:

Controller 5:

Controller 6:

Controller 7:

Controller 8:

Download i

connect

2

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Configuration

7 Click OK.Result: Your screen should now look like the one in this figure:

Step Action


XPSMCWIN


i i



C1 (XPSMC32 ZP): ’Controller1’i 16

o1

o2

o3

o4

o5

o6

R1

R2

Telemecanique


i

i16


EDM Devices

Start Devices


Enabling Devices

Controller

State of Outputs

XPSMC16 Z


XPSMC16 Xi

XPSMC32 Zi32



XPSMC32 Xi32

16

16

16

Monitoring Devices

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Configuration

Assigning the Switch Position

Introduction For safety reasons, a position switch is necessary, which determines if the machine will be started with the safety guard OR with the enabling switch (see the block diagram in the chapter Generals, p. 117).

To configure this OR connection, the symbol of the OR device has to be moved to the o1 output as follows:

Configuration

Configuration: ’Robot 1’C1 (XPSMC32 ZP): ’Controller 1’i32

o1OR

o2

1

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Assigning the Protective Guard Function


Step Action

1 In the Safety Guard folder (which is located in the Monitoring Devices folder), select the 2-channel protection door symbol, and drag it onto the symbol of the OR component.Result: A window opens, in which you have to define the function properties, for example:

2 Confirm with OK.Result: The protection door device is then assigned with the OR component to safety output o1.

Safety Guard

Control Output:

CancelOK

c02

2-channelName:

one channel, w/o lock

two channel, w/o lock

Control Output: c03

?

Function

Inputs

Ch 1: i02

Ch 2: i03

0.90Sync Time: s

(0.45 ... 2.40 s)

Start Interlock

two channel, with lock

Options

Sync Time Monitoring Ch. 1 - Ch. 2:

Control Output:Lock:

C1 (XPSMC32 ZP): ’Controller 1’i32o1

OR’2-channel’

1

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Assigning the Starting Function


Step Action

1 In the Start Devices folder, which is located in the Monitoring Devices folder, select the Monitored Start device symbol and drag-and-drop it to the Safety Guard Device in the configuration window.Result: A dialog box for the definition of the function properties opens. The following figure shows an example of the dialog box:

2 Confirm with OK.Result: The Monitored Start Device is assigned to the Safety Guard device safety output o1.

Start

Start guardName:

Automatic Start

Non monitored Start

Control Output:

CancelOK

c01

?

Input

Start: i01

Function

positiv

negativ

Trigger Edge:

Options

Monitored Start

Configuration: ’Robot 1’C1 (XPSMC32 ZP): ’Controller 1’i32

o1OR

’Safety Guard’

’Start guard’

1

126 33003281

Configuration

Assigning the Enabling Device

Introduction According to this example application, the safety guard can be bypassed by the 3 channel enabling device. This gives the possibility for the Robot to run with the safety guard open when the 3 channel enabling device is used (when selector switch is in appropriate position).


Step Action

1 Drag the 3-channel enabling device symbol from the Enabling Devices folder onto the OR Device symbol in the Configuration window and fill in the window.

2 Confirm with OK.The following image shows the resulting configuration:

Enable Switch

Control Output:

CancelOK

c05

Enable Device Robot 1Name:

two channels

Control Output: c06

?

Function

Inputs

Ch 1: i06

Ch 2: i07

Enable Time: min

(0.5 ... 10 min)

Enable Time Monitoring:

three channels

Options

Control Output: c07Ch 3: i08

NO

NC

NO

Configuration: ’Robot 1’C1 (XPSMC32 ZP): ’Controller1’i32

o1OR

’2-channel’

’Start guard’’Enabling Device Robot 1’

1

33003281 127

Configuration

EDM Adjustment

Introduction The opening contacts of switches Ko1 and Ko2 must be defined with a synchroni-zation time of 0.2 s, i.e. within 0.2 s after the activation of safety outputs o1 and o2, and the return circuit must be open.


Step Action

1 Drag the EDM symbol from the EDM Devices folder onto symbol o1 in the Configuration window.

2 Confirm with OK.The following image shows the resulting configuration:

EDM

EDM Ko1 and Ko2Name:

Control Output:

CancelOK

c04

?

Inputs

Input: i04

0.15EDM Time:

(0.15 .. 0.50 s)

Options


s

Configuration: ’Robot 1’C1 (XPSMC32 ZP): ’Controller1’i32

o1OR

’2-channel’


’EDM Ko1 and Ko2’

1

128 33003281

Configuration

Assign a Name and a Stop Category to a Safety Output


Step Action

1 Click the right mouse button on its function symbol in the Configuration window to assign a name and a stop category to safety output o1.

2 Select the Properties menu option. Indicate a name and the stop category.

Note: Any safety output not modified has a default stop category of 0.

3 Confirm with OK.Result: This completes the configuration of safety output o1.

Output

Delay Off Input:

CancelOK

Safety GuardName:

Stop Category 0

Stop Category 1

Delay Time:

(0.15 .. 300 s)

Interruption of Delay Time:

Control Output:

? ?

s

33003281 129

Configuration

Copying the State of One Safety Output onto another Safety Output

Description In our example, o2 represents the 2nd channel of a safety control system, and must consequently behave exactly like o1. Left-click o1 in the configuration window, then drag and drop it onto o2.

The global protection door function is then configured for safety outputs o1 and o2.

Your screen should look like the one below:


XPSMCWin


i i


i

i16XPSMC16 ZC - CANopen Extensioni

EDM Devices

Start Devices


Enabling Devices

Configuration: ’Robot 1’Controller

State of Outputs

C1 (XPSMC32 ZP): ’Controller 1’iXPSMC16 Z


XPSMC16 Xi

XPSMC32 Zi32XPSMC32 ZC - CANopen Extensioni32XPSMC32 ZP - Profibus Extensioni32

XPSMC32 Xi32

16

16

16

32

Monitoring Devices

o1: ’Safety guard’

OR

’2-channel’

’Start guard’

’Enable Device Robot 1’


o2

o1(C1)

o3

o4

o5

o6

R1

R2

1

Inputs left: 25 I Load: 15 %

Telemecanique

130 33003281

Configuration

5.3 Configuring the Emergency Stop Function

At a Glance

Overview This section contains the configuration description of the Emergency Stop function.



Topic Page

Emergency Stop 132

Master E-Stop Device 136

33003281 131

Configuration

Emergency Stop

Description Depending on the application, the machine’s global control system must be able to be stopped by means of Emergency Stop button S1 which activates free outputs 13 / 14 and 23 / 24 of relay group R1. Their contactors KE1 and KE2 are assigned to ensure that when the machine is started, KE1 and KE2 are stopped in a statutory fashion.


Step Action

1 Drag the Two-Channel Emergency Stop symbol from the Emergency Stop folder (which is located in the Monitoring Devices folder) onto the output symbol of R1 in the Configuration window, and fill in the window.

2 Confirm with OK.Result: Now the E-Stop device is assigned to the safety relays group R1.

3 To also assign it to the solid state output o1, click with the right mouse button on the E-Stop device in the Configuration window.

4 Choose Copy from the selection.Result: The E-Stop device will then be copied with all its properties.

5 Click with right mouse button on the symbol of the output o1.

Emergency Stop

Control Output:

OKCancel

c08

Emergency Stop compl. machineName:

one channel switch

two channel switch

Control Output: c01

?

Function

Inputs

Ch 1: i09

Ch 2: i10

132 33003281

Configuration

6 Select Paste and as copy of device.Result: The E-Stop device will now also act on the output o1, and as the output state o1 is linked with o2, it will also act on o2.Note: To view the copies of a device, right click the mouse on the device. Mark e.g. E-Stop and select the menu Mark Copies. On the copies a green bubble appears. To remove the bubbles click Unmark Copies.

7 To adjust the return circuit, drag the EDM device symbol from the EDM Devices folder onto the symbol for R1 in the Configuration window, fill in the dialog box in accordance with the application.

Step Action


’Emergency Stop compl. Machine’

o1(C1)

’Emergency Stop compl. Machine’

’EDM E-Stop’

o2

o3

o4

o5

o6

R1

2

2

?

?

EDM

EDM E-StopName:

Control Output:

CancelOK

c02

?

Inputs

Input: i12

EDM Time:

(0.1 ... 0.5 s)

Options


s

33003281 133

Configuration

8 Confirm with OK.Result: This ensures that the installation can only be started when KE1 and KE2 are closed and the external start conditions (ESC) are fulfilled.Note: If a control output c1...c8 has been used, a "*" follows the name, for example "c2*", appears when this output is selected.The user must guarantee that no dangerous fault can occur when this control output is used more then once, as a dangerous short-circuit, for example, is no longer detected.Your screen should now look like the one below:

9 Complete the creation of the example configuration by saving and download it to the XPSMC.

Step Action


XPSMCWin


i i


i

i16


EDM Devices

Start Devices


Enabling Devices

Controller

State of Outputs

XPSMC16 Z


XPSMC16 Xi

XPSMC32 Zi32



XPSMC32 Xi32

16

16

16

Monitoring Devices

Inputs left: 25 I Load: 15 %

Telemecanique




OR

’2-channel’



o2

o1(C1)

o3

o4

o5

o6

R1

R2

1

’Emergency Stop compl. machine’

’EDM E-Stop’


134 33003281

Configuration

LOSS OF SAFETY INPUT CROSS-CONNECTION DETECTION

Ensure that no more than one critical safety input is connected to each of the control outputs.


WARNING

33003281 135

Configuration

Master E-Stop Device

Description A E-Stop device acts as a Master E-Stop on all the other devices of the output. The other devices will be deactivated when the Master E-Stop is pressed. When this occurs, the start of this output is not possible until the start conditions of all the other devices are met.

This is also available for all the copies of the E-Stop devices.

Note: An output state does not transfer a master E-Stop command on other devices. Only the status itself is transferred.

136 33003281

Configuration

5.4 Save the Configuration

Save

Description The configuration can be saved by opening the File → Save menu option (or by

clicking on the floppy disk symbol button ) under the current name or by opening the File → Save As... option and assigning a new path/name.

Note: When you close the configuration file and then open it again, a back-up copy is created in the same directory, with a .mcb extension. This way your last saved and closed configuration is stored as a back-up file.

33003281 137

Configuration

138 33003281

Configuration

5.5 Requesting/Changing the Password

Password

Enter Password

Each XPSMC command involving quitting the RUN mode (setting up the XPSMC for example) must be confirmed with a password. If such a command is performed, a dialogue window opens in which the password must be entered.

Change Password

The default password is safety; as a safety measure, it must be changed to an individual password. The password must contain between 4 and 12 symbols. Any combination of letters and numbers may be used.

The password can be modified with command Controller → Change password.

Note: Your PC must be connected to the XPSMC safety controller.

Note: The password is case sensitive. Security and security are thus two different passwords.

33003281 139

Configuration

140 33003281

Configuration

5.6 Sending a Configuration from the PC to the XPSMC and Performing a Check

Sending a Configuration

Procedure To send a completed configuration from the PC to the safety controller, follow this procedure:

Step Action

1 Select Check → Check Configuration to check the configuration.You can click on the Check Configuration icon alternatively:

Result: If the configuration contains no errors, the following message box appears:

If the configuration contains errors, a yellow question mark will be seen, and a corresponding message box will appear.


i i

XPSMCWIN

OK

No errors found.

33003281 141

Configuration

2 Go to Controller → Download Configuration to Controller to download the configuration:

You can click on the Configuration icon alternatively:

Step Action

File Edit Mode Check

XPSMCWIN

Device Library:

i i

i


EDM Devices

Start Devices

Controller

XPSMC16 Z


XPSMC16 Xi


XPSMC32 Xi32

16

16

16

Monitoring Devices

Run Controller

Change Password



Stop Controller

Validated Copy

Read Validation


Open Protocol



Controller Info

COM Settings ...

i

i

i

i

Options HelpController

Controller Options Help

Configuration

i i

142 33003281

Configuration

3 Click on the Download button.

Result: If the controller already has a configuration, the following message will appear:

4 Click Yes to continue the procedure.Result: If the controller is in RUN mode, the following message will appear:

Step Action

Connect the controller you want to configureto your PC.

Which is the corresponding controller in yourconfiguration?

Start download (or cancel).

Select Controller

Controller 1 ‘Controller 1‘

CancelDownload

i 32

Controller 2

Controller 3

Controller 4

Controller 5

Controller 6

Controller 7

Controller 8

1.

2.

3.

Yes No

Downloading the new configuration will overwrite the existing.

XPSMCWIN

Do you want to continue?

NoYes

Controller in RUN mode. For configuration it needs to be stopped.

Do you want to stop it now?

XPSMCWIN

33003281 143

Configuration

5 Click Yes to continue the procedure.Result: To stop the controller, enter your password (default password is safety in lower case)

6 Click OK to continue.Result: The download procedure is starting.After the download, you will see the protocol:

Note: Read this protocol carefully and check it with your hardware configuration. With Validate you confirm the correctness of the software configuration in the controller shown in the protocol.

7 Click on Validate button to validate the protocol.

Step Action

Please enter the password:

OK Cancel

Password

******

Protocol

0000 ************************************************************************************0001 XPS-MC V2.260002 Build: DB0A0110C70A021AC70A021A0003 Configuration protocol0004 Controller number: 010005 Configuration name: Robot 10006 Configuration date: 2006/02/10 10:240007 ************************************************************************************0008 RESPONSETIME: 30ms0009 RESPONSETIME: Device Safety mat = 45ms0010 ************************************************************************************0011 Modbus parameter:0012 Address: 0010013 Bitrate: 192000014 Parity: even0015 Stopbits: 10016 ************************************************************************************0017 Profibus Parameter0018 Address: 0020019 Baudrate: Autodetect0020 ************************************************************************************0021 Assignment control outputs / inputs:0022 Control output group: 010023 Used inputs: 01, 10,0024 Control output group: 020025 Used inputs: 02, 12,

CancelValidate

i

144 33003281

Configuration

8 Enter your name in the Validation dialog box:

9 Click OK to continue.Result:The Password dialog box will be displayed:

10 Enter your password and click OK.

11 Click OK to continue.Result: The following message will be displayed:

12 Click Yes to upload the protocol.Result: The following message will be displayed:

Step Action

Validation

CancelOK

I

Your name (max. 20 characters):

Options

Allow copying of validated configuration from controller

Create a copy of validated configuration now

Please enter the password:

OK Cancel

Password

******

NoYes

Do you want to upload the protocol of the validation for your documentation now?

Alternatively you can upload it later by using the menu ‘Controller‘.

XPSMCWIN

OK

Configuration downloaded successfully.

XPSMCWIN

No

Do you want the controller in RUN mode now?

33003281 145

Configuration

13 Click OK to start the controller.Result: The following message will be displayed

14 Click OK to finish the procedure.

Step Action

OK

Controller is in RUN mode now.

XPSMCWIN

146 33003281

Configuration

Typical Configuration Errors

Configuration error 1: If you forgot to assign a start device to the Two-Channel Safety Guard, the main window and the message box will look as follows:


XPSMCWin


i i

i

i16


EDM Devices

Start Devices


Enabling Devices

Controller

State of Outputs

XPSMC16 Z


XPSMC16 Xi

XPSMC32 Zi32



XPSMC32 Xi32

16

16

16

Monitoring Devices


C1 (XPSMC32 ZP): ’Controller1’i32


OR

’2-channel’

’Start guard’

’Enabling Device Robot 1’


o2

o1(C1)

o3

o4

o5

o6

R1

R2

1


’EDM E-Stop’


?

XPSMCWIN

OK

MISSING START DEFINITION.

Some devices require a start to be defined but haven’t by now.Please see the yellow question mark(s) in configuration tree and attach a start device to the marked items(s).

33003281 147

Configuration

Configuration error 2: If you forgot to set the inputs and outputs of the start device, the main window and the message box will look as follows:


XPSMCWin


i i

i


EDM Devices

Start Devices


Enabling Devices

Controller

State of Outputs

XPSMC16 Z


XPSMC16 Xi


XPSMC32 Xi32

16

16

16

Monitoring Devices




OR

’2-channel’

’Start’

’Enabling Device Robot 1’


o2

o1(C1)

o3

o4

o5

o6

R1

R2

1


’EDM E-Stop’


?

XPSMCWIN

OK

MISSING PROPERTIES.

Some device properties still need to be set.See the yellow question mark(s) in configuration tree.

Automatic Start

Non-Monitored Start

Monitored Start

148 33003281

Configuration

5.7 Loading a Configuration

Loading

Description The configuration of a controller can be uploaded at any time without stopping the controller.


Step Action

1 Connect your PC to the XPSMC safety controller.

2 Choose the command Controller → Upload Configuration from Controller or

click on the button in the toolbar.Reaction: The configuration is loaded from the XPSMC and then represented in the usual tree structure.

i

33003281 149

Configuration

150 33003281

Configuration

5.8 Creation/Transfer of a Validated Configuration Copy

At a Glance

Overview This section contains the description of creation and transfer a validated configuration copy.



Topic Page

Copy/Saving of a Validated Configuration 152

Transfer of a Validated Configuration Copy 153

33003281 151

Configuration

Copy/Saving of a Validated Configuration

Condition As a condition to create a copy of a validated configuration, the Enable copying of validated configuration from controller option must be selected during the validation of the configuration, see also Sending a Configuration, p. 141, step for the validation. Under this condition the user is able to make a copy of the validated configuration from the XPSMC into a binary file at any time. In addition, the Create a copy of the validated configuration now option can be selected in order to immediately create such a copy during the validation.

Copy of a Validated Configuration

Included with the configuration itself, the following data of the original controller is taken:� validation counter (VDC)� password� validation data (name, date)� device parameters (Modbus parameters, controller number)

This file can be used as a safety copy to transfer the validated configuration to another controller without the need of a new validation.

Saving a Validated Configuration

Proceed as follows:

Step Action

1 Connect the PC to the controller containing the validated configuration which is free for copy.

2 Choose the command Controller → Create validated copy.Result: The configuration will be read out of the controller.

3 Enter the save location and file name in the window which appears.Result: The copy will be saved as this file.

152 33003281

Configuration

Transfer of a Validated Configuration Copy

Description When a file with a copy of a validated configuration has been made (see chapter Copy/Saving of a Validated Configuration, p. 152) for a certain controller, it is easy to transfer the configuration into another controller, especially for replacement of a XPSMC unit for service or for installation of controllers in identical machines.

Procedure 1 - New Controller

Proceed as follows:

Step Action

1 Connect the PC to the controller in which the validated configuration is to be transferred.Result: The controller is not configured, the Power LED is on, and the CNF LED is blinking.

2 Choose the command Controller → Validated copy → Transfer validated copy to controller.Result: You get 2 messages:� Please connect the controller you want the configuration to transfer to and

press ’OK’ to start the transfer.� Transferring the copy will overwrite the existing configuration in the controller.

Do you want to continue?

3 Indicate in the appearing window the name of the validated configuration file.Result: The validated configuration is transferred into the connected controller.A message box tells you to powercycle the controller to start the new configuration.

33003281 153

Configuration

Procedure 2 -Configured Controller, Password Available

Proceed as follows:

Procedure 3 - Configured Controller, Password Unavailable

Reset the controller by pressing the Reset button and simultaneously performing a power cycle. Then follow Procedure 1 - New Controller, p. 153.

Validated Configuration into another Controller

The new controller now has the validated configuration, including the validation counter (VDC), the password, the validation data (name, date) and the device parameters (Modbus parameters, controller number).

It can be used like the original controller from which the copy was made from, except that the running time (OPC) of the configuration is set to zero.

Step Action

1 Connect the PC to the controller in which the validated configuration is to be transferred.

2 Choose the command Validated copy → Transfer validated copy to controller.Note: If the controller is running, another message box reminds you that the controller has to be stopped. You will also be reminded to enter your password. If you do not have a password, you will have to reset the controller by powercycling it and simultaneously pressing the Reset button. See also Procedure 1 - New Controller, p. 153 for downloading a validated copy.

3 Indicate in the appearing window the name of the file.Result: The validated configuration is picked out from the file and transferred into the connected controller.A message box tells you that you have to powercycle the controller to start the new configuration and run the controller.

Note: To modify the configuration, you need the password of the validated configuration. The controller password has been overwritten.

154 33003281

Configuration

5.9 Read Protocol from Controller



Step Action

1 Connect the PC to the XPSMC safety controller.

2 The controller has to be put in Stop mode with the menu Controller → Stop Controller.

3 A window appears, and you are asked to enter your password to stop the controller.

4 Choose the menu Controller → Read Protocol from Controller.Result: The protocol will be displayed in a separate window and can be printed.Note: This print is just a work tool.The only proof of the correctness of the configuration is the validated and signed protocol. (See chapter Sending a Configuration, p. 141)

33003281 155

Configuration

156 33003281

33003281

6
Diagnosis
XPSMC Safety Controller Diagnostics

Introduction Various states of an XPSMC can be loaded from a PC for fault diagnostics and error finding purposes.

Procedure The fault Diagnostic mode is activated as follows:

Note: During the fault diagnostics, the XPSMC continues to operate without being influenced, to allow the progress of a complete machine cycle to be monitored.

Step Action

1 Connect your PC to the XPSMC safety controller in operation.

2 Start the XPSMCWIN software.

3 Open a configuration from a file or upload the configuration from the controller.Note: During the opening of a saved configuration from a file, the configuration must correspond to the one already in the controller. The controller configuration must have been validated.

4 Choose the Diagnostic mode. To do this, choose the menu Mode → Diagnostic

or click on the icon for the Diagnostic mode. Result: The window will become grey, to show that no modifications can be made.

157

Diagnosis

Color Definitions In the Configuration window, a colored circle is placed next to each function symbol of the configuration tree.

The color indicates the current status of the corresponding function:

Meaning of symbols

Symbols Meaning

Red Point The safety output concerned is deactivated, or this device has not been validated (for example, protection door open, Emergency Stop not initiated, etc.), or the concerned input is opened.

Red Point with a Yellow Flash An error exists for this device (input/output). The error message will then be shown by clicking on the device.

Green Point The safety output concerned is activated, or this device has been validated (for example, protection door closed, emergency stop initiated, etc.), or the concerned input is closed.

File Mode Diagnosis Options HelpXPSMCWIN 2.00

Device Library Configuration

Monitoring DevicesEDM DevicesStart Devices

Miscellaneous DevicesEnabling Devices

i i

Diagnostic Mode Diagnostic running Com5

ConfigurationController

State of Outputs

C1 [XPSMC32 ZP]: ’Controller1’i32

[259] o1[257] ’Emergency Stop’

i01: ’Ch. 1’

i

Telemecanique

Device [257] : Short circuit between inputs.

[261] o2[260] ’Light Curtain’

[258] Auto Start ’Auto. Start’i02: ’OSSD 1’

i03: ’OSSD 2’

o3o4o5o6[262] R1

[260] ’Light Curtain’[258] Auto Start ’Auto. Start’i02: ’OSSD 1’

i03: ’OSSD 2’R2

158 33003281

Diagnosis

Fault Diagnostics of Different Devices

Proceed as follows

Green Point with a Hourglass This output has a category 1 stop.The commutation conditions are no longer fulfilled, but the time delay is not yet finished.

Yellow Point This component or this outputs are enabled (i.e. the starting conditions are fulfilled), but not yet started.

Grey Point The safety output concerned is not used, or the PC has not yet received the fault diagnostics data from the XPSMC (all the points are then dimmed).

Symbols Meaning

Step Action

1 Click on the symbol of the device to see the state of the inputs of the different devices

2 Click the right mouse button within the Diagnostic window.Result: A special menu will appear.

3 Select Overview from the menu.Result: A new window appears displaying the diagnostics of all the inputs and outputs of the controller.

4 Click on Pause diagnostic in the menu Diagnostics to pause the diagnostics. Result: The Diagnostic window keeps the status.

5 Click on Start diagnostic in the menu Diagnostics to start the diagnostics.Result: The window will be continuously updated.

33003281 159

Diagnosis

160 33003281

Appendices

At a glance

Overview Additional information that is not necessarily required for an understanding of the documentation.

What's in this Appendix?

The appendix contains the following chapters:

Chapter Chapter Name Page

A Wiring (Examples) and Functional Diagrams 163

33003281 161

Appendices

162 33003281

33003281

A
Wiring (Examples) and Functional Diagrams
At a Glance

Overview This chapter contains examples of wiring and functional diagrams.

Note: The data for safety categories in accordance with EN 954-1 refers to the maximum achievable categories. The machine control must also be appropriately configured in order to achieve the desired category.

163

Wiring and Functional Diagrams



Topic Page

Electrical Diagram for the XPSMC 165

Three One-Channel Emergency Stops, with Automatic Start 167

Two Two-Channel Emergency Stop, with Start Button 169

Safety Guard with One Channel 171

Two Channel Safety Guard 174

Two Channels Safety Guard with Lock 178

Light Curtain with Relay Outputs 182

Light Curtain with Transistor Outputs 186

Muting for Light Curtains Type 4 190

Magnetic Switch 192

Two-Hand Control 196

Safety Mat 198

Zero Speed Detection 200

Injection Molding Machines 204

Hydraulic Press Valve Monitoring 207

Hydraulic Press 2 209

Eccentric Press 215

Eccentric Press 2 219

Selector Switch 224

Timer 226

Shaft/Chain-Break Monitoring 229

Seat Valve Monitoring 231

Enabling Device 2 Channel 233

Enabling Device 3 Channel 235

Foot Switch 237

164 33003281


Electrical Diagram for the XPSMC

Response Time When not other mentioned the following drawings show a XPSMC16 with a response time of 20 ms.

Wiring Diagram

XPSMC16 / XPSMC32

The static outputs are rated category 4 according to EN954-1.

HAZARDOUS VOLTAGE

Disconnect all power before servicing equipment.


DANGER

XPSMC16safety controllerT

A1 c8 c7 c6 c5 c4 c3 c2 c1

A2 GND GND GND o1 o2 o3 o4 o5 o6 14 24 34 44

13 23 H1 33 34

K3

K4

K1

K2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

TERK0

µC 1

µC 1

LOGIC

24 V

5 V

XPSMC16

XPSMC32


A1 c8 c7 c6 c5 c4 c3 c2 c1

A2 GND GND GND o1 o2 o3 o4 o5 o6 14 24 34 44

i1 i2 i3 i4 i5 i6 i7 i8 i9 i10 i11 i12 i13 i14 i15 i16 13 23 H1 33 34

K3

K4

K1

K2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

TERK0

µC 1

µC 1

LOGIC

24 V

5 V

c8 c7 c6 c5 c4 c3 c2 c1 ... i32i17

i1 i2 i3 i4 i5 i6 i7 i8 i9 i10 i11 i12 i13 i14 i15 i16

33003281 165


Technical Data Description of terminals

Terminal Layout Meaning

A1-A2 24V power supply; A1 is the + pole (+24 VDC), A2 is the - pole (0 VDC, GND)

GND It is identical to the 0 V potential on A2 for loads on the o1...o6 semiconductor safety outputs.

c1-c8 control outputs for safety input power supplyThe control outputs contain a signal which enables short circuit detection monitoring, voltage intrusion and open circuit detection for all connected control components.

i1-i16 or i1-i32 safety inputs

H1 connection for muting lamp

o1-o6 semiconductor safety outputs

13/14, 23/24, 33/34, 43/44

safety outputs, potential free

TER 8 pin RJ45 connector used to connect the XPSMC safety controller to a PC for configuration and/or diagnostics. The communication via the TER terminal is Modbus RTU protocol and can also be used to connect to a HMI magelis operating terminal, or a standard PLC.

Fieldbus connector for a fieldbus dependant on version:� Profibus DP: 9 pin D-SUB female connector� CANopen: 9 pin D-SUB male connector.

166 33003281


Three One-Channel Emergency Stops, with Automatic Start

Functional Diagram

The following diagram shows three One-Channel Emergency Stops and the relevant control outputs for categories 0 and 1:

OperationEmergency

Stop

OperationEmergency

Stop

Operation

InputEmergency Stop 1



Relay Outputs K1/K2Stop Category 0

Relay Outputs K3/K4Stop Category 1

tv = 0.1…300 s tv = 0.1…300 s

33003281 167


Wiring Diagram The following image shows the wiring diagram of the One-Channel Emergency Stop:

(1) See Technical Data in XPSMC safety controller Hardware manual for maximum fuse sizes.


F1(1)

Safety ControllerXPSMC16T

A2 GNDGNDGND o1 o2 o3 o4 o5 o6 14 24 34 44

K3

K4

K1

K2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

K0

µC 1

µC 1

LOGIC

24 V

5 V

0V

230V ~ 230V ~

A1 c8 c7 c6 c5 c4 c3 c2 c1 i1 i2 i3 i4 i5 i6 i7 i8 i9 i10 i11 i12 i13 i14 i15 i16 13 23 H1 33 34

TERFieldbus

0V

EmergencyStop

F2(1)

+24 V +24 V

F3(1)

Emergency Stop Category 0

S1

Emer-gencyStop 1

S2

Emer-gencyStop2

S3

Emer-gencyStop3

Note: A jumper between the 2 terminals of an Emergency Stop will not be recognised. Short-circuit between i1, i2, i3 will be recognised.

168 33003281


Two Two-Channel Emergency Stop, with Start Button

Functional Diagram

The following functional diagram shows two Two-Channel Emergency Stops and the relevant control outputs for Categories 0 and 1:

OperationEmergency

Stop

OperationEmergency

StopOperation

Input Emergency Stop 1Channel 1




InputStart

Output o1Stop Category 0

Output o2Stop Category 1

tv = 0.1…300s tv = 0.1…300s

33003281 169


Wiring Diagram The following wiring diagram shows two Two-Channel Emergency Stops and the relevant control outputs for the Categories 0 and 1:



0 V 0 V

F1(1)



K3

K4

K1

K2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

TERK0

µC 1

µC 1

LOGIC

24 V

5 V

+24 V +24 V

S3S2S1

A1 c8 c7 c6 c5 c4 c3 c2 c1 i1 i2 i3 i4 i5 i6 i7 i8 i9 13 23 H1 33 34

Emer-

gency

Push

Button

StartEmer-

gency

Push

Button

Emergency stop category 0

Emergency stop category 1

i10 i11 i12 i13 i14 i15 i16

170 33003281


Safety Guard with One Channel

Functional Diagram

The following functional diagram shows the Safety Guard with One Channel with Start Interlock and different Start Functions:

Start Function Start Interlock = YES

Automatic Start

Monitored StartRising Edge

Monitored StartFalling Edge

InputLimit switch

Output

Guardopened

Guardclosed

GuardclosedP

ower

no start

Input Limit Switch

Output

Guardopened

Guardclosed

GuardclosedP

ower

no start

Input MonitoredStart

Input LimitSwitch

Output

Guardopened

Guardclosed

GuardclosedP

ower

no start


33003281 171


The following functional diagram shows the Safety Guard with One Channel without Start Interlock and different Start Functions:

Start Function Start Interlock = NO

Automatic Start



InputLimit switch

Output

Guardopened

Guardclosed

GuardclosedP

ower

InputLimit switch

Output

Guardopened

Guardclosed

GuardclosedP

ower


Input LimitSwitch

Output

Guardopened

Guardclosed

GuardclosedP

ower


172 33003281


Wiring Diagram The following wiring diagram shows the Safety Guard with One Channel with and without Start Interlock and different Start Functions:



F1(1)



K3

K4

K1

K2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

K0

µC 1

µC 1

LOGIC

24 V

5 V

0V

230V ~ 230V ~


TERFieldbus

0V

S1

Start

S2

��

open

Release

F2(1)

+24 V +24 V

33003281 173


Two Channel Safety Guard

Functional Diagram

The following functional diagram shows the Two-Channel Safety Guard with Start Interlock and different Start Functions:


Automatic Start


Input limit switch1

Input EDM

Guardopened

Guardclosed

GuardclosedP

ower

Input limit switch2

Output t < t EDM

t < t syn.

no start

EDM: External Device Monitoring

Input limit switch1

Input monitoredstart

Guardopened

Guardclosed

GuardclosedP

ower

Input limit switch2

Input EDM

t < t syn.

no start

Outputt < t EDM


174 33003281


The following functional diagram shows the Two-Channel Safety Guard without Start Interlock and different Start Functions:



Automatic Start


Input limit switch1


Guardopened

Guardclosed

GuardclosedP

ower

Input limit switch2

Input EDM

t < t syn.

no start

Outputt < t EDM


Input limit switch1

Input EDM

Guardopened

Guardclosed

GuardclosedP

ower

Input limit switch2

Output t < t EDM

t < t syn.

t = t EDM

t > t EDM


33003281 175





Input limit switch1


Guardopened

Guardclosed

GuardclosedP

ower

Input limit switch2

Input EDM

t < t EDM

t < t syn.

Output


Input limit switch1


Guardopened

Guardclosed

GuardclosedP

ower

Input limit switch2

Input EDM

t < t EDM

t < t syn.

Output


176 33003281


Wiring Diagram The following wiring diagram shows the Two-Channel Safety Guard with and without Start Interlock and different Start Functions:

ESC External Start ConditionsEDM External Device Monitoring(1) See Technical Data in XPSMC Safety Controller Hardware manual for maximum fuse size


F1(1)



K3

K4

K1

K2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

K0

µC 1

µC 1

LOGIC

24 V

5 V

0V

+24 V +24 V


TERFieldbus

K01 K02

Channel 1 Channel 2

0V

ESC

K01

K02S1

Start

S2S3

��

open

EDM

33003281 177


Two Channels Safety Guard with Lock

Functional Diagram

The following functional diagram shows the Two-Channel Safety Guard with Lock and with Start Interlock and different Start Functions:


Automatic Start


Input limit switch1

Input lock

Guardclosed

GuardclosedP

ower

Input limit switch2

Output

t < t syn.

Guardopened

no start

Input limit switch1

Input lock

Guardclosed

GuardclosedP

ower

Input limit switch2


t < t syn.

Guardopened

Output

no start

178 33003281


The following functional diagram shows the Two-Channel Safety Guard with Lock and without Start Interlock and different Start Functions:



Automatic Start


Input limit switch1

Input lock

Guardclosed

GuardclosedP

ower

Input limit switch2


t < t syn.

Guardopened

Output

no start

Input limit switch1

Input lock

Guardclosed

GuardclosedP

ower

Input limit switch2

Output

t < t syn.

Guardopened

33003281 179





Input limit switch1

Input lock

Guardclosed

GuardclosedP

ower

Input limit switch2


t < t syn.

Guardopened

Output

Input limit switch1

Input lock

Guardclosed

GuardclosedP

ower

Input limit switch2


t < t syn.

Guardopened

Output

180 33003281


Wiring Diagram The following wiring diagram shows the Two-Channel Safety Guard with Lock and with and without Start Interlock and different Start Functions:

ESC External Start ConditionsEDM External Device Monitoring(1) See Technical Data in XPSMC Safety Controller Hardware manual form maximum fuse

size


��

��

F1(1)



K3

K4

K1

K2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

K0

µC 1

µC 1

LOGIC

24 V

5 V

0V

+24 V +24 V


TERFieldbus

K01 K02

Channel 1 Channel 2

0V

ESC

K01

K02

S3

Start

S4

open

EDM

��

S2

S1 ��

��

33003281 181


Light Curtain with Relay Outputs

Functional Diagram

The following functional diagram shows the Light Curtain with Relay Outputs with Start Interlock and different Start Functions:


Automatic Start


Input OSSD 1

Input EDM

Light curtainfree

Light curtain freeR

ising

Input OSSD 2

Output

t < t syn.

Light curtain inter-rupted

t < tEDMno start

OSSD: Output Safety Switching Device

Input OSSD1


Light curtainfree

Light curtain freeR

ising

Input OSSD2

Input EDM

t < t syn.


t < tEMD no start

Output


182 33003281


The following functional diagram shows the Light Curtain with Relay Outputs without Start Interlock and different Start Functions:



Automatic Start


Input OSSD1


Light curtainfree

Light curtain freeR

ising

Input OSSD2

Input EDM

t < t syn.


t < tEDM no start

Output


Input OSSD 1

Input EDM

Light curtainfree

Light curtainR

ising

Input OSSD 2

Output

t < t syn.


t < t EDMt = t EDM

t > t EDM


33003281 183





Input OSSD1


Light curtainfree

Light curtainR

ising

Input OSSD2

Input EDM

t < t syn.


t < tEDMOutput


Input OSSD1


Light curtainfree

Light curtainR

ising

Input OSSD2

Input EDM

t < t syn.


t < t EDMOutput


184 33003281


Wiring Diagram The following wiring diagram shows the Light Curtain with Relay Outputs with and without Start Interlock and different Start Functions:

ESC External Start ConditionsEDM External Device MonitoringESPE Electro Sensitive Protective EquipmentOSSD Output Safety Switching Device(1) See Technical Data in XPSMC Safety Controller Hardware manual form maximum fuse

size


F1(1)



K3

K4

K1

K2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

K0

µC 1

µC 1

LOGIC

24 V

5 V

0V

+24 V +24 V


TERFieldbus

K01 K02

Channel 1 Channel 2

0V

ESPE =ESPE output

S1

Start

ESC

K01

K02(1) (2)

(1)ESPE

OSSD1 OSSD2

EDM

(2)

33003281 185


Light Curtain with Transistor Outputs

Functional Diagram

The following functional diagram shows the Light Curtain with Transistor Outputs with Start Interlock and different Start Functions:


Automatic Start


Input OSSD1

Input EDM

Light curtainfree

Light curtain freeR

ising

Input OSSD2

Output

t < t syn.


t < tEDM

no start


Input OSSD1


Light curtainfree

Light curtain freeR

ising

Input OSSD2

Input EDM

t < t syn.


t < tEDMno start

Output


186 33003281


The following functional diagram shows the Light Curtain with Transistor Outputs without Start Interlock and different Start Functions:



Automatic Start


Input OSSD1


Light curtainfree

Light curtain freeR

ising

Input OSSD2

Input EDM

t < t syn.


t < tEDMno start

Output


Input OSSD1

Input EDM

Light curtainfree

Light curtain freeR

ising

Input OSSD2

Output

t < t syn.


t < t EDMt = t EDM

t > t EDM


33003281 187





Input OSSD1


Light curtainfree

Light curtain freeR

ising

Input OSSD2

Input EDM

t < t syn.


t < tEDMOutput


Input OSSD1


Light curtainfree

Light curtain freeR

ising

Input OSSD2

Input EDM

t < t syn.


t < t EDMOutput


188 33003281


Wiring Diagram The following wiring diagram shows the Light Curtain with Transistor Outputs with and without Start Interlock and different Start Functions

ESC External Start ConditionsEDM External Device MonitoringESPE Electro Sensitive Protective EquipmentOSSD Output Safety Switching Device(1) See Technical Data in XPSMC Safety Controller Hardware manual form maximum fuse

size


F1(1)



K3

K4

K1

K2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

K0

µC 1

µC 1

LOGIC

24 V

5 V

0V

+24 V +24 V


TERFieldbus

K01 K02

Channel 1 Channel 2

0V

ESPE =ESPE output

S1

Start

ES

K01

K02(-) (1) (2)

(+)ESPE

OSSD1 OSSD2

EDM

33003281 189


Muting for Light Curtains Type 4

Functional Diagram

The following functional diagram shows the Muting for light curtains type 4:

Start

Required

Input

Start

Input

Muting A1

Input

Muting B1

Input

Muting A2

Input

Muting B2

Input

Override

Output H1

Muting Lamp

Output

Channel 1

Output

Channel 2

Muting

t > t syn.

ESPE

Protects

Muting Active

Detection Zone By-Passed

ESPE

Protects

Muting

Fault

Outputs

Off

Override Active

Detection Zone by-

Passed

ESPE

Protects

t < t Muting

t < t syn.

t < t syn.

Detection Zone

Interrupted

t < t Override

Input

OSSD 1

Input

OSSD 2

Override (F)

Detection Zone

190 33003281


Wiring Diagram The following wiring diagram shows the Muting for light curtains type 4:

ESC External Start ConditionsEDM External Device MonitoringESPE Electro Sensitive Protective Equipment(1) See Technical Data in XPSMC Safety Controller Hardware manual form maximum fuse

size


F1(1)



K3

K4

K1

K2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

K0

µC 1

µC 1

LOGIC

24 V

5 V

0V

+24 V +24 V


TERFieldbus

K01 K02

Channel 1 Channel 2

0V

Muting lampESPE =ESPE output

S6

Override

S5

MutingB2

S3

MutingB1

S4

Muting

S2

Muting

S1

Start

ES

K01

K02(-) (1) (2)

(+)ESPE

OSSD1 OSSD2

H1

A1 A2

EDM

33003281 191


Magnetic Switch

Functional Diagram

The following functional diagram shows the Magnetic Switch with Interlock and different Start Functions:


Automatic Start


Input NC

MagnetpresentP

ower

Magnetabsent

t < t syn.

Magnetpresent

Input NO

Input EDM

Output

no start

t < tEDM

Input NC

MagnetpresentP

ower

Magnetabsent

t < t syn.

Magnetpresent

Input NO


Input EDM

no startt < tEDM

Output

192 33003281


The following functional diagram shows the Magnetic Switch without Interlock and different Start Functions:



Automatic Start


Input NC

MagnetpresentP

ower

Magnetabsent

t < t syn.

Magnetpresent

Input NO


Input EDM

no startt < tEDM

Output

Input NC

MagnetpresentP

ower

Magnetabsent

t < t syn.

Magnetpresent

Input NO

Input EDM

Outputt < t EDM t = t EDM

t > t EDM

33003281 193





Input NC

Magnetpresent

Power Magnet

absent

t < t syn.

Magnetpresent

Input NO


Outputt < tEDM

Input EDM

Input NC

MagnetpresentP

ower

Magnetabsent

t < t syn.

Magnetpresent

Input NO


Outputt < t EDM

Input EDM

194 33003281


Wiring Diagram The following wiring diagram shows the Magnetic Switch with and without Interlock and different Start Functions


size


F1(1)



K3

K4

K1

K2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

K0

µC 1

µC 1

LOGIC

24 V

5 V

0V

+24 V +24 V


TERFieldbus

K01 K02

Channel 1 Channel 2

0V

ESC

K01

K02S2

Start

S1 =Magnetic switch

EDM

BK BU

WH BN+

Mag-net NC NO

S1

33003281 195


Two-Hand Control

Functional Diagram

The following functional diagram shows the Two-Hand Control device:

Two-Hand-Control

Activated

Two-Hand-Control

Not Activated

Two-Hand-Control

Activated

Input Push Button 1NO

Input Push Button 1NC

Input Push Button 2NO

Input Push Button 2NC

Output

No Start

t < 500ms

Power ON (RUN)

196 33003281


Wiring Diagram The following wiring diagram shows the Two-Hand Control device:



F1(1)



K3

K4

K1

K2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

K0

µC 1

µC 1

LOGIC

24 V

5 V

0V

+24 V +24 V

A1 c8 c7 c6 c5 c4 c3c2 c1 i1 i2 i3 i4 i5 i6 i7 i8 i9 i10 i11 i12 i13 i14 i15 i16 13 23 H1 33 34

TERFieldbus

Channel 1 Channel 2

Valves

0V

S2S1NO NC NO NC S1 =

2-Hand push-button 1

S2 =2-Hand push-button 2

Y1 Y2

33003281 197


Safety Mat

Functional Diagram

The following functional diagram shows the Safety Mat:

Power

ON

(RUN)

Safety MatNot Activated

Safety MatActuated


Power

ON

(RUN)


Safety MatActuated


Power

ON

(RUN)


Safety MatActuated


Input 1Safety Mat

Input 2Safety Mat

InputStart

Input 1Safety Mat

Output

Input 2Safety Mat

InputEDM

Input 1Safety Mat

Output

Input 2Safety Mat

InputEDM

InputStart

t = t EDMt > t EDM

t < t EDM

t < t

Output

InputEDM

t < t EDM

Start Function

AutomaticStart



198 33003281


Wiring Diagram The following wiring diagram shows the Safety Mat:


size


F1(1)



K3

K4

K1

K2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

K0

µC 1

µC 1

LOGIC

24 V

5 V

0V

+24 V +24 V


TERFieldbus

K01 K02

Channel 1 Channel 2

0V

ESC

K01

K02

S2

Start

S1

Safety Mat

Control outputs which are connected to asafety Mat cannot be used for other items.

EDM

33003281 199



Functional Diagram

The following functional diagram shows the Zero Speed Detection:

Note: It is vital to use inputs i1 and i2 for zero speed detection. The two sensors must be arranged so that only one sensor is activated at any given time. If the inputs are in the low state, the zero speed signal will disappear after t=1/f seconds and an open-circuit will be indicated. If the 2 inputs are in the high state, the zero speed signal will disappear after t=1/f seconds and a short-circuit will be indicated. If the 2 inputs are in the high or low state after starting, no enabling will take place.

Input i1Sensor 1

Input i2Sensor 2

Output

pF1,F2 < F Max. F1, F2 > F Max.

pF1, F2 < F Max.

Sensor control: Sensor 1

Sensor 2

200 33003281


Wiring Diagram The following wiring diagram shows the Zero Speed Detection:



F1(1)

XPSMC16Safety ControllerT


K3

K4

K1

K2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

K0

µC 1

µC 1

LOGIC

24 V

5 V

0V

+24 V +24 V


TERFieldbus

K01 K02

0V

Channel 2

-

Channel 1

+-

+

A

A

Sensor 2

Sensor 1

33003281 201


Important Key Points to Observe

The following points should be observed for the correct operation of the zero speed detection:� The sensors must be arranged so that only 1 sensor is activated at any given time

(= HIGH-Signal).� If both sensors are in the LOW state, a cable break error message is indicated

and the corresponding outputs are deactivated.� If both sensors are in the HIGH state after power on of the XPSMC, a notification

is available via Modbus RTU, or via the configuration terminal (PC), and the corresponding outputs are deactivated. After a zero speed detection and a subsequent motion the notification is reset.

� If zero speed is already detected and both sensors are in HIGH state, a notification is available via Modbus RTU, or via the configuration terminal (PC), and the corresponding outputs are activated.

� If only 1 sensor produces a dynamic signal after a zero speed, an error message appears after 30 s and the corresponding outputs are deactivated.

� If, after the XPSMC has started, both sensors are in the LOW state, an error message is available via the Error LED on the XPSMC and Modbus RTU, or via the configuration terminal (PC).

Note: You cannot use the Zero Speed Detection device simultaneously with the Shift/Chain Break Monitoring device on the XPSMC safety controller, because there are only two counter inputs (i1 and i2) per controller.

Note: The output will be activated if the sensors detect no motion.

202 33003281


Sensor States and Behavior

Switch-on Sequence

Operation

* If the state of the sensors is inverse (0/1, 1/0), the behavior is identical.

** If the firmware version is earlier than 2.34 an error message (short circuit between inputs) appears instead of a notification. This error message must be acknowledged with the reset button.

Error Message External error messages must be acknowledged with the reset button.

Notification A notification, sent via Modbus, does not need to be acknowledged. As soon as the sensor states change, it will be acknowledged automatically.



Behavior Error Message Zero Speed Notification (**)

Output 0 1 0



Behavior Error Message Zero Speed Notification

Output 0 1 1

33003281 203


Injection Molding Machines

Functional Diagram

The following functional diagram shows the Safety Guard with One Channel with Start Interlock and different Start Functions:


Automatic Start


InputLimit switch 1

Guardclosed

Guardopened

Guardclosed

t < t syn.

Power ON

(RUN)

InputLimit switch 2

InputValve monitoring

Output

no start

InputLimit switch 1

Guardclosed

Guardopened

Guardclosed

t < t syn.

Power ON

(RUN)

InputLimit switch 2


InputStart

no start

Output

204 33003281




InputLimit switch 1

Guardclosed

Guardopened

Guardclosed

t < t syn.

Power ON

(RUN)

InputLimit switch 2


Input Start

no start

Output

33003281 205


Wiring Diagram The following wiring diagram shows the Injection Molding with Start Functions:

EDM External Device MonitoringESC External Start Conditions(1) See Technical Data in XPSMC safety controller Hardware manual for maximum fuse sizes.


F1(1)



K3

K4

K1

K2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

K0

µC 1

µC 1

LOGIC

24 V

5 V

0V

+24 V +24 V


TERFieldbus

K01 K02

Channel 1 Channel 2

0V

ES

K01

K02

S1

Start

S2 S3

open

EDM

S4 =Monitoring of the second power cir-cuit cutoff device.

��

S4

206 33003281



Functional Diagram

The following functional diagram shows the Hydraulic Press Valve Monitoring:

Stopin OTS

Opening of PressStopin BDC

Closing of PressStop

in OTS

InputClosing of Press

InputOpening of Press

InputValve O+C

OutputClosing of Press

OutputOpening of Press

t < t syn.

t < t syn.

t < t syn.

InputValve C

InputValve O

Sensor signals at valve level:

Valve Stop(Opened)

Pressing(Closing)

Stop(Closed)

Retraction(Opening)

Valve C

Valve O

Valve O + C

Sensor

1

2

3

33003281 207


Wiring Diagram The following wiring diagram shows the Hydraulic Press Valve Monitoring:



F1(1)



K3

K4

K1

K2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

K0

µC 1

µC 1

LOGIC

24 V

5 V

0V

+24 V +24 V


TERFieldbus

K01 K02

0V

Press Opening Enable

-

Press Closing Enable

S5

Openthe

Press

S4

Closethe

Press+-

+

+-

Sensor 3 - Valve O + C

Sensor 2 - Valve O

Sensor 1 - Valve C

A

A

A

Sensor 3

Sensor 2

Sensor 1

208 33003281


Hydraulic Press 2

Functional Diagrams

The following functional diagram shows the Hydraulic Press 2, Mode = INCHING

Mode AUTOMATIC

Emergency Stop

Mode INCHING

Mode SINGLE STORKE

OPENING COMMAND

SAFETY COMMAND

OTS

NWK*

UT

VALVE C*

VALVE O*

VALVE O+C*

OUTPUT OPENING

OUTPUT CLOSING

OVERTRAVEL OK

HYDRAULIC PUMP*

CLOSING COMMAND*

* = not used

Hyd

rau

lic P

ress

, Mo

de

= In

chin

g

33003281 209


The following functional diagram shows the Hydraulic Press 2, Mode = SINGLE STROKE, with overtravel monitoring and Open + Close command from the PLC:

Hyd

rau

lic P

ress

, Mo

de

= S

ING

LE

STO

RK

E, w

ith

ove

rtra

vel m

on

ito

rin

g a

nd

Op

en +

Clo

se

com

man

d f

rom

PL

C

Emergency Stop

Mode INCHING

Mode SINGLE STROKE

Mode AUTOMATIC

HYDRAULIC PUMP

OPENING COMMAND

CLOSING COMMAND

SAFETY COMMAND

OTS

NWK

UT

VALVE C

VALVE O

VALVE O+C

OUTPUT OPENING

OUTPUT CLOSING

OVERTRAVEL OK

210 33003281


The following functional diagram shows the Hydraulic Press 2, Mode = SINGLE STROKE:

Emergency Stop

Mode INCHING

Mode SINGLE STROKE

Mode AUTOMATIC

HYDRAULIC PUMP*

OPENING COMMAND*

CLOSING COMMAND*

SAFETY COMMAND

OTS

NWK*

UT*

VALVE C

VALVE O

VALVE O+C

OUTPUT OPENING

OUTPUT CLOSING

OVERTRAVEL OK*

* = not used

Hyd

rau

lic P

ress

, Mo

de

= S

ING

LE

ST

RO

KE

33003281 211


The following functional diagram shows the Hydraulic Press 2, Mode = Automatic, with overtravel monitoring and Open + Close command from the PLC:

Hyd

rau

lic P

ress

, Mo

de

= A

UT

OM

AT

IC, w

ith

ove

rtra

vel m

on

ito

rin

g a

nd

Op

en +

Clo

se c

om

-m

and

fro

m P

LC

Emergency Stop

Mode INCHING

Mode SINGLE STROKE

Mode AUTOMATIC

HYDRAULIC PUMP

OPENING COMMAND

CLOSING COMMAND

SAFETY COMMAND

OTS

NWK

UT

VALVE C

VALVE O

VALVE O+C

OUTPUT OPENING

OUTPUT CLOSING

OVERTRAVEL OK

212 33003281


The following functional diagram shows the Hydraulic Press 2, Mode = AUTOMATIC, without OT + UT signals:

Emergency Stop

Mode INCHING

Mode SINGLE STROKE

Mode AUTOMATIC

HYDRAULIC PUMP*

OPENING COMMAND

CLOSING COMMAND

SAFETY COMMAND

OTS*

NWK*

UT*

VALVE C

VALVE O

VALVE O+C

OUTPUT OPENING

OUTPUT CLOSING

OVERTRAVEL OK*

* = not used

Hyd

rau

lic P

ress

, Mo

de

= A

UT

OM

AT

IC, w

ith

ou

t O

T +

UT

sig

nal

s

33003281 213


Wiring Diagram The following wiring diagram shows the Hydraulic Press 2:

0 V

230 V AC

0 V

230 V AC

F1


A1 c8 c7 c6 c5 c4 c3 c2 c1



K3

K4

K1

K2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

TERK0

µC 1

µC 1

LOGIC

24 V

5 V

N N

i17 i1

KM1

KM1SM2

OFF

SM1

ON

FM1

2

1

E-Stop

+24 V +24 V

i1 i2 i2 i2 i2 i2 i2 i2 i2 i2 i2 i3 i3 i3

210 3

OTS = Top Dead CenterUT = Bottom Dead CenterNWK = Overtravel Monitoring

Y1

S8

Operation Modes+-

B1

F2

close

Y2

open

Y3

open+close

S7

Two-hand button 2

S6

Two-hand button 1

S5

Emergency Stop

KM1

Kx

S4

NWK

S3

UT

S2

OTSOpen Command

Close Command

S1

OPEN

Valve C

+-

B2

Valve O

+-

B3

Valve O+C

0 - Off1 - Inching2 - Single Stroke3 - Automatic

214 33003281


Eccentric Press

Functional Diagrams

The following functional diagram shows the Eccentric Press, Mode = SINGLE STROKE

Bra

king

Sin

gle

Str

oke

Off

EmergencyStop

OperationMode:

Inpu

t Pus

h B

utto

n 1

NO

Inpu

t Pus

h B

utto

n 1

NC

Inpu

t Pus

h B

utto

n 2

NO

Inpu

t Pus

h B

utto

n 2

NC

Inpu

t Em

erge

ncy

Sto

pC

hann

el 1

Inpu

t Em

erge

ncy

Sto

pC

hann

el 2

Inpu

tO

TS

Inpu

tU

NIn

put

PS

V 1

Inpu

tP

SV

2In

put

Con

tinuo

us O

ff

Inpu

tR

eset

Inpu

tM

ode

Sel

ecto

r S

witc

h O

ff

Inpu

tM

ode

Sel

ecto

r S

witc

h In

chin

gIn

put

Mod

e S

elec

tor

Sw

itch

Sin

gle

Str

oke

Inpu

tM

ode

Sel

ecto

r S

witc

hC

ontin

uous

Aut

omat

icO

utpu

tV

alve

1O

utpu

tV

alve

2

Out

put

Em

erge

ncy

Sto

p

Sto

p in

OT

S

Start

SINGLESTROKE

Clo

sing

of

Pre

ssS

top

in O

TS

t < 5

00m

s

max

. Ove

rtra

vel

Mai

ntai

n au

tom

. ru

n-up

t < t

syn.

t < t

syn.

Bra

king

33003281 215


The following functional diagram shows the Eccentric Press, Mode = INCHING

Eng

age

Dis

enga

geE

ngag

eD

isen

gage

Eng

age

Dis

enga

geS

top

OT

S

t < 5

00m

st <

500

ms

t < 5

00m

s

Inch

ing

Off

EmergencyStop

Reset SelectorSwitchInching

Inpu

t 2-H

and

Pus

h B

utto

n 1

NO

Inpu

t 2-H

and

Pus

h B

utto

n 1

NC

Inpu

t 2-H

and

Pus

h B

utto

n 2

NO

Inpu

t 2-H

and

Pus

h B

utto

n 2

NC

Inpu

t Em

erge

ncy

Sto

pC

hann

el 1

Inpu

t Em

erge

ncy

Sto

pC

hann

el 2

Inpu

tO

TS

Inpu

tU

NIn

put

PS

V 1

Inpu

tP

SV

2In

put

Con

tinuo

us O

ff

Inpu

tR

eset

Inpu

tM

ode

Sel

ecto

r S

witc

h O

ff

Inpu

tM

ode

Sel

ecto

r S

witc

h In

chin

gIn

put

Mod

e S

elec

tor

Sw

itch

Sin

gle

Str

oke

Inpu

tM

ode

Sel

ecto

r S

witc

hC

ontin

uous

Aut

omat

icO

utpu

tV

alve

1O

utpu

tV

alve

2

Out

put

Em

erge

ncy

Sto

p

Irre

leva

nt

216 33003281


The following functional diagram shows the Eccentric press, Mode = CONTINUOUS

EmergencyStop

Operation Mode:

CONTINUOUS

Inpu

t 2-H

and

Pus

h B

utto

n 1

NO

Inpu

t 2-H

and

Pus

h B

utto

n 1

NC

Inpu

t 2-H

and

Pus

h B

utto

n 2

NO

Inpu

t 2-H

and

Pus

h B

utto

n 2

NC

Inpu

t Em

erge

ncy

Sto

pC

hann

el 1

Inpu

t Em

erge

ncy

Sto

pC

hann

el 2

Inpu

tO

TS

Inpu

tU

NIn

put

PS

V 1

Inpu

tP

SV

2In

put

Con

tinuo

us O

ff

Inpu

tR

eset

Inpu

tM

ode

Sel

ecto

r S

witc

h O

ff

Inpu

tM

ode

Sel

ecto

r S

witc

h In

chin

gIn

put

Mod

e S

elec

tor

Sw

itch

Sin

gle

Str

oke

Inpu

tM

ode

Sel

ecto

r S

witc

hC

ontin

uous

Aut

omat

icO

utpu

tV

alve

1O

utpu

tV

alve

2

Out

put

Em

erge

ncy

Sto

p

Start

ContinuousOff

Con

tinuo

usS

top

in O

TS

Sto

pin

O

TS

t < 5

00m

s

Max

. Ove

rtra

vel

t < t

syn.

t < t

syn.

Off

Con

tinuo

us

Bra

king

ContinuousOff

Braking

33003281 217


Wiring Diagram

The following wiring diagram shows the Eccentric Press:

OTS Top Dead CenterPSV Safety Valve(1) See Technical Data in XPSMC safety controller Hardware manual for maximum fuse sizes.


HAZARDOUS VOLTAGE



DANGER

Fieldbus

0 V

230 V ~

0 V

230 V ~

F1(1)



K3

K4

K1

K2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

TERK0

µC 1

µC 1

LOGIC

24 V

5 V

N N

KM1

KM1SM2

On

SM1

Off

FM1

2

1

+24 V +24 V

210 3

Valve ControlPSV1

PSV1 PSV2

(Y1a)Y1

Valve ControlPSV2

(Y1b)

a bP

2

4

1P

2

4

1

S8

S7

RESET

S6

(Y1b)

PSV 2

1

P>

S5

UN

S4

OTS

S3S2S1

Main drive


2-Hand

Push

Button1

2-Hand

Push

Button2

Emer-

gency

11

12

21

22

(Y1a)

PSV1 2

1

P>

22

21

1

2

3

4

5

6

7

8

F2(1)

S9

Closed

tool

Closedtool

218 33003281


Eccentric Press 2

Functional Diagram

The following functional diagram shows the Eccentric Press 2, Mode = INCHING:

Emergency Stop

Mode INCHING

Mode SINGLE STROKE

Mode CONTINUOUS

Mode CONTINUOUS

AUTOMATIC

Safety Means + Start

SAFETY Means for Continuous

Automatic*

Shaft / Chain Break Sensor*

OTS*

UN*

PSV1*

PSV2*

CONTINUOUS OFF*

RESET

OUTPUT

* = Not Used

Ecc

entr

ic P

ress

: IN

CH

ING

33003281 219


The following functional diagram shows the Eccentric Press 2, Mode = SINGLE STROKE:

Emergency Stop

Mode INCHING

Mode SINGLE STROKE

Mode CONTINUOUS

Mode CONTINUOUS AUTO-

MATIC



Automatic*

Shaft / Chain Break Sensor*

OTS

UN

PSV1

PSV2

CONTINUOUS OFF*

RESET

OUTPUT

* = Not Used

Ecc

entr

ic P

ress

: S

ING

LE

ST

RO

KE

T < Tsync

T < Tsync

T < TTot

220 33003281


The following functional diagram shows the Eccentric Press 2, Mode = CONTINUOUS:

Emergency Stop

Mode INCHING

Mode SINGLE STROKE

Mode CONTINUOUS


MATIC



Automatic*

Shaft / Chain Break Sensor

OTS

UN

PSV1

PSV2

CONTINUOUS OFF*

RESET

OUTPUT

* = Not Used

Ecc

entr

ic P

ress

: C

ON

TIN

UO

US

T < Tsync

T < Tsync

T < TTot

33003281 221


The following functional diagram shows the Eccentric Press 2, Mode = CONTINUOUS AUTOMATIC:

Emergency Stop

Mode INCHING

Mode SINGLE STROKE

Mode CONTINUOUS


MATIC



Automatic

Shaft / Chain Break Sensor

OTS

UN

PSV1

PSV2

CONTINUOUS OFF

RESET

OUTPUT

* = Not Used

Ecc

entr

ic P

ress

: C

ON

TIN

UO

US

AU

TOM

AT

IC

T < Tsync

T < Tsync

T < TTot

222 33003281


Wiring Diagram

The following image shows the wiring diagram of the Eccentric Press 2 device:

OTS Top Dead Center PSV Safety Valve

HAZARDOUS VOLTAGE



DANGER

0 V

230 V AC

0 V

230 V AC

F1


A1 c8 c7 c6 c5 c4 c3 c2 c1



K3

K4

K1

K2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

TERK0

µC 1

µC 1

LOGIC

24 V

5 V

N N

i17 i18

KM1

KM1SM2

OFF

SM1

ON

FM1

2

1

E-Stop

+24 V +24 V

i19 i20 i21 i22 i23 i24 i25 i26 i27 i28 i29 i30 i31 i32

210 3

Valve controlPSV1

PSV1 PSV2

(PSV = Safety valve)

(Y1a)Y1

Valve controlPSV2

(Y1b)

a bP

2

4

1P

2

4

1

S8

Mode Selector SwitchS7

RESET

S6

Endur..

OFF

(Y1b)

PSV2 2

1

P>

(Y1a)

PSV1 2

1

P>

S5

UN

S4

OTS

S3

Emer-

gency

stop

NCNOS2

2-Hand

push-

button 2

NCNOS1

2-Hand push-

button 1

S10

Safety-

gate 1

S9

Safety

gate 1

Cam

Control-

ler B1

+-

A

33003281 223


Selector Switch

Functional Diagram

The following image represents the functional diagram of the Selector Switch device:


Input Position 1

Input Position 2

Input Position 3

Input Position 4

Input Position 5

Pos

ition

0

Pos

ition

1

Pos

ition

2

Pos

ition

3

Pos

ition

4

Pos

ition

5

224 33003281


Wiring Diagram The following two images represent the wiring diagrams of the Selector Switch device:

0 V

+24 V

0 V

+24 V

F1


A1 c8 c7 c6 c5 c4 c3c2 c1



K3

K4

K1

K2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

TERK0

µC

µC

LOGIC

24

5 V

2 54310

Operating Modes

S1

33003281 225


Timer

Functional Diagram

The following image represents the functional diagram of the Timer device for the On-/Off-Delay:

Input

On-Delay

Pow

er O

N

Output

Timedelay

Input

Off-Delay

Pow

er O

N

Output

Time delay

226 33003281


The following image represents the functional diagram of the Timer device for the On-/Off Pulse:

Input

On Pulse

Pow

er O

N

Output

Pulse Time

Input

Off Pulse

Pow

er O

N

Output

Pulse Time

33003281 227


Wiring Diagram The following image represents the wiring diagram of the Timer device:



0 V 0 V

F1(1)



K3

K4

K1

K2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

TERK0

µC 1

µC 1

LOGIC

24 V

5 V

+24 V +24 V

Control

signal


Output

signal

228 33003281


Shaft/Chain-Break Monitoring

GBS Function Diagram

The following diagram shows the GBS function of the Shaft/Break-Chain Monitoring device:

Sensor Position The following diagram shows the Shaft/Chain-Break Monitoring function when the sensor is high or low at standstill:

+ 24 V

Sensor B1

Tooth Wheelin Cam Switch Mechanism

B1

PNP-A+

Input 1i1 or i2

+ 24 V

Pulse timet p = 0.01 - 0.1s

0 V

OUTPUT

E I

- -

0 V

Shaft/ChainBreak Sensor

Output

Movement of Shaft or Chain Standstill or FailureStandstill

t < tp t > tp + th

33003281 229


Wiring Diagram The following image is the Shaft/Chain-Break Monitoring wiring diagram:


0 V

+24 V

0 V

+24 V

Sensor at the Encoding Wheel in the Cam Controller

F1

+


A1 c8 c7 c6 c5 c4 c3 c2 c1



K3

K4

K1

K2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

TERK0

µC 1

µC 1

LOGIC

24 V

5 V

Only at i1 or i2.

A-

B1

230 33003281



Functional Diagram

The following image represents the functional diagram of the Seat Valve Monitoring device:

Power ON

(RUN) Start

Not ActivatedStart

ActivatedStart

Not Activated

InputStart

Output

InputValve Contact NO

t < t syn.

InputValve Contact NC

No Start

33003281 231


Wiring Diagram The following image represents the wiring diagram of the Seat Valve Monitoring device:



F1(1)



K3

K4

K1

K2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

K0

µC 1

µC 1

LOGIC

24 V

5 V

0V

+24 V +24 V


TERFieldbus

Y1

0V

S1

Seat Valve

Seat

Valve

Operat-

ing Start

S2

Valve

contact

232 33003281


Enabling Device 2 Channel

Functional Diagram

The following diagram represents the functional diagram of the Enabling Device 2 Channel:

Position 1

Output

Position 0

InputEnable Switch NO

InputEnable Switch NC

Power ON

(RUN)

t < t Enable

Position 1

Position 1

Position 0

Position 2

No Start

33003281 233


Wiring Diagram The following diagram represents the wiring diagram of the Enabling Device 2 Channel:



F1(1)



K3

K4

K1

K2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

K0

µC 1

µC 1

LOGIC

24 V

5 V

0V

+24 V +24 V


TERFieldbus

K01 K02

0V

Channel 2Channel 1

S4

Enabling Device 2 Channel Contact Function

NO 13 - 14

NC 21 - 22

0 21On

Off

13

14

NO21

22

NC

EnableSwitch

0 21 Legend

Note: XPSMC32 with 32 inputs i1...i32, otherwise identical.

234 33003281


Enabling Device 3 Channel

Functional Diagram

The following diagram represents the functional diagram of the 3-contact Enable Switch:

Position 1


Output

No Start


InputEnable Switch NC

Power ON

(RUN)

t < t Enable

Position 1Position 0 Position 2 Position 1 Position 0

33003281 235


Wiring Diagram The following diagram represents the wiring diaram of the 3-contact Enable Switch:



F1(1)



K3

K4

K1

K2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

K0

µC 1

µC 1

LOGIC

24 V

5 V

0V

+24 V +24 V


TERFieldbus

K01 K02

0V

Channel 2Channel 1

S4

3-Contact Enable Switch Contact Function:

NO 1 - 2

NO 3 - 4NC 5 - 6

0 21NO 1 - 2

NO 3 - 4NC 5 - 6

0 21On

Off

1

2

NO3

4

NO5

6

NC

Enable

Switch

0 21

Note: XPSMC32 with 32 inputs i1...i32, otherwise identical.

236 33003281


Foot Switch

Functional Diagram

The following images represents the Foot Switch functional diagram:


Input NC

Volgage ON

(RUN) confirmed foot switch not confirmed confirmed

Input NO

Output

t < tsyn.

Input NC

Volgage ON

(RUN) confirmed foot switch not confirmed

Input NO

Output

t < tsyn.

confirmed foot switch

no switch on

Start interlock = NO

Start interlock = YES

33003281 237


Wiring Diagram The following image represents the Foot Switch wiring diagram:

0 V

+24 V

0 V

+24 V

With Added Safeguards

F1

S1

Foot Switch

13

14

21

22


A1 c8 c7 c6 c5 c4 c3 c2 c1



K3

K4

K1

K2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

Channel 1

Channel 2

TERK0

µC 1

µC 1

LOGIC

24 V

5 V

238 33003281

Glossary

EDM external device monitoring

ESC external start conditions

ESPE electro sensible protective equipment

OSSD output safety switching device

OTS top dead center (Oberer Totpunktschalter)

RUN Mode XPSMC functional status during which the connected circuit members are monitored and the safety outputs are switched.

E

O

R

33003281 239

Glossary

Safety Input Monitored input for connection of switching devices. By using various control outputs (c1...c8) to power the safety inputs, cross-connections, external voltage and earth connections can be detected on the safety inputs.

Safety Outputs Relay or solid-state output activated by the XPSMC logic unit, which are able to cut off the subordinate control elements.

Synchronization Time

maximum time difference allowed between the appearance of 2 input signals

TER (Connector for Terminal)

8 pin RJ45 connector for the connections of a PC for the configuration or diagnostic (bus system with Modbus protocol) or connections of another Modbus module (PLC, terminals, etc. ...).

VDC validation counter

S

T

V

240 33003281

CBAIndex

Aapplication examples

3-contact Enable Switch, 235eccentric press, 215eccentric press 2, 219electrical diagram for XPSMC, 165Enabling Device 2 Channel, 233foot switch, 237hydraulic press 2, 209hydraulic press valve monitoring, 207injection molding machines, 204light curtain with relay outputs, 182light curtain with transistor outputs, 186magnetic switch, 192muting for light curtains type 4, 190One-Channel Emergency Stop, with automatic start, 167safety guard with one channel, 171safety mat, 198seat valve monitoring, 231timer, 226two channel safety guard, 174two channels safety guard with lock, 178Two-ChannelEmergency Stop, with start button, 169two-hand control, 196zero speed detection, 200

assigning the enabling device, 127assigning the protective guard function, 125assigning the starting function, 126assigning the switch position, 124

33003281

Cclosed tool, 112color definitions, 158configuration errors, 147connecting a device to a safety output, 49connection drawing

3-contact Enable Switch, 235eccentric press, 215eccentric press 2, 219electrical diagram for XPSMC, 165Enabling Device 2 Channel, 233foot switch, 237hydraulic press 2, 209hydraulic press valve monitoring, 207injection molding machines, 204light curtain with relay outputs, 182light curtain with transistor outputs, 186magnetic switch, 192muting for light curtains type 4, 190One-Channel Emergency Stop, with automatic start, 167safety guard with one channel, 171safety mat, 198seat valve monitoring, 231selector switch, 224shaft/chain-break monitoring, 229timer, 226two channel safety guard, 174two channels safety guard with lock, 178Two-ChannelEmergency Stop, with start

241

Index

button, 169two-hand control, 196zero speed detection, 200

copy/saving of a validated configuration, 152create a configuration, 34creating a new configuration, 120

Ddevice

closed tool, 112EDM, 97enabling, 100monitoring, 52OR, 106selector switch, 109start, 98timer, 104

diagnosticsXPSMC safety controller, 157

Eeccentric press, 84eccentric press 2, 88EDM adjustment, 128EDM device, 97emergency stop, 54, 132

Ffault diagnostics, 159foot switch control device, 107

Ggenerals, 117

Hhydraulic press 2, 80hydraulic press valve monitoring, 78

242

Iinjection molding machine, 76installation, 14installing the USB driver for the TSXCUSB485 cable, 13

Llight curtain

with muting, 60light curtains (ESPE) of category 4

without muting, 58loading, 149

Mmagnetic switch, 65master E-Stop device, 136maximum response time, 118menu command

check, 23controller, 24diagnostics, 29edit, 21file, 20help, 28mode, 22options, 27

modifying the properties, 50

OOR device, 106output states, 113overview of all control devices, 52

Ppassword, 139

Rread protocol from controller, 155response time, 34

33003281

Index

Ssafety guards, 55safety mat, 67safety output

assign a name, 129assign a stop category, 129copying the state of one onto another, 130

save, 137seat valve monitoring, 95select a controller type, 120selector switch device, 109sending a configuration, 141setting the safety outputs, 47shaft/chain break monitoring, 94shaft/chain break monitoring dialog settings, 94start device, 98system requirements, 12

Ttime

response time, 34timer, 104transfer of a validated configuration copy, 153two-channel or three-channel enabling device, 100two-hand control, 66

Uuser interface

elements of a window, 18window types, 16

Zzero speed detection, 69

33003281
243

Index

244
33003281