Mitsubishi Electric WS0 XTIO84202 User's Manual v2

WS0-XTIO84202/WS0-XTDI80202

Safety Controller Safety I/O Module User's Manual (Hardware)

Mitsubishi Electric Corporation 2-7-3 Marunouchi, Chiyoda-ku, Tokyo, Japan Mitsubishi Electric Europe BV Gothaer strasse 8, 40880 Ratingen, Germany All rights reserved Specified product properties and technical data do not represent a guarantee declaration.

MODEL WS-IO-U-HW MODEL CODE 13J201

IB(NA)-0800444-F(1208)MEE 2009 MITSUBISHI ELECTRIC CORPORATION

Precautions regarding warranty and specifications MELSEC-WS series products were jointly developed and manufactured by Mitsubishi and SICK AG, Industrial Safety Systems, in Germany. Note that there are some precautions regarding warranty and specifications of MELSEC-WS series products. The gratis warranty term of the product shall be for one (1) year after the

date of delivery or for eighteen (18) months after manufacturing, whichever is less.

The onerous repair term after discontinuation of production shall be for four (4) years.

Mitsubishi shall mainly replace the product that needs a repair. It may take some time to respond to the problem or repair the product

depending on the condition and timing. General specifications of the products differ.

MELSEC-WS MELSEC-Q MELSEC-QS Operating ambient temperature -25 to 55C*1 0 to 55C 0 to 55C

Operating ambient humidity 10 to 95%RH 5 to 95%RH 5 to 95%RH

Storage ambient temperature -25 to 70C -25 to 75C -40 to 75C

Storage ambient humidity 10 to 95%RH 5 to 95%RH 5 to 95%RH

*1: When the WS0-GCC100202 is included in the system, operating

ambient temperature will be 0 to 55C. EMC standards that are applicable to the products differ.

MELSEC-WS MELSEC-Q, MELSEC-QS

EMC standards EN 61000-6-2, EN 55011 EN 61131-2

1 About this document This document is the original manual.

1.1 Documentations for the MELSEC-WS system This manual describes the mounting of the safety I/O modules (WS0-XTIO and WS0-XTDI) of a MELSEC-WS safety controller. Mounting of the MELSEC-WS CPU modules (WS0-CPU0 and WS0- CPU1), network modules (WS0-GETH and WS0-GCC1) and the relay output module (WS0-4RO) is described in separate manuals. The installation, configuration and commissioning of the MELSEC-WS safety controller are described in the "Safety Controller Users Manual" and "Safety Controller Setting and Monitoring Tool Operating Manual".

Title Number

Safety Controller Users Manual WS-CPU-U-E (13JZ32)

Safety Controller Ethernet Interface Users Manual

WS-ET-U-E (13JZ33)

Safety Controller CC-Link Interface Users Manual

WS-CC-U-E (13JZ45)

Safety Controller Setting and Monitoring Tool Operating Manual

SW1DNNWS0ADR-B-O-E (13JU67)

1.2 Function of this document This manual instructs the technical staff of the machine manufacturer and/or of the machine operator on the safe mounting of the safety I/O module of the MELSEC-WS safety controller. In addition mounting protective devices also requires specific technical skills which are not detailed in this documentation. This manual does not provide manuals for operating the machine in which the safety controller is, or will be, integrated. Information of this kind will be found in the manuals for the machine.

2 On safety This chapter deals with your own safety and the safety of the equipment operators. Please read this chapter carefully before beginning with the installation.

2.1 Qualified safety personnel The MELSEC-WS safety controller may only be installed by qualified safety personnel. Qualified safety personnel are defined as persons who have undergone the appropriate technical training and who have been instructed by the responsible machine operator in the

operation of the machine and the current valid safety guidelines and have access to the MELSEC-WS manuals and have read and

familiarized themselves with them and have access to the manuals for the protective devices (e.g. light

curtains) connected to the safety controller and have read and familiarized themselves with them.

2.2 Applications of the device The MELSEC-WS safety controller is a configurable controller for safety applications. It can be used in accordance with IEC 61508 to SIL 3 in accordance with IEC 62061 to SILCL 3 in accordance with EN/ISO 13849-1 up to Performance Level e The degree of safety actually attained depends on the external circuit, the realization of the wiring, the parameter configuration, the choice of the pick-ups and their location at the machine. Opto-electronic and tactile safety sensors (e.g. light curtains, laser scanners, safety switches, sensors, emergency-stop buttons) are connected to the safety controller and are linked logically. The corresponding actuators of the machines or systems can be switched off safely via the switching outputs of the safety controller.

2.3 Correct use

ATTENTION

The MELSEC-WS safety controller fulfils the requirements of Class A (industrial applications) in accordance with the "Interference emission" basic specifications! The MELSEC-WS safety controller is therefore only suitable for use in an industrial environment and not for private use.

The MELSEC-WS safety controller may only be used within specific operating limits (voltage, temperature, etc., refer to the technical data and to the section "Application areas of the device"). It may only be used by specialist personnel and only at the machine at which it was mounted and initially commissioned by qualified personnel in accordance with the "Safety Controller Users Manual". The modules of the MELSEC-WS safety controller conform to Class A, Group 1, in accordance with EN 55011. Group 1 encompasses all the ISM devices in which intentionally generated and/or used conductor-bound RF energy that is required for the inner function of the device itself occurs. Mitsubishi Electric Corporation accepts no claims for liability if the equipment is used in any other way or if modifications are made to the device, even in the context of mounting and installation. UL/CSA applications: Use 60C/75C conductors. The terminal tightening torque must be 5-7 lbs in. To be used in a Pollution Degree 2 environment only. Memory plug and CPU module shall be supplied by an isolating power

source protected by an UL248 fuse, rating 42.4VDC which is the maximum voltage requirements of UL508.

The safety functions are not evaluated by UL. The approval is accomplished according to UL508, general use applications.

2.4 General protective notes and protective measures

ATTENTION

Observe the protective notes and measures! Please observe the following items in order to ensure proper use of the MELSEC-WS safety controller.

When mounting, installing and using the MELSEC-WS safety controller,

observe the standards and directives applicable in your country. The national/international rules and regulations apply to the installation,

use and periodic technical inspection of the MELSEC-WS safety controller, in particular: Machinery Directive 2006/42/EC EMC Directive 2004/108/EC Use of Work Equipment Directive 89/655/EC Low-Voltage Directive 2006/95/EC The work safety regulations/safety rules

Manufacturers and owners of the machine on which a MELSEC-WS safety controller is used are responsible for obtaining and observing all applicable safety regulations and rules.

It is imperative that the notices, in particular the test notice of the manual must be observed.

The tests must be carried out by specialised personnel or specially qualified and authorised personnel and must be recorded and documented to ensure that the tests can be reconstructed and retraced at any time by third parties.

2.5 Disposal Disposal of unusable or irreparable devices should always occur in accordance with the applicable country-specific waste-disposal regulations (e.g. European Waste Code 16 02 14).

3 Conditions of use for the product (1) Although MELCO has obtained the certification for Product's

compliance to the international safety standards IEC 61508, EN 954- 1/ISO 13849-1 from TUV Rheinland, this fact does not guarantee that Product will be free from any malfunction or failure. The user of this Product shall comply with any and all applicable safety standard, regulation or law and take appropriate safety measures for the system in which the Product is installed or used and shall take the second or third safety measures other than the Product. MELCO is not liable for damages that could have been prevented by compliance with any applicable safety standard, regulation or law.

(2) MELCO prohibits the use of Products with or in any application involving, and MELCO shall not be liable for a default, a liability for defect warranty, a quality assurance, negligence or other tort and a product liability in these applications. 1) power plants, 2) trains, railway systems, airplanes, airline operations, other

transportation systems, 3) hospitals, medical care, dialysis and life support facilities or

equipment, 4) amusement equipments, 5) incineration and fuel devices, 6) handling of nuclear or hazardous materials or chemicals, 7) mining and drilling, 8) and other applications where the level of risk to human life, health

or property are elevated.

4 Product description 4.1 Description

4.1.1 Safety I/O combined module WS0-XTIO The WS0-XTIO module is an input/output extension with 8 safety inputs and 4 safety outputs. It fulfils the following tasks: Monitoring of the connected sensor equipment Passing on the input information to the CPU module Receiving the control signals from the CPU module and corresponding

switching of the outputs Fast Shut Off The WS0-XTIO module can only be used in combination with a CPU module (WS0-CPU0 or WS0-CPU1) (see the Safety Controller Setting and Monitoring Tool Operating Manual). Simultaneous use of several WS0-XTIO modules is possible (a maximum total of 12 WS0-XTIO and WS0-XTDI). Voltage for the internal logic and the test outputs is supplied from the memory plug via the FLEXBUS+ backplane bus. Voltage for the WS0-XTIOs outputs Q1 ... Q4 must be supplied directly via A1/A2 on the respective module. A WS0-XTIO has two test signal generators. Short circuits between test outputs X1 and X2 are recognised.

4.1.2 Safety input module WS0-XTDI The WS0-XTDI module is the input extension with 8 safe inputs. It fulfils the following tasks: Monitoring of the connected sensor equipment Passing on the input information to the CPU module The WS0-XTDI module can only be used in combination with a CPU module (WS0-CPU0 or WS0-CPU1) (see the Safety Controller Setting and Monitoring Tool Operating Manual). Simultaneous use of several WS0-XTDI modules is possible (a maximum total of 12 WS0-XTIO and WS0-XTDI). Voltage supply is effected via the FLEXBUS+ backplane bus. A WS0-XTDI has two test signal generators. One test signal generator is responsible for the odd-numbered test pulse outputs X1, X3, X5 and X7, the other for the even-numbered test pulse outputs X2, X4, X6 and X8.

ATTENTION

WS0-XTDI recognises short-circuits between odd- numbered (X1, X3, X5, X7) and even-numbered (X2, X4, X6, X8) test pulse outputs if the test gaps <4ms. If the test gaps 4ms, the short-circuits are not always recognize in every case. Short-circuits under the odd-numbered (X1, X3, X5, X7) test pulse outputs or under the even-numbered (X2, X4, X6, X8) test pulse outputs are not recognize. Take this into account for the wiring, e.g. by separate

routing or sheathing lines.

4.2 Display elements

4.2.1 Displays of the MS LED MS LED Meaning

Off Supply voltage lies outside range Flashes red/green (1Hz) Recoverable external error Flashes green (1Hz) System is in Stop state Lights up green System is in Run state Flashes red (1Hz) Configuration required

Flashes red (2Hz) Critical error in the system, possibly in this module. Application is stopped. All outputs are switched off.

Lights up red Critical error in the system, possibly in another module. Application is stopped. All outputs are switched off.

4.2.2 Displays of the input/output LEDs Input LEDs (I1 ... I8)

Output LEDs (Q1 ... Q4) (only WS0-XTIO)

Meaning

Off Input/output is inactive. Lights up green Input/output is active. Flashes green (1Hz)

synchronous with the red MS LED

Input/output is inactive and there is a correctable error.

Flashes green (1Hz) alternating with the red MS LED

Input/output is active and there is a correctable error.

4.3 Terminal assignment

4.3.1 Terminal assignment WS0-XTIO Module Terminal Assignment

X1/X2 Test outputs 1 and 2 I1 ... I4 Inputs 1 to 4 A1 24V A2 GND I5 ... I8 Inputs 5 to 8

Q1 ... Q4 Outputs 1 to 4

4.3.2 Terminal assignment WS0-XTDI Module Terminal Assignment

X1/X3 Test output 1 (test signal generator 1)

X2/X4 Test output 2 (test signal generator 2)

I1 ... I4 Inputs 1 to 4 I5 ... I8 Inputs 5 to 8

X5/X7 Test output 1 (test signal generator 1)

X6/X8 Test output 2 (test signal generator 2)

5 Mounting/Dismantling

ATTENTION

The MELSEC-WS safety controller is only suitable for mounting in a control cabinet with at least IP 54 degree of protection. While supply voltage is applied, modules must not be plugged to nor be removed from the MELSEC-WS safety controller.

5.1 Mounting the modules In a MELSEC-WS safety controller, the WS0-CPU0 or WS0-CPU1 is

positioned at the far left and the two optional network modules follow directly. Only then do the safety I/O modules follow. The WS0-4RO module has to be mounted at the far right.

The modules are located in a 22.5mm wide modular system for 35mm DIN rails to IEC/EN 60715.

The connection between the modules is effected by means of the plug connection integrated in the housing.

Mount the modules in accordance with EN 50274 Ensure that suitable ESD protective measures are also taken during

mounting. Otherwise the FLEXBUS+ backplane bus may be damaged. Take suitable measures to ensure that foreign matter does not enter the

connector openings, in particular that of the memory plug.

Make sure that the voltage supply of the MELSEC-WS safety controller is switched off.

Hang the device onto the DIN rail (1)). Ensure that the earthing spring contact is positioned correctly (2)). The

earthing spring contact of the module must contact the DIN rail securely to allow electrical conductivity.

Snap the module onto the DIN rail by pressing it lightly in the direction of the arrow (3)).

If there are several modules, slide the modules together individually in the direction of the arrow until the side plug connection latches in.

Install the end clips on the left and right.

5.2 Steps for dismantling the modules

Remove the removable terminals with wiring and the end clips.

If there are several modules, slide the modules away from each other individually in the direction of the arrow until the side plug connection is separated.

Press the module downwards at the rear (1)) and remove it from the DIN rail in the direction of the arrow while keeping it pressed down (2)).

6 Electrical installation

ATTENTION

De-energize the entire system! The system could start up unexpectedly while you are connecting the devices. Observe the relevant safety standards! All safety related parts of the installation (cabling, connected sensors and actuators, configuration settings, EDM) must be according to the relevant safety standards (e.g. IEC 62061 or EN/ISO 13849-1).

The MELSEC-WS safety controller fulfils the EMC requirements in accordance with the basic specification IEC 61000-6-2 for industrial use.

Electrical installation in accordance with IEC 60204-1 To ensure full electromagnetic compatibility (EMC), the DIN rail has to

be connected to functional earth (FE). The voltage supply of the devices must be capable of buffering brief

mains voltage failures of 20ms as specified in IEC 60204-1. The voltage supply has to fulfil the regulations for extra-low voltages with

safe separation (SELV, PELV) in accordance with IEC 60664 and EN 50178 (equipment of electrical power installation with electronic devices).

You must to connect all the modules of the MELSEC-WS safety controller, the connected protective devices as well as the voltage supply/ies with the same 0VDC (GND).

All connected pick-ups and downstream controllers as well as wiring and installation have to fulfil the required safety characteristics.

Depending on the external loads, especially for inductive loads, additional external protective elements, e.g. varistors or RC elements may be necessary in order to protect the safety outputs. Take into account that the response times may increase, depending on the type of protective element.

If a module is replaced the correct terminal assignment has to be guaranteed, for example by labelling or suitable cable routing.

For further information that is to be taken into consideration when the MELSEC-WS safety controller is used refer to the "Safety Controller Users Manual" and "Safety Controller Setting and Monitoring Tool Operating Manual".

7 Configuration and commissioning

ATTENTION

Do not commission without a check by qualified safety personnel! Before initial commissioning of a system using a MELSEC-WS safety controller, it must be checked and released by qualified personnel. Document the result of the safety check.

The MELSEC-WS safety controller can be configured by the Setting and Monitoring Tool connected to the RS-232 interface of a CPU module or the port of an Ethernet interface module. Note The Setting and Monitoring Tool version 1.3.0 or higher is

required to configure and commission the MELSEC-WS safety controller.

The system configuration of the complete MELSEC-WS safety controller is stored in the memory plug. The system does not have to be reconfigured when a module is replaced.

8 Technical data

8.1 Technical data WS0-XTIO/WS0-XTDI Safety Integrity Level SIL3 (IEC 61508) SIL claim limit SIL CL3 (IEC 62061) Category

For single channel outputs with test pulses enabled for all safety outputs (Q1Q4)

Category 4 (EN/ISO 13849-1)

For single channel outputs with test pulses disabled for this or any other safety output (Q1Q4)

Category 3 (EN/ISO 13849-1)

For dual channel outputs with or without test pulses disabled for this or any other safety output (Q1Q4)

Category 4 (EN/ISO 13849-1)

Performance Level PL e (EN/ISO 13849-1) PFHd (mean probability of a dangerous failure per hour)

See the Safety Controller User's Manual.

TM (mission time) 20 years (EN ISO 13849-1) Protection class III (IEC 61140)

Enclosure rating Terminals: IP 20 (IEC 60529) Housing: IP 40 (IEC 60529)

Ambient temperature in operation -25 ... +55C Storage temperature -25 ... +70C Humidity 10% ... 95%, non-condensing

Climatic conditions 55C, 95% rel. humidity (IEC 61131-2), No corrosive gases

Vibration resistance 10-500Hz/5g (IEC 60068-2-6) Shock resistance

Continuous shock Single shock

10g, 16ms (IEC 60068-2-27) 30g, 11ms (IEC 60068-2-27)

Electromagnetic compatibility Class A (IEC 61000-6-2, EN 55011) System connection Dual level spring clamp terminals

Power input via FLEXBUS+

WS0-XTIO: Max. 2.2W (without currents to X1, X2) WS0-XTDI: Max. 2W (without currents to X1 X8)

Cross-section of connecting wires

Single-core or finely stranded: 0.2 ... 1.5mm2 Finely stranded with ferrules: 0.25 ... 1.5mm2

Data interface Backplane bus (FLEXBUS+) Dimensions (W H D) 22.5 106.5 120.8mm

Weight WS0-XTIO: 164g (5%) WS0-XTDI: 139g (5%)

Input circuit (I1 ... I8) Input voltage HIGH 13 ... 30VDC Input voltage LOW 5 ... +5VDC Input current HIGH 2.4 ... 3.8mA Input current LOW 2.5 ... 2.1mA

Input reverse current in case of ground interruption

Hardware version < V1.10: Max. 20mA, 1.5k effective reverse resistance to power supply Hardware version V1.10: Max. 2mA

Switching current (with mechanical contacts)

14.4mA at 5V 3mA at 24V

Input pulse filtering (pulses within these limits have no effect) Pulse width Pulse period

Max. 0.9ms Min. 4ms

Input capacitance Max. 10nF+10% Discrepancy times 4ms ... 30s, configurable Number of inputs 8 Test outputs (X1, X2) or (X1 ... X8)

Number of outputs XTIO: 2 (with 2 test pulse generators) XTDI: 8 (with 2 test pulse generators)

Output type PNP semiconductor, short-circuit protected, cross circuit monitoring (selectable)

Output voltage High 15 30VDC (max. 1.8V drop to terminal A1 of main module)

Output resistance Low 33 10%, current limited at approx. 10mA

Output current Max. 120mA at each test output Test pulse rate (test period) 1 25Hz, configurable Test pulse duration (test gap) 1 ... 100ms, configurable

Load capacity 1F for test gap 4ms 0.5F for test gap 1ms

Cable resistance < 100

Power supply unit (A1, A2) (WS0-XTIO only) Supply voltage 24VDC (16.8VDC 30VDC)

Type of supply voltage

PELV or SELV The current of the power supply unit for the CPU module has to be limited to a maximum of 4A either by the power supply unit itself or by a fuse.

Power consumption Max. 120W (30V 4A), determined by the load at the outputs Q1 to Q4

Switch-on time Max. 18s

Short-circuit protection 4A gG (with tripping characteristic B or C)

Safety outputs (Q1 ... Q4) (WS0-XTIO only) Number of outputs 4

Output type PNP semiconductor, short-circuit protected, cross circuit monitoring (selectable)

Output voltage High 16 30VDC (max. 0.8V drop to terminal A1 of this module)

Leakage current Low Normal operation Fault case

Max. 0.1mA Hardware version < V1.10: Max. 1.6mA Hardware version V1.10: Max. 2.0mA

Output current Max. 2.0A Total current Isum

TA 45C TA 55C For UL/CSA applications

Max. 4.0A Max. 3.2A Max. 3.2A

Test pulse width < 650s Test pulse rate Max. 5Hz Capacitive load 0.5F Cable resistance Max. 5 (e.g. 100m 1.5mm = 1.2) Max. permitted coil energy without external protection elements