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Mitsubishi Electric MELSEC-QS Series Safety Application Manual

Safety programmable controller
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  • Page 1 Safety Application Guide...

  • Page 3: Safety Precautions

    SAFETY PRECAUTIONS (Read these precautions before using this product.) Before using the product, please read this manual, the relevant manuals introduced in this manual, standard programmable controller manuals, and the safety standards carefully and pay full attention to safety to handle the product correctly. In this manual, the safety precautions are classified into two levels: "...
  • Page 4 [Design Precautions] WARNING When a safety programmable controller detects an error in an external power supply or a failure in programmable controller main module, it turns off all the outputs. Create an external circuit to securely stop the power of hazard by turning off the outputs. Incorrect configuration may result in an accident.
  • Page 5 [Design Precautions] WARNING When a CC-Link Safety remote I/O module has detected CC-Link Safety error, it turns off all the outputs. Note that the outputs in a sequence program are not automatically turned off. If CC-Link Safety or CC-Link IE Field Network error has been detected, create a sequence program that turns off the outputs in the program.
  • Page 6 [Installation Precautions] CAUTION Use a safety programmable controller in the environment that meets the general specifications described in the QSCPU User's Manual (Hardware Design, Maintenance and Inspection). Using this programmable controller in an environment outside the range of the general specifications could result in electric shock, fire, erroneous operation, and damage to or deterioration of the product.
  • Page 7 [Wiring Precautions] CAUTION Ground the FG and LG terminals correctly. Not doing so could result in electric shock or malfunctions. Use a solderless terminal with insulation sleeve for wiring of a terminal block. Use up to two solderless terminals for a single terminal. Use applicable solderless terminals and tighten them with the specified torque.
  • Page 8 [Wiring Precautions] CAUTION Be sure to fix the communication cables or power cables by ducts or clamps when connecting them to the module. Failure to do so may cause damage of the module or cables due to a wobble, unintentional shifting, or accidental pull of the cables, or malfunctions due to poor contact of the cable.
  • Page 9 [Startup and Maintenance precautions] WARNING Do not touch the terminals while power is on. Doing so could result in electric shock. Correctly connect the battery connector. Also, do not charge, disassemble, heat, place in fire, short circuit, or solder the battery. Mishandling of battery can cause overheating, cracks, or ignition which could result in injury and fires.
  • Page 10 [Startup and Maintenance precautions] CAUTION Completely turn off the external supply power used in the system before mounting or removing the module. Not doing so may result in a failure or malfunctions of the module. Restrict the mounting/removal of a module, base unit, and terminal block up to 50 times (IEC 61131-2 compliant), after the first use of the product.

  • Page 11: Conditions Of Use For The Product

    CONDITIONS OF USE FOR THE PRODUCT (1) Although MELCO has obtained the certification for Product's compliance to the international safety standards IEC61508, ISO13849-1 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.

  • Page 12: Revisions

    This manual confers no industrial property rights or any rights of any other kind, nor does it confer any patent licenses. Mitsubishi Electric Corporation cannot be held responsible for any problems involving industrial property rights which may occur as a result of using the contents noted in this manual.

  • Page 13: Table Of Contents

    INTRODUCTION Thank you for purchasing the Mitsubishi Electric safety programmable controller MELSEC-QS series. Before using the equipment, please read this manual carefully to develop full familiarity with the functions and performance of the QS series programmable controller you have purchased, so as to ensure correct use.
  • Page 14 Network-Related Switch Settings of Module..................5 - 2 5.2.1 Safety power supply module..................... 5 - 2 5.2.2 Safety CPU module ........................5 - 2 5.2.3 CC-Link Safety master module....................5 - 2 5.2.4 CC-Link Safety remote I/O module................... 5 - 3 Parameter Settings of CC-Link Safety .....................

  • Page 15: Manual

    MANUAL The manual related to this product is shown below. Please place an order as needed. Related manuals Manual number Manual name (Model code) Safety Guidelines IB-0800424 Explains the specifications of the QSCPU, safety power supply module and safety base unit, etc. (13JY84) (Supplied with the product) QSCPU User's Manual (Hardware Design, Maintenance and Inspection)
  • Page 16 Remark If you would like to obtain a manual individually, printed materials are available separately. Order the manual by quoting the manual number on the table above (model code). - 14...

  • Page 17: How This Manual Is Organized

    HOW THIS MANUAL IS ORGANIZED The section in this manual or another relevant manual that can be referred to is shown as follows: Section 3.5) In addition, this manual provides the following explanations. POINT In addition to description of the page, notes or functions that require special attention are described here.

  • Page 18: Generic Terms And Abbreviations

    GENERIC TERMS AND ABBREVIATIONS Unless otherwise specified, this manual uses the following generic terms and abbrevia- tions. When a clear indication of target model name is required, the module name is indi- cated. Generic term/ Description abbreviation Generic product name for models SWnD5C-GPPW, SWnD5C-GPPW-A, SWnD5C-GPPW-V, GX Developer and SWnD5C-GPPW-VA Remote register (Read area for CC-Link Safety and CC-Link IE Field Network)

  • Page 19: Terminology

    Generic term/ Description abbreviation Safety CPU module Abbreviation for the QS001CPU type safety CPU module Safety power supply Abbreviation for the QS061P-A1 and QS061P-A2 type safety power supply modules module Generic term for a safety CPU module, a safety power supply module, a safety main base unit, Safety programmable a CC-Link Safety master module, CC-Link Safety remote I/O modules, and a CC-Link IE Field controller...

  • Page 20: Chapter 1 Overview

    OVERVIEW CHAPTER 1 OVERVIEW This chapter describes the overview of the safety programmable controller. The safety programmable controller has acquired certification of the highest safety level (SIL3 of IEC 61508, Category 4 of EN 654-1, and Category 4 performance level "e" of EN ISO 13849-1) applicable to programmable controllers.
  • Page 21 OVERVIEW Power supply/CPU/CC-Link Safety master module/ Power supply/CPU/CC-Link Safety master module/ CC-Link IE Field Network master/local module CC-Link IE Field Network master/local module (with safety functions)* (with safety functions)* CC-Link IE Field Network Safety remote I/O station on CC-Link Safety Safety remote I/O station on CC-Link Safety GX Developer (Version 8.40S or later)*...

  • Page 22: Chapter 2 Application Example

    APPLICATION EXAMPLE CHAPTER 2 APPLICATION EXAMPLE (1) When performing safety control for the entire line using a single safety programmable controller The application image for the car welding line is shown as an application example of the safety programmable controller in Figure 2.1. A safety application operated by the safety programmable controller is configured for the following purposes: •...
  • Page 23 APPLICATION EXAMPLE (2) When performing safety control for the entire line using several safety programmable controllers Figure 2.2 shows an application of safety control interfacing with control processes. A safety application operated by safety programmable controllers is configured for the following purposes: •...

  • Page 24: Chapter 3 Risk Assessment And Safety Level

    RISK ASSESSMENT AND SAFETY LEVEL CHAPTER 3 RISK ASSESSMENT AND SAFETY LEVEL Conforming to EN954-1, ISO13849-1, and IEC61508, select the risk assessment, safety category, PL, and SIL to reduce the risk. This chapter briefly describes the risk assessment, risk reduction and safety category, PL, and SIL.

  • Page 25: Risk Reduction

    RISK ASSESSMENT AND SAFETY LEVEL 3.1.1 Risk reduction As a result of the risk assessment, when the machinery is judged as unsafe, the risk reduction must be performed. The measures for the risk reduction are standardized in ISO12100 and ISO14121 as shown in Figure 3.2.

  • Page 26: Safety Category

    RISK ASSESSMENT AND SAFETY LEVEL Safety Category The safety category is standardized in EN954-1. The risk graph to be used for the safety category selection is shown in Figure 3.3. Risk analysis result Safety category selection Safety category Frequency and time of Possibility of hazard Severity of the injury exposure to hazard...
  • Page 27 RISK ASSESSMENT AND SAFETY LEVEL The requirements of standards for the safety category are shown in Table 3.1. Table 3.1 Summary of safety category requirements Principles to achieve Summary of requirements Category System behavior safety Safety-related parts of control systems and/or their protective equipment, as well as their The occurrence of a fault components, shall be designed, constructed,...
  • Page 28 RISK ASSESSMENT AND SAFETY LEVEL The PL is specified in ISO13849-1. Determine a required performance level (PLr). The PLr refers to a performance level required for safety functions to achieve required risk reduction. Figure 3.4 is a risk graph used to determine a PLr. Seriousness of Frequency and/or Possibility to...
  • Page 29 RISK ASSESSMENT AND SAFETY LEVEL Figure 3.5 shows relationship between Category, DCavg (average diagnostic coverage), and MTTFd (mean time to dangerous failure) of each channel and the resulting PL. Category B Category 1 Category 2 Category 2 Category 3 Category 3 Category 4 =None DC =None DC...

  • Page 30: Sil

    RISK ASSESSMENT AND SAFETY LEVEL SIL is standardized in IEC61508. The risk graph to be used for the SIL selection is shown in Figure 3.6. Probability of risk Degree of Exposure Possibility of event occurrence influence frequency risk event Frequent Moderate Infrequent avoidance...

  • Page 31: Chapter 4 Precautions For Use Of Safety Programmable Controller

    PRECAUTIONS FOR USE OF SAFETY PROGRAMMABLE CONTROLLER CHAPTER 4 PRECAUTIONS FOR USE OF SAFETY PROGRAMMABLE CONTROLLER The safety standards conformance approval must be made by the user for the entire safety-related system. The safety system inspection is made for the entire safety-related system including safety components and a sequence program.
  • Page 32 PRECAUTIONS FOR USE OF SAFETY PROGRAMMABLE CONTROLLER Variable Definition PFD/PFH of the CC-Link Safety remote I/O module to which the safety output device is connected PFD/PFH of safety input equipment PFD/PFH of safety output equipment * 1: For PFD/PFH of C and D, refer to the manuals, etc. of the used safety components. PFD/PFH of the safety programmable controller is listed in Table 4.2.
  • Page 33 PRECAUTIONS FOR USE OF SAFETY PROGRAMMABLE CONTROLLER (a) When using one QS0J65BTB2-12DT = (PFD of A) + (PFD of B) + (PFD of C) + (PFD of D) = (4.10 + 8.75 ) + (2.57 ) + (PFD of C) + (PFD of D) = (1.54 ) + (PFD of C) + (PFD of D) = (PFH of A) + (PFH of B) + (PFH of C) + (PFH of D)
  • Page 34 PRECAUTIONS FOR USE OF SAFETY PROGRAMMABLE CONTROLLER (b) When using one QS0J65BTS2-8D and one QS0J65BTS2-4T = (PFD of A) + (PFD of B) + (PFD of C) + (PFD of D) = (4.10 + 8.75 ) + (1.68 + 1.68 ) + (PFD of C) + (PFD of D) = (1.62 ) + (PFD of C) + (PFD of D)
  • Page 35 PRECAUTIONS FOR USE OF SAFETY PROGRAMMABLE CONTROLLER (c) When using CC-Link IE Field Network between safety programmable controllers = (PFD of input side A) + (PFD of input side B) + (PFD of C) + (PFD of output side A) + (PFD of output side B) + (PFD of D) = (4.10 + 8.75...
  • Page 36 PRECAUTIONS FOR USE OF SAFETY PROGRAMMABLE CONTROLLER (d) When using CC-Link IE Field Network between safety programmable controllers (multiple output points) = (PFD of A1) + (PFD of B1) + (PFD of C1) + (PFD of D1) + (PFD of A2) + (PFD of B2) + (PFD of D2) = (4.10 + 8.75 ) + (2.57...
  • Page 37 PRECAUTIONS FOR USE OF SAFETY PROGRAMMABLE CONTROLLER (3) Connecting safety components Connect safety components according to the safety level by dual wiring and single wiring as shown in Figure 4.5. Doubling wiring Doubling wiring Safety programmable Single wiring Single wiring controller Figure 4.5 Wiring of safety components POINT...
  • Page 38 PRECAUTIONS FOR USE OF SAFETY PROGRAMMABLE CONTROLLER (4) Using the monitor data of GX Developer The monitor data of GX Developer should not be used for the operation related to the safety. (For example, the operations for the safety such as starting a machine or resetting the stop status should not be performed with checking the monitor data of GX Developer.) 4.1 Precautions for Designing Safety Application...

  • Page 39: Precautions For Programming

    PRECAUTIONS FOR USE OF SAFETY PROGRAMMABLE CONTROLLER Precautions for Programming (1) Basic programming Configure a program for realizing safety functions with attention to the following points. • Program so that a machine is started only when safe state can be confirmed at the time the start switch is pressed.
  • Page 40 PRECAUTIONS FOR USE OF SAFETY PROGRAMMABLE CONTROLLER (2) Devices used in a program for realizing the safety functions Data can be used as safety I/O data are the following safety refresh devices. Use the safety refresh devices to create a program for realizing the safety functions. (a) Safety refresh device •...
  • Page 41 PRECAUTIONS FOR USE OF SAFETY PROGRAMMABLE CONTROLLER (3) Detecting errors in CC-Link Safety Errors occurred in CC-Link Safety can be detected using safety refresh communication status shown in Table 4.3. Create a program using safety refresh communication status, which turns off safety outputs in case of an error.
  • Page 42 PRECAUTIONS FOR USE OF SAFETY PROGRAMMABLE CONTROLLER (4) Resetting error status of CC-Link Safety If an error occurs in CC-Link Safety, the safety station interlock status shown in Table 4.4 turns on. To restart communication on CC-Link Safety, turn on the safety station interlock cancel request.
  • Page 43 PRECAUTIONS FOR USE OF SAFETY PROGRAMMABLE CONTROLLER (a) Program example Figure 4.9 shows the program when the interlock for the safety remote I/O station of station No. 1 on CC-Link Safety, connected to the first CC-Link Safety master module is cleared. SD1072.0 SET SD1076.0 Reset switch...
  • Page 44 PRECAUTIONS FOR USE OF SAFETY PROGRAMMABLE CONTROLLER (b) Program example • When communicating with station No. 0 Figure 4.10 shows the program that handles an error occurred in CC-Link IE Field Network during communication with station No. 0. Status of safety refresh communication with station No. 0 can be checked using SM1421, and the information is output to station No.
  • Page 45 PRECAUTIONS FOR USE OF SAFETY PROGRAMMABLE CONTROLLER (6) Resetting error status of CC-Link IE Field Network If an error occurs in CC-Link IE Field Network, the safety station interlock status shown in Table 4.6 turns on. To restart communication on CC-Link IE Field Network, turn on the safety station interlock release request.
  • Page 46 PRECAUTIONS FOR USE OF SAFETY PROGRAMMABLE CONTROLLER (a) Program example • When communicating with station No. 0 Figure 4.12 shows the program that releases interlock of CC-Link IE Field Network during communication with station No. 0. Status of safety station interlock with station No. 0 can be checked using SM1700, and safety station interlock for station No.
  • Page 47 PRECAUTIONS FOR USE OF SAFETY PROGRAMMABLE CONTROLLER (8) User registration Define the user who handles the corresponding project, then register the user information and authorization required for the login authentication in the project. For the user registration, refer to the following. GX Developer Version 8 Operating Manual (Safety Programmable Controller) 4.2 Precautions for Programming - 17...

  • Page 48: Precautions For Startup

    PRECAUTIONS FOR USE OF SAFETY PROGRAMMABLE CONTROLLER Precautions for Startup When new safety-related system will be started up or existing safety-related system will be changed, confirm the below points. (1) Confirmation of network connection configuration Confirm that the CC-Link Safety remote I/O module used is set as designed. The confirmation items are shown below.

  • Page 49: Precautions For Safety Functions Maintenance

    PRECAUTIONS FOR USE OF SAFETY PROGRAMMABLE CONTROLLER Precautions for Safety Functions Maintenance (1) Periodic inspection To confirm whether the emergency stop switch, safety sensor, etc. are not faulty, execute a periodic inspection every one year for meeting Category 3, every six months for meeting Category 4.

  • Page 50: System Configuration

    SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) CHAPTER 5 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) This chapter describes a configuration example of a safety application using a single safety programmable controller. System Configuration This chapter describes a safety application using the system configuration shown in Figure 5.1.

  • Page 51: Network-Related Switch Settings Of Module

    SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) Remark In this chapter, the following abbreviations are used for each module. Abbreviation Module name CC master (1) CC-Link Safety master module (link ID = 0, station number 0) CC master (2) CC-Link Safety master module (link ID = 1, station number 0) CC remote (1) CC-Link Safety remote I/O module (link ID = 0, station number 1)

  • Page 52: Cc-Link Safety Remote I/O Module

    SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) 5.2.4 CC-Link Safety remote I/O module Set the link ID setting switch, station number setting switch, and transmission speed setting switch. POWER L RUN L ERR. SAFETY ERR. QS0J65BTB2-12DT RESET LINK ID STATION NO.

  • Page 53: Parameter Settings Of Cc-Link Safety

    SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) Parameter Settings of CC-Link Safety Set the following values to the network parameters. For descriptions and setting ranges of the parameters, refer to the following. CC-Link Safety System Master Module User's Manual Table 5.2 Setting example of network parameters Module CC master (1)

  • Page 54: Station Information Setting

    SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) 5.3.1 Station information setting Set station information as follows. Table 5.3 Example of station information setting Module Station No. Station type Exclusive station count Reserve station count Safety remote I/O station Exclusive station 1 No setting CC master (1)

  • Page 55: Relationship Between Safety Cpu Module Devices And Remote Inputs/Outputs

    SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) Relationship Between Safety CPU Module Devices and Remote Inputs/Outputs The following shows the relationship between safety CPU module devices and inputs/ outputs of remote I/O stations on CC-Link Safety with the settings described in Table 5.2. Use devices in shaded areas in the sequence program.

  • Page 56: Wiring Diagram And Parameter Setting Of Standard Input

    SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) Wiring Diagram and Parameter Setting of Standard Input (1) Using the QS0J65BTB2-12DT of module technical version D or later • Wiring example of a reset switch, start switch, and stop switch CC remote (3) QS0J65BTB2-12DT(3) (Link ID: 0, Station number: 3)
  • Page 57 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) • Parameter setting example Table 5.5 CC remote (3) SR_IO3 parameter settings *3*4 Item Option "1ms" 1. Time of noise removal filter X0, 1 "1ms" 2. Time of noise removal filter X2, 3 "1ms"...
  • Page 58 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (2) Using the QS0J65BTB2-12DT of module technical version C or earlier • Wiring example of a reset switch, start switch, and stop switch CC remote (3) QS0J65BTB2-12DT(3) (Link ID: 0, Station number: 3) COM- Reset switch (NO) +24V...

  • Page 59: Case Examples

    SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) Case Examples 5.6.1 Emergency stop circuit (1) Application overview The emergency stop circuit is the safety application that turns off the power source of a robot with the emergency stop switch. The application controls the start and stop of a robot by turning on or off the main contact of the contactor which opens and closes the power source of a robot at the safety relay contact.
  • Page 60 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (2) Connection of safety devices : CC-Link Safety remote I/O module CC remote (4): SR_IO4 used in this case example X200-20F Y200-203 Refer to the following: Figure 5.8 Wiring: Table 5.7 Parameters: CC-Link Safety CC remote (3): SR_IO3...
  • Page 61 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (3) Wiring diagram and parameter settings Wire the emergency stop switch and safety relays to the CC-Link Safety remote I/O module as follows. Connect the close contact of the safety relay between CC remote (4) the input terminal and the QS0J65BTB2-12DT(4)
  • Page 62 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) For the emergency stop switch and the safety relays, set the parameters as follows. Table 5.7 CC remote (4) SR_IO4 parameter settings *4*5 Item Setting "1ms" 2. Time of noise removal filter X2, 3 "1ms"...
  • Page 63 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (5) Sequence program The sequence program performs the following processing. Ladder which checks the off fall of the reset switch, accepts reset request, and clears the interlock for the CC-Link Safety. Ladder which confirms the interlock processing completion and cancels interlock clear request.
  • Page 64 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (b) Way of using the internal devices Table 5.9 Way of using the internal devices Internal device Description Timer device Times out after a lapse of the time specified at K Word device Used as restart status in this program.
  • Page 65 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (7) Program using safety FB Table 5.10 Safety FBs to be used FB name Function Description This FB monitors safety equipment such as External device F+EDM an actuator and a contactor and controls a monitor safety output.
  • Page 66 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (8) Timing chart Emergency Emergency Contact welding stop switch stop switch detected in the remote (4) When the reset switch is activated activated safety relay 4 error activated, the F+ESTOP Reset Start Reset...

  • Page 67: Door Monitor Circuit

    SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) 5.6.2 Door monitor circuit (1) Application overview This application de-energizes a robot with the safety switch on the door of a safety barrier when the door is opened. The robot cannot be started while the door on the safety barrier is open. The application controls the start and stop of a robot by turning on or off the main contact of the contactor which opens and closes the power source of a robot at the safety relay contact.
  • Page 68 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (2) Connection of safety devices : CC-Link Safety remote I/O module CC remote (4): SR_IO4 used in this case example X200-20F Y200-203 Refer to the following: Figure 5.17 Wiring: Table 5.12 Parameters: CC-Link Safety CC remote (1): SR_IO1...
  • Page 69 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (3) Wiring diagram and parameter settings (a) CC remote (1): SR_IO1 Wire the safety switch to the CC-Link Safety remote I/O module as follows. CC remote (1) QS0J65BTB2-12DT (1) (Link ID=0, Station number 1) COM- Safety switch COM-...
  • Page 70 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) For the safety switch, set the parameters as follows. Table 5.11 CC remote (1) SR_IO1 parameter settings *4*5 Item Setting "1ms" 1. Time of noise removal filter X0. 1 "100ms" 9.
  • Page 71 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (b) CC remote (4): SR_IO4 Wire the relay with forcibly guided (mechanically linked) contacts to the CC-Link Safety remote I/O module as follows. Connect the close contact of the safety relay between the input CC remote (4) terminal and the test...
  • Page 72 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) For the relay with forcibly guided (mechanically linked) relays, set the parameters as follows. Table 5.12 CC remote (4) SR_IO4 parameter settings *4*5 Item Setting "1ms" 2. Time of noise removal filter X2, 3 "100ms"...
  • Page 73 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (4) Device numbers to be used The following device numbers are used in the sequence program. Table 5.13 Device numbers to be used Safety/standard External device Device number Safety Safety switch X100 or X101 Safety Safety relay...
  • Page 74 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (b) Way of using the internal devices Table 5.14 Way of using the internal devices Internal device Description Timer device Times out after a lapse of the time specified at K Word device Used as restart status in this program.
  • Page 75 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (7) Program using safety FB Table 5.15 Safety FBs to be used FB name Function Description This FB monitors safety equipment such as External device F+EDM an actuator and a contactor and controls a monitor safety output.
  • Page 76 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) For details on the safety FBs, F+GMON, and F+EDM, refer to the following. QSCPU Programming Manual (Safety FB) In this example, the guard status (open or close) is monitored using one safety switch. The input signals of the F+GMON (S_GuradSwitch1 and S_GuradSwitch2) are connected to the same signal of the safety switch (X100 or X101).

  • Page 77: Entering Detection And Existence Detection Circuit 1

    SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) 5.6.3 Entering detection and existence detection circuit 1 (1) Application overview The entering detection and existence detection circuit is the safety application that detects the entrance and existence of a human in a hazardous area and turns off the power source of a robot.
  • Page 78 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (2) Connection of safety devices : CC-Link Safety remote I/O module CC remote (4): SR_IO4 used in this case example X200-20F Y200-203 Refer to the following: Figure 5.26 Wiring: Table 5.17 Parameters: CC-Link Safety CC remote (1): SR_IO1...
  • Page 79 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (3) Wiring diagram and parameter settings Wire the light curtain and the laser scanner to the CC-Link Safety remote I/O module as follows. (a) CC remote (1): SR_IO1 Optical transmitter Create dual wiring 24VDC CC remote (1)
  • Page 80 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) For the light curtain and the laser scanner, set the parameters as follows. Table 5.16 CC remote (1) SR_IO1 parameter settings *4*5 Item Setting "1ms" 3. Time of noise removal filter X4, 5 "1ms"...
  • Page 81 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (b) CC remote (4): SR_IO4 Wire the contactors to the CC-Link Safety remote I/O module as follows. CC remote (4) QS0J65BTB2-12DT (4) (Link ID=1, Station number1) COM- COM- +24V 24VDC COM- Use two contactors which can be activated...
  • Page 82 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) For the contactors, set the parameters as follows. Table 5.17 CC remote (4) SR_IO4 parameter settings *4*5 Item Setting "1ms" 5. Time of noise removal filter X8, 9 "100ms" 13. Doubling input discrepancy detection time X8, 9 21.
  • Page 83 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (5) Sequence program The sequence program performs the following processing. Ladder which checks the falling edge OFF) of the reset switch, accepts the reset request, and releases the interlock for the CC-Link Safety. Ladder which confirms the interlock released status and cancels the interlock release request.
  • Page 84 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (b) Way of using the internal devices Table 5.19 Way of using the internal devices Internal device Description Timer device Times out after a lapse of the time specified at K Word device Used as restart status in this program.
  • Page 85 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (6) Timing chart Detecting Approach Exit remote (4) Approach relay welding error Pressing Pressing Pressing Pressing Pressing Pressing Pressing Pressing the reset the start the reset the start the reset the reset the start the reset...
  • Page 86 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (7) Program using safety FB Table 5.20 Safety FBs to be used FB name Function Description This FB monitors safety equipment such as External device F+EDM an actuator and a contactor and controls a monitor safety output.
  • Page 87 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (8) Timing chart Contact welding Entry Exit Entry remote (4) detected in the When the reset switch is detected confirmed detected error contactor 1 activated, the F+ESPE safety outputs (M1 and M11) are Reset Start Reset...

  • Page 88: Entering Detection And Existence Detection Circuit 2

    SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) 5.6.4 Entering detection and existence detection circuit 2 (1) Application overview The entering detection and existence detection circuit is the safety application that detects the entrance and existence of a human in a hazardous area and turns off the power source of a robot.
  • Page 89 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) Figure 5.32 Entering detection and existence detection (Partially quoted from "Safety Guide Book - the safety measures of machinery in the workplace" : Nippon Electric Control Equipment Industries Association.) 5.6 Case Examples - 40 5.6.4 Entering detection and existence detection circuit 2...
  • Page 90 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (2) Connection of safety devices : CC-Link Safety remote I/O module CC remote (4): SR_IO4 used in this case example X200-20F Y200-203 Refer to the following: Wiring: Figure 5.35 Table 5.22 Parameters: CC-Link Safety CC remote (1): SR_IO1...
  • Page 91 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (3) Wiring diagram and parameter settings (a) CC remote (1): SR_IO1 Wire the light curtain and the mat switch to the CC-Link Safety remote I/O module as follows. Optical transmitter Create dual wiring 24VDC CC remote (1)
  • Page 92 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) For the light curtain and the mat switch, set the parameters as follows. Table 5.21 CC remote (1) SR_IO1 parameter settings *4*5 Item Setting "1ms" 3. Time of noise removal filter X4, 5 "1ms"...
  • Page 93 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (b) CC remote (4): SR_IO4 Wire the contactors to the CC-Link Safety remote I/O module as follows. CC remote (4) QS0J65BTB2-12DT (4) (Link ID=1, Station number1) COM- COM- +24V 24VDC COM- Use two contactors COM-...
  • Page 94 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) For the contactors, set the parameters as follows. Table 5.22 CC remote (4) SR_IO4 parameter settings *4*5 Item Setting "1ms" 5. Time of noise removal filter X8, 9 "100ms" 13. Doubling input discrepancy detection time X8, 9 21.
  • Page 95 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (5) Sequence program The sequence program performs the following processing. Ladder which checks the falling edge (ON OFF) of the reset switch, accepts the reset request, and releases the interlock for the CC-Link Safety. Ladder which confirms the interlock released status and cancels the interlock release request.
  • Page 96 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (b) Way of using the internal devices Table 5.24 Way of using the internal devices Internal device Description Timer device Times out after a lapse of the time specified at K Word device Used as restart status in this program.

  • Page 97: Door Lock Circuit

    SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) 5.6.5 Door lock circuit (1) Application overview This application prevents the door from being opened until a robot is de-energized with the safety switch on the door of a safety barrier. The safety switch is usually interlocked with spring.
  • Page 98 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) Figure 5.39 Isolation of hazardous area by door interlock (Partially quoted from "Safety Guide Book - the safety measures of machinery in the workplace" : Nippon Electric Control Equipment Industries Association.) 5.6 Case Examples - 49 5.6.5 Door lock circuit...
  • Page 99 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (2) Connection of safety devices : CC-Link Safety remote I/O module CC remote (4): SR_IO4 used in this case example X200-20F Y200-203 CC-Link Safety CC remote (1): SR_IO1 CC remote (3): SR_IO3 CC remote (2): R_IO2 X120-12F X100-10F...
  • Page 100 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (3) Wiring diagram and parameter settings (a) CC remote (1): SR_IO1 Wire the safety switch and contactors to the CC-Link Safety remote I/O module as follows. CC remote (1) QS0J65BTB2-12DT (1) (Link ID=0, Station number 1) COM- COM-...
  • Page 101 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) For the safety switch and contactors, set the parameters as follows. Table 5.25 CC remote (1) SR_IO1 parameter settings *4*5 Item Setting "1ms" 6. Time of noise removal filter XA, B "1ms"...
  • Page 102 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (5) Sequence program The sequence program performs the following processing. Ladder which checks the falling edge OFF) of the reset switch, accepts the reset request, and releases the interlock for the CC-Link Safety. Ladder which confirms the interlock released status and cancels the interlock release request.
  • Page 103 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) The following shows the constant and internal devices used in the program. (a) Way of using the constant indicates decimal number. Example) K1 = 1 of decimal number (b) Way of using the internal devices Table 5.27 Way of using the internal devices Internal device Description...
  • Page 104 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (6) Timing chart Error occurred on Error on the Stop Stop Welding Powered Door Door the safety remote safety remote I/O switch switch detected opened closed I/O station on station on CC-Link activated activated in the contactor...
  • Page 105 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (7) Program using safety FB Table 5.28 Safety FBs to be used FB name Function Description This FB monitors safety equipment such as External device F+EDM an actuator and a contactor and controls a monitor safety output.
  • Page 106 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) For details on the safety FBs, F+GLOCK, and F+EDM, refer to the following. QSCPU Programming Manual (Safety FB) In this example, the door open/close signal of the safety switch is used as an input signal.

  • Page 107: 3-Position Enable Switch

    SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) 5.6.6 3-position enable switch (1) Application overview This application controls energization of a robot with 3-position enable switch while a worker teaches or maintenances the robot in a safety barrier with the safety barrier door open.
  • Page 108 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (2) Connection of safety devices : CC-Link Safety remote I/O module CC remote (4): SR_IO4 used in this case example X200-20F Y200-203 CC-Link Safety Refer to the following: Figure 5.50 Wiring: CC remote (3): SR_IO3 CC remote (1): SR_IO1...
  • Page 109 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (3) Wiring diagram and parameter settings (a) CC remote (1): SR_IO1 Wire the enable switch, safety switch, and contactors to the CC-Link Safety remote I/O module as follows. CC remote (1) QS0J65BTB2-12DT (1) (Link ID=0, Station number 1) Release of interlock...
  • Page 110 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) For the enable switch, safety switch, and contactors, set the parameters as follows. Table 5.29 CC remote (1) SR_IO1 parameter settings *4*5 Item Setting "1ms" 1. Time of noise removal filter X0, 1 "1ms"...
  • Page 111 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (b) CC remote (2): R_IO2 Wire the reset switch, start switch, and mode selection (manual, automatic) switch to the standard remote I/O module as follows. +24V 24VDC Reset switch Start switch Mode input (manual) Mode input (automatic) Figure 5.50 CC remote (2) R_IO2 wiring...
  • Page 112 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (4) Device numbers to be used The following device numbers are used in the sequence program. Table 5.30 Device numbers to be used Safety/standard External device Device number Safety Safety switch X100 or X101 Safety Enable switch...
  • Page 113 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) The following shows the constant and internal devices used in the program. (a) Way of using the constant indicates decimal number. Example) K1 = 1 of decimal number (b) Way of using the internal devices Table 5.31 Way of using the internal devices Internal device Description...
  • Page 114 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (7) Program using safety FB Table 5.32 Safety FBs to be used FB name Function Description This FB monitors safety equipment such as External device F+EDM an actuator and a contactor and controls a monitor safety output.
  • Page 115 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) Ladder which monitors the status of the enable switch. This safety FB is enabled only when the manual mode is selected. Ladder which monitors the status of the safety switch. This safety FB is enabled only when the automatic mode is selected.
  • Page 116 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (8) Timing chart Mode switched Mode: Automatic (X123) Mode: Manual (X122) In manual mode, the reset switch F+MODSEL S_Mode1Sel output (M11) and start switch cannot be used. F+MODSEL S_Mode0Sel output (M10) Error occurred on the safety remote I/O Reset switch (X120)

  • Page 117: Sequential Muting

    SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) 5.6.7 Sequential muting (1) Application overview This function temporarily invalidates a shading detection signal such as a light curtain. This function allows carrying members into a hazardous area without de-energizing a robot.
  • Page 118 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) Previous Member process Figure 5.56 Sequential muting (Partially quoted from "Safety Guide Book - the safety measures of machinery in the workplace" : Nippon Electric Control Equipment Industries Association.) 5.6 Case Examples - 69 5.6.7 Sequential muting...
  • Page 119 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (2) Connection of safety devices : CC-Link Safety remote I/O module CC remote (4): SR_IO4 used in this case example X200-20F Y200-203 CC-Link Safety Refer to the following: Figure 5.59 Wiring: CC remote (3): SR_IO3 CC remote (1): SR_IO1...
  • Page 120 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (3) Wiring diagram and parameter settings (a) CC remote (1): SR_IO1 Wire the light curtain and contactors to the CC-Link Safety remote I/O module as follows. Optical transmitter 24VDC CC remote (1) 24VDC QS0J65BTB2-12DT (1) (Link ID=0, Station number 1)
  • Page 121 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) For the light curtain and contactors, set the parameters as follows. Table 5.33 CC remote (1) SR_IO1 parameter setting *4*5 Item Setting "1ms" 3. Time of noise removal filter X4, 5 "1ms"...
  • Page 122 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (b) CC remote (2): R_IO2 Wire the reset switch, start switch, and muting sensors to the standard remote I/O module as follows. +24V 24VDC Reset switch Start switch Muting start enable sensor Before wiring muting sensors, check the specifications of...
  • Page 123 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (5) Program using safety FB Table 5.35 Safety FBs to be used FB name Function Description This FB monitors safety equipment such as External device F+EDM an actuator and a contactor and controls a monitor safety output.
  • Page 124 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) For details on the safety FBs, F+MUTES, and F+EDM, refer to the following. QSCPU Programming Manual (Safety FB) In this example, an error occurs on the safety remote I/O station on CC-Link Safety when a disconnection occurs in the muting lamp wiring.

  • Page 125: Two-Hand Operation Switch

    SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) 5.6.8 Two-hand operation switch (1) Application overview This application prevents a worker from approaching to hazardous area by energizing a robot only when two buttons are simultaneously activated with both hands. A press machine that starts sliding by activating two buttons is the typical application example.
  • Page 126 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (2) Connection of safety devices : CC-Link Safety remote I/O module CC remote (4): SR_IO4 used in this case example X200-20F Y200-203 CC-Link Safety CC remote (1): SR_IO1 CC remote (3): SR_IO3 CC remote (2): R_IO2 X120-12F X100-10F...
  • Page 127 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (3) Wiring diagram and parameter settings (a) CC remote (1): SR_IO1 Wire the contactors to the CC-Link Safety remote I/O module as follows. CC remote (1) QS0J65BTB2-12DT (1) (Link ID=0, Station number 1) COM- COM- +24V...
  • Page 128 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) For the contactors, set the parameters as follows. Table 5.36 CC remote (1) SR_IO1 parameter settings *4*5 Item Setting "1ms" 6. Time of noise removal filter XA, B "100ms" 14. Doubling input discrepancy detection time XA, B 22.
  • Page 129 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (b) CC remote (3): R_IO3 1) Using the QS0J65BTB2-12DT of module technical version D or later • Wiring example of a two-hand operation switch CC remote (3) QS0J65BTB2-12DT (3) (Link ID=0, Station number 3) COM- COM- +24V...
  • Page 130 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) • Parameter setting example Table 5.37 CC remote (3) SR_IO3 parameter settings *3*4 Item Setting "1ms" 5. Time of noise removal filter X8, 9 "1ms" 6. Time of noise removal filter XA, B "1ms"...
  • Page 131 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) 2) Using the QS0J65BTB2-12DT of module technical version C or earlier • Wiring example of a two-hand operation switch CC remote (3) QS0J65BTB2-12DT (3) (Link ID=0, Station number 3) COM- COM- +24V 24VDC...
  • Page 132 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) • Parameter setting example Table 5.38 CC remote (3) SR_IO3 parameter settings *3*4 Item Setting "1ms" 5. Time of noise removal filter X8, 9 "1ms" 6. Time of noise removal filter XA, B "1ms"...
  • Page 133 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) (5) Program using safety FB Table 5.40 Safety FBs to be used FB name Function Description This FB provides the two-hand control Two hand switch Type F+2HAND3 functionality (Fixed specified time difference is 500 ms).
  • Page 134 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING A SINGLE SAFETY PROGRAMMABLE CONTROLLER) For details on the safety FBs, F+ANTI, F+2HAND3, and F+EDM, refer to the following. QSCPU Programming Manual (Safety FB) In this example, the time difference (within 500ms) for two buttons to be turned on is checked.

  • Page 135: System Configuration

    SAFETY APPLICATION CONFIGURATION EXAMPLE (USING SEVERAL SAFETY PROGRAMMABLE CONTROLLERS) CHAPTER 6 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING SEVERAL SAFETY PROGRAMMABLE CONTROLLERS) This chapter describes a configuration example of a safety application using three safety programmable controllers that perform safety communication. System Configuration This chapter describes a safety application using the system configuration shown in Figure 6.1.

  • Page 136: Network-Related Switch Settings Of Module

    SAFETY APPLICATION CONFIGURATION EXAMPLE (USING SEVERAL SAFETY PROGRAMMABLE CONTROLLERS) Remark In this chapter, the following abbreviations are used for each module. Network Abbreviation Module name CC master (1) CC-Link Safety master module (station No. 0) CC-Link Safety CC remote (1) CC-Link Safety remote I/O module (station No.

  • Page 137: Cc-Link Safety Remote I/O Module

    SAFETY APPLICATION CONFIGURATION EXAMPLE (USING SEVERAL SAFETY PROGRAMMABLE CONTROLLERS) 6.2.4 CC-Link Safety remote I/O module Set the link ID setting switch, station number setting switch, and transmission speed setting switch. POWER L RUN L ERR. SAFETY ERR. QS0J65BTB2-12DT RESET LINK ID STATION NO. B RATE Figure 6.2 Positions of CC-Link Safety remote I/O module’s switches Table 6.1 Settings of CC-Link Safety remote I/O module’s switches Safety programmable...

  • Page 138: Parameter Settings

    SAFETY APPLICATION CONFIGURATION EXAMPLE (USING SEVERAL SAFETY PROGRAMMABLE CONTROLLERS) Parameter Settings This section describes parameter setting examples. For descriptions and setting ranges of the parameters, refer to the following. CC-Link Safety System Master Module User’s Manual MELSEC-QS CC-Link IE Field Network Master/Local Module User's Manual 6.3.1 Parameter settings of CC-Link Safety (1) Network parameter settings...
  • Page 139 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING SEVERAL SAFETY PROGRAMMABLE CONTROLLERS) (2) Station information setting Set station information of safety master stations on CC-Link Safety as follows. Table 6.3 Example of station information setting Exclusive station Reserve station Module Station No. Station type count count Safety programmable...

  • Page 140: Parameter Settings Of Cc-Link Ie Field Network

    SAFETY APPLICATION CONFIGURATION EXAMPLE (USING SEVERAL SAFETY PROGRAMMABLE CONTROLLERS) 6.3.2 Parameter settings of CC-Link IE Field Network (1) Network parameter settings Set the following values to the network parameters for the master station (safety station) and local stations (safety stations) on CC-Link IE Field Network. Table 6.4 Setting example of network parameters Safety Safety...
  • Page 141 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING SEVERAL SAFETY PROGRAMMABLE CONTROLLERS) (2) Safety communication setting Configure the following values to the safety communication setting for the master station (safety station) and local stations (safety stations) on CC-Link IE Field Network. Table 6.5 Example of safety communication setting Safety Safety Safety programmable...

  • Page 142: Case Example

    SAFETY APPLICATION CONFIGURATION EXAMPLE (USING SEVERAL SAFETY PROGRAMMABLE CONTROLLERS) Case Example 6.4.1 Emergency stop circuit (stop of all equipment) (1) Application overview This application uses a safety programmable controller in each process and cuts off a power to robots in all processes using an emergency stop switch in any process. The application controls the start and stop of a robot by turning on or off the main contact of the contactor which opens and closes the power source of a robot at the safety relay contact.
  • Page 143 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING SEVERAL SAFETY PROGRAMMABLE CONTROLLERS) (2) Connection of safety devices CC-Link IE Field Network Safety programmable Safety programmable Safety programmable controller (1) controller (2) controller (3) CC remote (1) CC remote (2) CC remote (1) CC remote (2) CC remote (1) CC remote (2) : SR_M1IO1...
  • Page 144 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING SEVERAL SAFETY PROGRAMMABLE CONTROLLERS) (3) Wiring diagram (a) CC remote (1): SR_M1IO1, SR_M2IO1, SR_M3IO1 Wire the emergency stop switches and safety relays to CC-Link Safety remote I/O modules of safety programmable controllers (1) to (3) as follows. Connect the close contact of the safety relay between the input terminal and the...
  • Page 145 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING SEVERAL SAFETY PROGRAMMABLE CONTROLLERS) (b) CC remote (2): SR_M1IO2 Wire the reset switch and start switch to the CC-Link Safety remote I/O module of the safety programmable controller (1) as follows. CC remote (2) QS0J65BTB2-12DT(2) (Link ID: 0, Station number: 2) COM- Reset switch (NO)
  • Page 146 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING SEVERAL SAFETY PROGRAMMABLE CONTROLLERS) (c) CC remote (2): SR_M2IO2, SR_M3IO2 Wire the reset switches and start switches to CC-Link Safety remote I/O modules of safety programmable controllers (2) and (3) as follows. CC remote (2) QS0J65BTB2-12DT(2) (Link ID: 0, Station number: 2) COM-...
  • Page 147 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING SEVERAL SAFETY PROGRAMMABLE CONTROLLERS) (4) Parameter settings Configure safety remote station settings of the safety programmable controllers (1) to (3) as shown in Table 6.6 to Table 6.8. Table 6.6 Safety remote station settings of the safety programmable controller (1) (using a module of module technical version D or later) –...
  • Page 148 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING SEVERAL SAFETY PROGRAMMABLE CONTROLLERS) * 5: The parameters are added to the QS0J65BTB2-12DT of technical version D or later, and is not available for modules of technical version C or earlier. * 6: For setting range, refer to the following. CC-Link Safety System Remote I/O Module User's Manual * 7: Always set the enclosed option for this case example.
  • Page 149 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING SEVERAL SAFETY PROGRAMMABLE CONTROLLERS) Table 6.7 Safety remote station settings of the safety programmable controller (2) (using a module of module technical version D or later) – : Default (unused) *6 *7 Safety programmable controller (2) Module SR_M2IO1 SR_M2IO2...
  • Page 150 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING SEVERAL SAFETY PROGRAMMABLE CONTROLLERS) Table 6.8 Safety remote station settings of the safety programmable controller (3) (using a module of module technical version D or later) – : Default (unused) *6 *7 Safety programmable controller (3) Module SR_M3IO1 SR_M3IO2...
  • Page 151 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING SEVERAL SAFETY PROGRAMMABLE CONTROLLERS) (5) Devices used (a) Relationship between safety CPU module devices and remote inputs/outputs in CC-Link Safety The following shows the relationship between safety CPU module devices and inputs/outputs of safety remote I/O stations on CC-Link Safety with the settings described in Section 6.3.1.
  • Page 152 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING SEVERAL SAFETY PROGRAMMABLE CONTROLLERS) (c) Device numbers to be used The following device numbers are used in the sequence program. Table 6.9 Device numbers to be used Safety programmable Safety/standard External device Device number controller Safety Emergency stop switch X104 or X105...
  • Page 153 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING SEVERAL SAFETY PROGRAMMABLE CONTROLLERS) (6) Sequence program using safety FB Figure 6.10 to Figure 6.12 show sequence programs used in safety programmable controllers (1) to (3). Table 6.10 Safety FBs used FB name Function name Description This FB monitors safety equipment such F+EDM...
  • Page 154 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING SEVERAL SAFETY PROGRAMMABLE CONTROLLERS) Ladder which releases the interlock when communication failure or an I/O error occurs on the safety remote I/O station on CC-Link Safety. Ladder which releases the interlock when an error occurs on CC-Link IE Field Network. Ladder which converts the Reset input bit of the safety FB, F+EDM.
  • Page 155 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING SEVERAL SAFETY PROGRAMMABLE CONTROLLERS) Ladder which releases the interlock when communication failure or an I/O error occurs on the safety remote I/O station on CC-Link Safety. Ladder which releases the interlock when an error occurs on CC-Link IE Field Network. Ladder which converts the Reset input bit of the safety FB, F+EDM.
  • Page 156 SAFETY APPLICATION CONFIGURATION EXAMPLE (USING SEVERAL SAFETY PROGRAMMABLE CONTROLLERS) (7) Timing chart Emergency stop switch is activated on Network error with the safety Emergency stop switch is activated on the safety programmable controller (1). programmable controller (1) the safety programmable controller (2). Reset switch Start switch Reset switch...

  • Page 157: Appendices

    APPENDICES APPENDICES Appendix 1 Calculating Safety Response Time of CC-Link Safety This manual explains the maximum value of safety response time. For normal values, refer to the following. CC-Link Safety System Master Module User's Manual To employ calculation formulas described in this section, use GX Developer and modules with the following versions.
  • Page 158 APPENDICES Link Scan Time of CC-Link Safety LS/WDT (Round up the calculated value to the nearest integer.) Safety refresh response processing time/(WDT n) (Round up the calculated value to the nearest integer.) Safety refresh response processing time User's manual for the safety remote I/O station used on CC-Link Safety DT1, DT2: Response time of a sensor or output-target device.
  • Page 159 APPENDICES POINT (1) If setting value of the safety data monitoring time is equal to or less than the value gained by the calculation formula above, an error may occur even in normal communication status. If setting value of the safety data monitoring time is needlessly long, the time taken for (c) in Table APPX.1 may lengthen in the case of a safety programmable controller error, resulting in excessive delay of safety response performance.
  • Page 160 APPENDICES (a) Link scan time of CC-Link Safety (LS) The following is the formula to calculate link scan time (LS) [ s] of CC-Link Safety. LS = BT (27 + (NI 4.8) + (NW 9.6) + (N 30) + (ni 4.8) + (nw 9.6) + TR) + ST + RT+ F [ s]...
  • Page 161 APPENDICES RT : Retry processing time (only when there is a faulty station) (Number of detected faulty stations - 1) : Retry processing time for first module ((200 + R) Set number of retries + 200) R: 51.6 + (NI 4.8) + (NW 9.6) : Retry processing time for second or subsequent module...
  • Page 162 APPENDICES (2) Calculation example This section describes calculation examples when the following values are set: • WDT setting value: 10ms • Link scan time (synchronous mode): 0.3ms • Link scan time (asynchronous mode): 1.4ms • Safety remote station input response time: 12.2ms •...
  • Page 163 APPENDICES (c) Calculation example for the maximum value of response time 1) In synchronous mode DT1 + DT2 + Safety remote station input response time + Safety data monitoring time + Safety remote station output response time = DT1 + DT2 + 12.2 + 80 + 10.4 = DT1 + DT2 + 102.6 [ms] 2) In asynchronous mode DT1 + DT2 + Safety remote station input response time + Safety data...
  • Page 164 APPENDICES (3) Calculation example of link scan time of CC-Link Safety The following shows the calculation example of LS (Link scan time) used in Appendix 1 (2) Calculation example. The following shows the calculation example when the transmission speed is 10 Mbps in the following system configuration example.
  • Page 165 APPENDICES Appendix 2 Calculating Safety Response Time When CC-Link Safety and CC-Link IE Field Network are Used This section describes the maximum value of safety response time in a system where CC-Link Safety and CC-Link IE Field Network are used. CC remote (1) Safety CPU CC master (1)
  • Page 166 APPENDICES (1) Calculation method The maximum value of safety response time will be the sum of (a) to (c) in Table APPX.2 For normal values, refer to the following. • Transmission time of CC-Link Safety CC-Link Safety System Master Module User’s Manual •...
  • Page 167 APPENDICES (b) Calculating output transmission time of CC-Link Safety The following is the formula to calculate output transmission time [ms] of CC-Link Safety. Output transmission time of CC-Link Safety = (Safety refresh monitoring time of CC master (2) + Output response time of CC remote (2) - (((WDT (2) 2 + (WDT (2) n) + WDT (2)) [ms]...
  • Page 168 APPENDICES (c) Calculating transmission time of CC-Link IE Field Network The following is the formula to calculate transmission time [ms] of CC-Link IE Field Network. Transmission time of CC-Link IE Field Network = (Safety refresh monitoring time of CC-Link IE Field Network - (Transmission interval monitoring time of CC IE master - (Transmission interval monitoring time of CC IE local + (WDT(2)

  • Page 169: Appendix 2 Calculating Safety Response Time When Cc-Link Safety And Cc-Link Ie Field Network Are Used

    APPENDICES 2) Transmission interval monitoring time of CC-Link IE Field Network This time is required to calculate the transmission time of CC-Link IE Field Network. This is the time monitored by the receiving station for each safety connection to detect the following safety communication errors. •...
  • Page 170 APPENDICES 3) Link scan time (LS) of CC-Link IE Field Network This time is required to calculate the transmission time of CC-Link IE Field Network. The following is the calculation example. LS = (Total points assigned for cyclic transmission 0.08 + (Number of connected slave stations Ka) + Kb + Kc + Kd) 1000...
  • Page 171 APPENDICES (2) Calculation example In the system configuration of Figure APPX.2, when a signal from an emergency stop switch is input to the CC remote (1), a contactor connected to the CC remote (2) stops its output. This section describes examples for calculating safety response time for the situation above, using the following set values.
  • Page 172 APPENDICES 2) Safety refresh monitoring time of CC-Link Safety This time is required to calculate input transmission time of CC-Link Safety. The following is the calculation example for CC master (1). • In synchronous mode n: CCLS (1)/WDT (1) = 0.2/10 m: (Safety refresh response processing time/(WDT (1) = 9.6/(10 : CCLS (1) = 0.2...
  • Page 173 APPENDICES (b) Calculation example of output transmission time of CC-Link Safety 1) Link scan time of CC-Link Safety This time is required to calculate output transmission time of CC-Link Safety. For the calculation example, refer to Appendix 2 (1) (a). 2) Safety refresh monitoring time of CC-Link Safety This time is required to calculate output transmission time of CC-Link Safety.
  • Page 174 APPENDICES (c) Calculation example of transmission time of CC-Link IE Field Network 1) Link scan time (LS) of CC-Link IE Field Network This time is required to calculate transmission time of CC-Link IE Field Network. The following is the calculation example. (Condition: Only safety communication is performed and no communication error station exists.) For Ka to Ke, use values when the station is set to Normal mode.
  • Page 175 APPENDICES (d) Calculation example of safety response time (maximum value) The following is the calculation example of safety response time (maximum value). • In synchronous mode Safety response time (maximum value) = DT1 + DT2 + Safety data transmission time (maximum value) = DT1 + DT2 + Input transmission time of CC-Link Safety + Transmission time of CC-Link IE Field Network...

  • Page 176: Appendix 3 Checklist

    APPENDICES Appendix 3 Checklist Table APPX.4 Checklist Description Reference Check Backup and version management of a file Were the created date and author entered at the top of the sequence program using the Section 4.2(7) statement function of GX Developer? When modifying the sequence program, were the created date, author, and modified Section 4.2(7) description entered at the modified place using the statement function?
  • Page 177 APPENDICES Memo APPX Appendix 3 Checklist - 21...
  • Page 178 INDEX Application example ..........2-1 Related manuals ..........A-13 Reset of CC-Link IE Field Network error ..... 4-15 Reset of CC-Link Safety error......4-12 Response time ............4-1 Case examples Risk ..............A-17 Door lock circuit..........5-48 Risk assessment..........A-17,3-1 Door monitor circuit .......... 5-18 Risk graph............
  • Page 179 Memo...
  • Page 180 1. Limited Warranty and Product Support. a. Mitsubishi Electric Company ("MELCO") warrants that for a period of eighteen (18) months after date of delivery from the point of manufacture or one year from date of Customer's purchase, whichever is less, Mitsubishi MELSEC Safety programmable logic controllers (the "Products") will be free from defects in material and workmanship.
  • Page 181 g. The Product information and statements contained on MELCO's website and in catalogs, manuals, technical bulletins or other materials provided by MELCO are provided as a guide for Customer's use. They do not constitute warranties and are not incorporated in the contract of sale for the Products. h.
  • Page 182 The company names, system names and product names mentioned in this manual are either registered trademarks or trademarks of their respective companies. ® In some cases, trademark symbols such as '™' or ' ' are not specified in this manual. SH(NA)-080613ENG-H...
  • Page 184 SH(NA)-080613ENG-H(1811)MEE MODEL: QSCPU-APPLI-E MODEL CODE: 13JR90 HEAD OFFICE : TOKYO BUILDING, 2-7-3 MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN NAGOYA WORKS : 1-14 , YADA-MINAMI 5-CHOME , HIGASHI-KU, NAGOYA , JAPAN When exported from Japan, this manual does not require application to the Ministry of Economy, Trade and Industry for service transaction permission.

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