Mitsubishi Electric WS0-CPU0 Operating Manual

Melsec ws series, safety controller setting and monitoring tool

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Safety Controller Setting and Monitoring Tool

Operating Manual

-WS0-CPU0

-WS0-CPU1

-WS0-CPU3

-SW1DNN-WS0ADR-B

Table of Contents

Troubleshooting

Summary of Contents for Mitsubishi Electric WS0-CPU0

Page 1 Safety Controller Setting and Monitoring Tool Operating Manual -WS0-CPU0 -WS0-CPU1 -WS0-CPU3 -SW1DNN-WS0ADR-B...
Page 3 This document is protected by the law of copyright, whereby all rights established therein remain with the company Mitsubishi Electric Corporation. Reproduction of this document or parts of this document is only permissible within the limits of the legal determination of Copyright Law. Alteration or abridgement of the document is not permitted without the explicit written approval of the company Mitsubishi Electric Corporation.
Page 4: Safety Precautions
 SAFETY PRECAUTIONS  (Read these precautions before using this product.) Before using this product, please read this manual and the relevant manuals carefully and pay full attention to safety to handle the product correctly. In this manual, the safety precautions are classified into two levels: " WARNING"...
Page 5 CAUTION  Ensure that an entire system using the MELSEC-WS safety controller meets the requirements for the corresponding safety category.  The life of safety relays in the safety relay output module depends on the switching condition and/or load. Configure a system satisfying the number of switching times of the safety relays in the module.
Page 6 [Installation Precautions] WARNING  Do not use the MELSEC-WS safety controller in flammable gas atmosphere or explosive gas atmosphere. Doing so may result in a fire or explosion due to such as an arc caused by switching the relays. CAUTION ...
Page 7 [Wiring Precautions] WARNING  Shut off the external power supply for the system in all phases before wiring. Failure to do so may result in electric shock or damage to the product. The system could start up unexpectedly while you are connecting the devices. CAUTION ...
Page 8 [Startup and Maintenance Precautions] WARNING  Do not touch any terminal while power is on. Doing so will cause electric shock.  Shut off the external power supply for the system in all phases before cleaning the module or retightening the terminal screws. Failure to do so may result in electric shock. Tighten the terminal screw within the specified torque range.
Page 9 CAUTION  Before performing online operations (Force mode) for the running MELSEC-WS safety controller from the PC, read the relevant manuals carefully and ensure the safety. The online operations must be performed by qualified personnel, following the operating procedure determined at designing. Fully understand the precautions described in the Safety Controller Setting and Monitoring Tool Operating Manual before use.
Page 10: 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, EN954-1/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 11: 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 12 CONTENTS SAFETY PRECAUTIONS ................... 1 CONDITIONS OF USE FOR THE PRODUCT ............7 REVISIONS ........................ 8 CONTENTS ........................ 9 GENERIC TERMS AND ABBREVIATIONS .............. 15 1. About this document ..................... 16 1.1 Function of this document ................16 1.2 Target group ....................17 1.3 Function and structure of this manual .............
Page 13 5.5.8 Connection of SICK EFI-compatible devices ........... 42 5.5.9 Export and import of a partial application ..........44 5.5.10 RS-232 routing ..................47 5.6 Logic editor view ..................... 52 5.6.1 Exercise for using the logic editor ............53 5.6.2 Logic access levels ................... 54 5.6.3 Validation of the configuration ..............
Page 14 7.4.4 Flexi Link stations: Flexi Link data in the logic editor ....... 98 7.4.5 Flexi Link stations: Station X view and process image ......100 7.4.6 Flexi Link stations: Teach function ............102 7.4.7 Flexi Link teaching status and diagnostics ..........104 7.5 Flexi Link troubleshooting ................
Page 15 9.7.10 Clock generator ..................135 9.7.11 Event counter (Up, Down and Up and down) ........136 9.7.12 Fast shut off and Fast shut off with bypass .......... 139 9.7.13 Edge detection ..................144 9.7.14 Binary encoder ..................145 9.7.15 Binary decoder ..................148 9.7.16 Log generator ..................
Page 16 9.10.3 Information on wiring ................216 9.10.4 State transition from Stop to Run ............217 9.10.5 Error states and information on resetting ..........217 9.10.6 Parallel muting ..................218 9.10.7 Sequential muting ................. 220 9.10.8 Cross muting – direction of movement only forwards or backwards ..222 9.10.9 Cross muting –...
Page 17 14. Troubleshooting ....................283 15. Annex ........................ 284 15.1 Example application reports ................ 284 15.1.1 Example application Newspaper palletizer ........... 284 15.1.2 Example application Wood scanner ............. 295 15.1.3 Example application Ramp down detection ......... 304 15.2 List of function block status in simulation mode .......... 312 15.3 Precautions ....................
Page 18: Generic Terms And Abbreviations
WS0-GCC1 The abbreviation for the WS0-GCC100202 MELSEC-WS safety controller CC-Link interface module CPU module A generic term for the WS0-CPU0, WS0-CPU1 and WS0-CPU3 Safety I/O module A generic term for the WS0-XTIO and WS0-XTDI Network module A generic term for the WS0-GETH and WS0-GCC1...
Page 19: About This Document
Chapter 1 About this document About this document Please read this chapter carefully before working with this manual and the MELSEC- WS safety controller. Function of this document For the MELSEC-WS safety controller there are sets of manuals with clearly defined applications as well as user’s manuals (hardware) for each module.
Page 20: Target Group
Chapter 1 About this document The following shows the relevant manuals. Table 1: Title Number Overview of the MELSEC- WS manuals WS-CPU-U-E Safety Controller User’s Manual (13JZ32) WS-ET-U-E Safety Controller Ethernet Interface Module User’s Manual (13JZ33) WS-CC-U-E Safety Controller CC-Link Interface Module User’s Manual (13JZ45) Safety Controller Setting and Monitoring Tool Operating SW1DNN-WS0ADR-B-O-E...
Page 21: Function And Structure Of This Manual
Chapter 1 About this document Function and structure of this manual This manual instructs the technical personnel of the machine manufacturer or machine operator in the software configuration, operation and diagnostics of a MELSEC-WS safety controller using the Setting and Monitoring Tool. It only applies in combination with the Safety Controller User’s Manual.
Page 22: Abbreviations Used
Chapter 1 About this document Abbreviations used External device monitoring Enhanced function interface ESPE Electro-sensitive protective equipment (e.g. C4000) Output signal switching device OSSD Revolutions (1 Rev = 360°) Symbols and notations used Recommendations are designed to give you some assistance in your decision- Recommendation making process with respect to a certain function or a technical measure.
Page 23: On Safety
MELSEC-WS manuals. Mitsubishi Electric Corporation accepts no claims for liability if the software or the devices are used in any other way or if modifications are made to the software or the ATTENTION devices - even in the context of mounting and installation.
Page 24: General Protective Notes And Protective Measures
Chapter 2 On safety General protective notes and protective measures Observe the protective notes and measures! Please observe the following items in order to ensure proper use of the MELSEC- WS safety controller.  When mounting, installing and using the MELSEC-WS safety controller, observe Note the standards and directives applicable in your country.
Page 25: Version, Compatibility And Features
Chapter 3 Version, compatibility and features Version, compatibility and features For the MELSEC-WS series several firmware versions and function packages exist that allow different functions. This chapter gives an overview which firmware version, which function package and/or which version of the Setting and Monitoring Tool is required to use a certain function or device.
Page 26 Chapter 3 Version, compatibility and features WS0-XTIO/ Setting and Device WS0-CPU Monitoring Tool WS0-XTDI Ethernet interface module V1.11 – V1.2.0 (Revision 1.xx) CC-Link interface module V1.11 – V1.2.1 (Revision 1.xx) ROHS conformity WS0-XTIO – V1.01 – “–” means “any” or “not applicable”. All other modules from product launch onwards.
Page 27: Installation And Removal
Chapter 4 Installation and removal Installation and removal System requirements Recommended system configuration:  Windows XP (32 Bit/64 Bit), Windows Vista (32 Bit/64 Bit), or Windows 7 (32 Bit/64 Bit)  Microsoft .NET Framework 3.5  1 GHz processor  1 GB RAM ...
Page 28: Removal
Chapter 4 Installation and removal Removal The Setting and Monitoring Tool can be removed as follows:  In the Windows Start menu, start Uninstall Setting and Monitoring Tool in the Setting and Monitoring Tool program folder. Troubleshooting Table 3: Error/Error message Cause Rectification Errors and error elimination...
Page 29: The Graphical User Interface
Chapter 5 The graphical user interface The graphical user interface This chapter familiarizes you with the basic elements of the graphical user interface as Note an introduction. This chapter does not give any information on the configuration of MELSEC-WS modules nor any instructions for logic programming. This chapter is only intended to explain the fundamental functioning of the Setting and Monitoring Tool on the basis of a small section of the functions.
Page 30: Standard Views
Chapter 5 The graphical user interface Standard views The Setting and Monitoring Tool has the following views that can be accessed via buttons below the menu bar. Figure 2: The view can be selected below the menu bar  The structure of a MELSEC-WS safety controller consisting of various hardware modules as well as the configuration of the inputs and outputs and the connected elements are specified in the Hardware configuration view.
Page 31: Positioning Windows
Chapter 5 The graphical user interface Positioning windows Every view consists of several sub-windows that can be positioned freely. You can  change the height, width and position of each sub-window by using the mouse to move the frame or title bar of the sub-window, ...
Page 32: Hardware Configuration View
Chapter 5 The graphical user interface Hardware configuration view The Hardware configuration window consists of the following sub-windows:  Tabs for switching between the Hardware configuration, Logic editor, Network modules (if the project contains at least one network interface module), Report, Diagnostics and Data Recoder view.
Page 33 Chapter 5 The graphical user interface Figure 4: The “Hardware configuration” view Note  A double click on the CPU module in the configuration area will open the logic editor.  A double click on any network module in the configuration area will open the network module configuration view for the respective network module.
Page 34: Exercise For Configuring The Melsec-Ws Modules
CPU modules.  Select the function package from the dropdown list under the desired CPU module (WS0-CPU0, WS0-CPU1 or WS0-CPU3). Function package Revision V 2.xx requires CPU firmware version 2.01 or higher (see Chapter 3).
Page 35 Chapter 5 The graphical user interface Note  A MELSEC-WS safety controller can contain maximally two network interface modules.  A MELSEC-WS safety controller can contain maximally twelve I/O modules. Enable configurations with more than twelve I/O modules  Using Setting and Monitoring Tool version V1.7.0 or higher you can enable configurations with up to 22 I/O modules.
Page 36: Module Status Bits In The Hardware Configuration View
Chapter 5 The graphical user interface 5.5.2 Module status bits in the Hardware configuration view When the MELSEC-WS safety controller is online (i.e. the Setting and Monitoring Tool is connected to the system), you can display the status bits of each module and their current values.
Page 37 Chapter 5 The graphical user interface Figure 11: WS0-XTIO module status bits in the Hardware configuration view Figure 12: WS0-XTDI module status bits in the Hardware configuration view How to export the module status bits:  In the Hardware configuration view, click on the Settings icon at the left of the Configuration area to open the Settings dialog.
Page 38: Exercise For Configuring The Connected Devices
Chapter 5 The graphical user interface 5.5.3 Exercise for configuring the connected devices  The selection tree in the Elements selection window can be expanded and Exercise collapsed by means of a mouse click. Optional: Right-click a device and select Edit current element in the context menu.
Page 39: Safe And Non-Safe Elements In The Hardware Configuration
Chapter 5 The graphical user interface 5.5.4 Safe and non-safe elements in the hardware configuration Safe and non-safe elements are shown in the hardware configuration using different colors:  Safe elements are marked yellow.  Non-safe elements are marked gray. The majority of elements are only marked as safe or non-safe when they are dragged to a corresponding input or output: ...
Page 40: Parameterization Of Connected Elements
Chapter 5 The graphical user interface 5.5.6 Parameterization of connected elements Input and output elements can be parameterized when they are located in the Parking area or in the Configuration area. Depending on the type of element you can: – assign a tag name (identifying name for the element) –...
Page 41 Chapter 5 The graphical user interface Element is connected to test outputs By activating or deactivating the option Element is connected to test outputs you can determine whether the respective element shall be tested or not. By connecting an element to the test outputs … ...
Page 42: Customized Elements
Chapter 5 The graphical user interface 5.5.7 Customized elements In addition to the standard input and output elements that are installed with the Setting and Monitoring Tool, it is possible to create, configure, import and export customized elements. This function allows you to create element templates with preset configuration options (e.g.
Page 43 Chapter 5 The graphical user interface How to configure a customized element:  Select the new customized element in the element tree and use the sub-element buttons under the element tree to add additional inputs or outputs. You can choose between single-channel and various dual-channel input and output types.
Page 44 Chapter 5 The graphical user interface  Select the customized element (or the sub-element) that you want to configure and click on the Settings file card to edit the configuration settings. Figure 17: Editing the configuration settings of a customized element ...
Page 45: Connection Of Sick Efi-Compatible Devices
Chapter 5 The graphical user interface How to export customized elements as XML files:  In the Elements window, right click on the customized element you want to export and choose the Export... command from the context menu. A folder selection dialog opens.
Page 46 Chapter 5 The graphical user interface EFI system integrity test The WS0-CPU1 or WS0-CPU3 can test the SICK EFI-compatible devices connected to the EFI interfaces at every voltage reset. The following parameters can be compared with the parameters saved the last time the CPU module was configured: ...
Page 47: Export And Import Of A Partial Application
Export and import of a partial application You can export or import a partial application. All modules with their associated inputs and outputs and logic are exported except for the WS0-CPU0/WS0-CPU1/WS0-CPU3. If you are exporting a project containing SICK EFI-compatible devices have to be reconfigured when you import the configuration into another project.
Page 48 How to exchange a CPU module in a project: Using the export and import function, it is possible to exchange a CPU module (e.g. WS0-CPU0 to WS0-CPU1 or another firmware version (from Ver.1 to Ver.1.xx or later)) in an existing project without having to re-configure the project (hardware configuration, logic).
Page 49 Chapter 5 The graphical user interface Note The configuration of any connected SICK EFI-compatible devices is not included in the exported partial application. Therefore these devices have to be reconfigured. How to exchange a safety I/O module in a project: ...
Page 50: Rs-232 Routing
Chapter 5 The graphical user interface 5.5.10 RS-232 routing You can access the input and output data on the MELSEC-WS safety controller via the RS-232 interface on the CPU. This feature makes possible, e.g., communication between the MELSEC-WS safety controller and a Programmable controller connected without using a network interface module or the connection of an HMI.
Page 51 Chapter 5 The graphical user interface Configuration of the input data for the RS-232 routing  On the Interfaces menu, click RS-232 [0] to open the dialog box for the RS-232 configuration.  Click the MELSEC-WS to RS-232 button on the left to display the routing configuration for the input data.
Page 52 Chapter 5 The graphical user interface  Reset to default restores the default routing configuration. You will be asked for confirmation. If you click Yes, all previously made changes that have not been saved will be lost. You can not undo this action. ...
Page 53 Chapter 5 The graphical user interface How to delete a data byte from the routing table:  Drag and drop the byte you want to delete to the trashcan icon in the bottom left corner of the RS-232 data area. ...
Page 54 Chapter 5 The graphical user interface The Tag names area shows the tag names associated to the byte selected in the RS- 232 data area.  Choose a byte in the RS-232 data area.  For each bit of the selected byte that you wish to use, enter a tag name. Each bit to which you assign a tag name here is then available as an RS-232 input in the logic editor.
Page 55: Logic Editor View
Chapter 5 The graphical user interface Logic editor view The Setting and Monitoring Tool includes a graphical Logic editor. The function logic is program-med by using logic and application-specific function blocks. The inputs, function blocks and outputs are positioned on a worksheet and are connected correspondingly.
Page 56: Exercise For Using The Logic Editor
Chapter 5 The graphical user interface 5.6.1 Exercise for using the logic editor  In the Hardware configuration view combine a CPU module, at least one Exercise WS0-XTIO module and one element.  Switch to the Logic editor by clicking the tab of the same name. ...
Page 57: Logic Access Levels
Chapter 5 The graphical user interface 5.6.2 Logic access levels The logic access levels function allows you to protect individual pages in the logic editor using a password. You can prevent changes to the logic page by unauthorized persons. There are the following logic access levels: Table 4: Access level Right...
Page 58: Validation Of The Configuration
Chapter 5 The graphical user interface The logic access level for a protected page is displayed at the top left of the page in a light-gray font. How to remove the page protection from a logic page:  In the logic editor open the page on which you want to remove the protection. ...
Page 59: Inputs And Diagnostics Bits Of The Main Module In The Logic Editor
Chapter 5 The graphical user interface 5.6.4 Inputs and diagnostics bits of the main module in the logic editor On the Inputs and Diagnostics tabs in the logic editor, the main module provides the following inputs and diagnostic bits: Logical 0 and Logical 1 The Logical 0 input can be used to set a function block input permanently to 0 (Low).
Page 60: Efi I/O Error Status Bits In The Logic Editor
Chapter 5 The graphical user interface Note With AOPD senders there is no EFI process data exchange. Therefore a communication error will not occur with these devices, i.e. a communication interruption can not be detected. 5.6.5 EFI I/O error status bits in the logic editor An I/O error status bit for each connected SICK EFI-compatible device or Flexi Link station is available in the Inputs tab of the Logic editor under the respective SICK EFI-compatible device or Flexi Link station and can be used as input for the logic...
Page 61: Cpu Markers
Chapter 5 The graphical user interface The input and output status for the WS0-XTIO and WS0-XTDI modules is available Note only with firmware version V2.00 and higher. 5.6.7 CPU markers CPU markers are available as inputs and outputs in the Logic editor. They can be used e.g.
Page 62: Jump Addresses
Chapter 5 The graphical user interface 5.6.8 Jump addresses Jump addresses can be used basically in the same way as CPU markers. They consist of a source jump address and a destination jump address. The destination jump address takes the same value (High or Low) as the corresponding source jump address without delay –...
Page 63: I/O Matrix
Chapter 5 The graphical user interface 5.6.9 I/O matrix The logic editor’s I/O matrix file card displays which inputs have an effect on which outputs. This can be useful to check whether your logic program is complete. A green field indicates that the respective input has an effect on the respective output; a white field indicates that there is no relation between this input and output.
Page 64: Tag Name Editor
Chapter 5 The graphical user interface 5.6.10 Tag name editor The Tag name editor is the central place where you can edit all tag names in your project. To open the tag name editor either click on the Edit tag names button in the Hardware configuration view or click on the Open dialog to edit logic result markers button in the Logic editor toolbar.
Page 65: Import And Export Tag Names
Chapter 5 The graphical user interface 5.6.11 Import and export tag names With the aid of the Import tag names and Export tag names buttons at the top left of this window you can save the tag names as a text file in the CSV format (comma separated values) or import tag names from a CSV file or Excel file.
Page 66: Report View
Chapter 5 The graphical user interface Report view In the Report view, a comprehensive report on the current project and all configuration settings including the logic program and detailed wiring information is available. You can individually configure the contents of the report. Figure 33: Report view The information to be summarized in the report can be selected individually from an...
Page 67: Diagnostics View
Chapter 5 The graphical user interface Diagnostics view Once you have completed your project and connected to your MELSEC-WS safety controller, you can perform a diagnostics on your system. In the Diagnostics view, a complete history of all messages, information, warnings and error messages of a connected MELSEC-WS safety controller is available in the upper part of the window.
Page 68 Chapter 5 The graphical user interface How to perform diagnostics:  Click on the Diagnostics button in the menu bar to open the Diagnostics view. In the toolbar, the following commands are available: Figure 35: Toolbar in the diagnostics view ...
Page 69: Data Recorder View
Chapter 5 The graphical user interface Data recorder view Once you have completed your project and established a connection to your MELSEC-WS safety controller, you can record input and output signals. Various selection windows area available in the Data recorder view for this purpose. Figure 37: Data recorder view The Data recorder view contains the following windows and elements:...
Page 70 Chapter 5 The graphical user interface If you have loaded the configuration from the device into Setting and Monitoring Tool, you can then start the recording using the Start recording button in the Status/control selection window. For this purpose Setting and Monitoring Tool must be connected to the device. You can also prepare a dedicated data recorder configuration that can then be transferred to the device.
Page 71: Connecting To The Melsec-Ws Safety Controller
Chapter 6 Connecting to the MELSEC-WS safety controller Connecting to the MELSEC-WS safety controller First steps for establishing a connection This chapter describes how to establish a connection between the MELSEC-WS safety controller and a PC or notebook. 6.1.1 Connecting the PC to the MELSEC-WS safety controller via RS-232 ...
Page 72: Online Status And Background Color
Chapter 6 Connecting to the MELSEC-WS safety controller As an example, the following hardware configuration may appear: Figure 40: Hardware configuration dialog (example)  Click Disconnect to go into the offline mode if you want to change the configuration of the MELSEC-WS modules. Alternatively, you can click on the Online edit mode button to make minor changes without having to disconnect each time.
Page 73: Editing The Communication Settings
Chapter 6 Connecting to the MELSEC-WS safety controller Editing the communication settings Using the COM settings command, you can create, edit and delete connection profiles. To edit the connection profiles, the Setting and Monitoring Tool must be in offline mode. ...
Page 74 Chapter 6 Connecting to the MELSEC-WS safety controller How to add a COM profile (serial port):  Click on the Add COM profile button. The Create new profile dialog is opened. Figure 42: Create new profile dialog (serial port)  Enter a name for the new profile. ...
Page 75 Chapter 6 Connecting to the MELSEC-WS safety controller How to add a USB profile:  Click on the Add USB profile button. The Create new profile dialog is opened. Figure 43: Create new profile dialog (USB)  Enter a name for the new profile ...
Page 76 Chapter 6 Connecting to the MELSEC-WS safety controller How to add a TCP/IP profile: To create a TCP/IP profile it is necessary that your MELSEC-WS safety controller Note contains an Ethernet interface module (WS0-GETH) which must be configured with a valid IP address for your network. For detailed instructions on the Ethernet interface module configuration please see the Safety Controller Ethernet Interface Module User's Manual.
Page 77 Chapter 6 Connecting to the MELSEC-WS safety controller  Click on the Scan button. Your network is scanned for connected network modules and the network modules found are displayed in the list. Figure 45: List of network modules found  Click on the desired network module. The IP address of the device is displayed in the IP address field.
Page 78 Chapter 6 Connecting to the MELSEC-WS safety controller How to change the network settings of a network module:  Click on the Network settings button. The Network scan dialog is opened.  If necessary, select the correct network adapter from the dropdown list at the bottom of the dialog.
Page 79: Establishing A Connection With The Melsec-Ws Safety Controller
Chapter 6 Connecting to the MELSEC-WS safety controller Establishing a connection with the MELSEC-WS safety controller Do not connect to the MELSEC-WS safety controller via the RS-232, the Ethernet interface and the USB at the same time! ATTENTION The MELSEC-WS safety controller can only communicate with one instance of the Setting and Monitoring Tool at one time.
Page 80: User Levels In The Setting And Monitoring Tool
Chapter 6 Connecting to the MELSEC-WS safety controller User levels in the Setting and Monitoring Tool If the Setting and Monitoring Tool is connected to the devices in a project (i.e. is in online mode), you can switch to the user levels of the Setting and Monitoring Tool. These user levels have different authorisations for the transfer of configurations to the devices: Table 12:...
Page 81: Identify Project
Chapter 6 Connecting to the MELSEC-WS safety controller Note The password may consist of 8 characters maximally. Figure 47: Change password dialog Identify project The Identify project command is equivalent to the Connect to physical device command that can be executed upon program start of the Setting and Monitoring Tool.
Page 82: Flexi Link
Flexi Link allows you to combine up to four Flexi Link stations via EFI for safe data communication. Only WS0-CPU1 and WS0-CPU3 modules can be used in a Flexi Link system, the connection of WS0-CPU0 modules is not possible. The process data of each station (inputs and outputs, logic results etc.) can be made available to all other stations in the Flexi Link system.
Page 83: Function Principle
Chapter 7 Flexi Link Function principle The configuration of a Flexi Link project requires two steps.  The first step is the configuration of the network settings and the Flexi Link address. Wiring errors or the presence of devices that are not suitable for Flexi Link projects are detected in this step automatically by the system.
Page 84 Chapter 7 Flexi Link Figure 48: Flexi Link IDs display in the Flexi Link System overview The Flexi Link IDs are also displayed in the Flexi Link Network settings view. If the configuration of any station in the Flexi Link system is changed in a way that affects the process image of the system (e.g.
Page 85: Getting Started
Chapter 7 Flexi Link Getting started This section describes how to set up a new Flexi Link system. In order to do this, you need to configure the hardware for your project first. You have two possibilities:  You can first set up and wire the hardware, then connect your PC to the system and read in the hardware setup using the Setting and Monitoring Tool.
Page 86 Chapter 7 Flexi Link Figure 49: Flexi Link Network settings without valid address assignment  Use the up and down arrow buttons or drag and drop the stations into the rows for Station A to D so that no two stations occupy the same address. ...
Page 87 Chapter 7 Flexi Link Step 3: Read in the hardware settings  Click on the System overview tab. The following view opens: Figure 52: Flexi Link System overview  Click on the Upload button. The Setting and Monitoring Tool will read in the hardware and configuration settings of all devices on this station.
Page 88: Setting Up A Flexi Link Project In The Setting And Monitoring Tool
Chapter 7 Flexi Link 7.3.2 Setting up a Flexi Link project in the Setting and Monitoring Tool If the required hardware is not available yet, you can set up the hardware configuration for your Flexi Link project in the Setting and Monitoring Tool. ...
Page 89: Flexi Link Configuration
Chapter 7 Flexi Link 7.3.3 Flexi Link configuration This section shows in detail how data can be shared between the single stations in a Flexi Link system. Example: Simple Flexi Link project with two stations. An emergency stop button and a restart button on Station A will control two robots connected to Station A and Station B.
Page 90 Chapter 7 Flexi Link Configuring the Flexi Link routing for Station A  In the Logic editor for Station A, add an additional Routing N:N function block, configure it for two inputs and outputs and connect its inputs to the WS0-XTIO inputs for the reset button and the emergency stop button.
Page 91 Chapter 7 Flexi Link Assigning tag names for the Flexi Link routing  Still in the Station A view, switch to the Flexi Link routing table using the Flexi Link station A button in the toolbar (if your project contains also one or two network modules, you will find this entry in the submenu under Network modules).
Page 92 Chapter 7 Flexi Link Configuring the logic for Station B  Click on the button for Station B in the toolbar. Then switch to the Logic editor view for Station B.  In the inputs selection window, find the two inputs from the Station A CPU module that are routed via Flexi Link.
Page 93: Transferring And Verifying The Flexi Link Configuration
Chapter 7 Flexi Link 7.3.4 Transferring and verifying the Flexi Link configuration To start your Flexi Link system, connect the PC with the system, transfer and verify the configurations and switch the stations into the Run state. This requires that you have finished the configuration as described in the previous section and that you have set up and connected the required MELSEC-WS modules and other hardware.
Page 94 Chapter 7 Flexi Link The Setting and Monitoring Tool will connect to the Flexi Link system, compare the existing hardware and software configuration with the configuration in the Designer and display the results. If the configuration in the Setting and Monitoring Tool is not identical to the configuration in the connected stations, these will be displayed with a blue background.
Page 95 Chapter 7 Flexi Link Verify the configuration  Switch to the Hardware configuration view for any station in your project. If the device configuration is valid and equal with the configuration in the Setting and Monitoring Tool, but not yet verified, the CV LED on the CPU module will flash as well as the Upload and verify configuration button on the left side of the configuration area.
Page 96: Flexi Link Functions
Chapter 7 Flexi Link Flexi Link functions This section gives a comprehensive overview over the Flexi Link functions in the Setting and Monitoring Tool. These functions are divided into Flexi Link system functions and functions that are related to the single stations in a Flexi Link system. You can switch between the view for the Flexi Link system and the individual station views using the additional buttons that appear in the toolbar of the Setting and Monitoring Tool if a Flexi Link project is open.
Page 97: Flexi Link System: System Overview
Chapter 7 Flexi Link  The Logic editor is used to configure which information each station will send to the other stations via the Flexi Link network. This is also where the information provided by the other Flexi Link stations in the network is available and can be used as input for logic applications.
Page 98 Chapter 7 Flexi Link To the left of each station you will find the following tool icons: Table 15: Icon Function Description Flexi Link system overview tools Adds a new station in the current slot (A to D) and switches to the view for the new station.
Page 99: Flexi Link System: Process Image
Chapter 7 Flexi Link 7.4.2 Flexi Link system: Process image The Flexi Link process image allows you to monitor the information that is exchanged between the Flexi Link stations. In the left area of the screen the hardware configuration for each station is displayed, on the right side the bits for EFI1 and EFI2 (if used) are displayed with their tag names.
Page 100: Flexi Link System: Network Settings
Chapter 7 Flexi Link 7.4.3 Flexi Link system: Network settings The Network settings view is where you can assign the Flexi Link address (A, B, C or D) to the individual stations in the Flexi Link network. This is a prerequisite for the configuration because it enables the Flexi Link Designer to address each station and to identify the bits in the Flexi Link process image, e.g.
Page 101: Flexi Link Stations: Flexi Link Data In The Logic Editor
Chapter 7 Flexi Link How to change the assigned Flexi Link address (A to D):  To change the address of a station, click on the up and down arrow buttons to move it up or down to the desired position in the window. Alternatively, you can drag and drop the station to the desired position.
Page 102 Chapter 7 Flexi Link Routing of data into the Flexi Link network In order to write data into the Flexi Link network so that it can be used by other stations you need to define which bit in the Flexi Link process image shall be set. You will find the bits that can be defined for each station in the Outputs panel in the logic editor under the symbol for the used CPU: Figure 74:...
Page 103: Flexi Link Stations: Station X View And Process Image
Chapter 7 Flexi Link Using data from the Flexi Link network You will find all available information from the other stations in the Flexi Link network in the Inputs tab of the logic editor under the symbol of the respective station’s CPU module: Figure 76: Flexi Link input bits from...
Page 104 Chapter 7 Flexi Link Figure 77: Flexi Link station A view The toolbar The toolbar contains icons for the following actions (from left to right):  Reset to default: Sets the tag names and configured default settings for all bits and bytes to the default values.
Page 105: Flexi Link Stations: Teach Function
Chapter 7 Flexi Link Figure 78: Default values for Flexi Link input bits Note Changing the default value of any bit changes the process image of the configuration and in consequence the Flexi Link ID for the EFI string the changed bit belongs to. You will be warned that you have to transfer the changed configuration to all stations in order to apply the new Flexi Link ID.
Page 106 Chapter 7 Flexi Link Note  A station is considered as “missing” and can be suspended if its power supply is switched off or if its EFI connection to the Flexi Link system has been interrupted completely. It is not possible to suspend a station if it is still connected and e.g. one of the following conditions applies: –...
Page 107: Flexi Link Teaching Status And Diagnostics
Chapter 7 Flexi Link  Now press the Teach button on any of the remaining stations. The system will now continue to operate as if the missing stations were still present. Their “real” process image will however be replaced with the static default values that you have configured before (see Section 7.4.5).
Page 108 Chapter 7 Flexi Link Table 16: CPU status bit Meaning Meaning of the Teaching status bits A station that has been suspended before, has reappeared in the Teach required system. In this case the process image of the all Flexi Link station is set to Low and the EFI I/O error bit is set to High.
Page 109: Flexi Link Troubleshooting
Chapter 7 Flexi Link Flexi Link troubleshooting This section deals with some common causes for malfunctions of the Flexi Link network and how to diagnose and correct them. For an overview of the LED error displays please refer to the Safety Controller User’s Manual.
Page 110: Flexi Line
Flexi Line enables you to reliably network up to 32 MELSEC-WS safety controller. Only WS0-CPU3 modules can be used in a Flexi Line system. It is not possible to connect any other CPU modules (WS0-CPU0, WS0-CPU1). A uniform process image is defined for the entire Flexi Line system. Each byte of this process image is either global, i.e.
Page 111: Principle Of Operation Flexi Line
Chapter 8 Flexi Line Principle of operation Flexi Line 8.2.1 Topology The individual stations within a Flexi Line system are not identified using addresses. Instead, each station is connected to its immediate neighbors. Communication is with the previous station and the next station. The arrangement of the stations in the Flexi Line system must be confirmed during commissioning by means of a teach process and subsequently monitored.
Page 112 Chapter 8 Flexi Line Flexi Line toolbar The Flexi Line toolbar contains buttons for the following functions:  importing a Flexi Line definition saved previously  exporting a Flexi Line definition  Teach function: confirmation of the topology of the Flexi Line system during commissioning as well as on changes to the topology ...
Page 113 Chapter 8 Flexi Line Byte configuration Figure 82: Flexi Line, Byte configuration view On the left of the view you will find an overview of the bytes in the Flexi Line process image. If you select a byte, you can edit the following settings for this byte on the right: ...
Page 114: Flexi Line Checksum (Crc)
Chapter 8 Flexi Line Default value The default value defines how a bit is affected by a station:  A bit with the default value High is set to 1 (logic status high) if all stations signal a 1 for this bit (logical AND). As soon as only one station sets the bit to the logic status low, the bit is set to 0.
Page 115: Flexi Line Data In The Logic Editor
Chapter 8 Flexi Line 8.2.4 Flexi Line data in the logic editor Each Flexi Line station automatically prepares a local instance of the process image from the data received from its neighboring stations. If local information on the related station affects global bits, these values are also immediately taken into account in the local instance of the process image.
Page 116: Teach Function
Chapter 8 Flexi Line 8.2.5 Teach function The topology of the Flexi Line system must be confirmed to activate the function. It can be executed using the Setting and Monitoring Tool. If it is to be possible to change the topology of the system later, an integrated Teach function is also available in the logic.
Page 117 Chapter 8 Flexi Line Teaching using Setting and Monitoring Tool In the Flexi Line view in Setting and Monitoring Tool there is a Teach button on the toolbar.  Click the Teach button during commissioning when all stations are switched on and in the Teach required state.
Page 118: Status And Diagnostics
Chapter 8 Flexi Line 8.2.6 Status and diagnostics The Diagnostics view shows which data have been received, used and forwarded. Figure 86: Flexi Line diagnostics The bytes in the process image for the actual station are shown in the Byte overview area on the left.
Page 119: Getting Started
Chapter 8 Flexi Line Figure 87: Flexi Line diagnostics In the example in Figure 87 bit 0 from byte 2 with the tag name Reset has been selected. This bit is low in the process images that are received from the neighboring stations, but high at the local input (marked in green).
Page 120: Conversion Of A Flexi Line System
Chapter 8 Flexi Line  Configure the Flexi Line process image as described in section 8.2.2. Plan the Flexi Line process image carefully. If you change the process image Recommendation subsequently, then you must transfer it again to each of the individual stations in the Flexi Line system.
Page 121: Configuration Of The Flexi Line Logic
Chapter 8 Flexi Line 8.3.3 Configuration of the Flexi Line logic The logic for a Flexi Line station is programmed in 2 steps:  Integration of the local data for the station into the Flexi Line process image: All local information of relevance for the Flexi Line process image must be integrated into the process image with the aid of a Routing function block.
Page 122 Chapter 8 Flexi Line Then these signals can be evaluated in the logic on any station in this Flexi Line system in the following manner: Figure 90: Usage of signals from the Flexi Line process image in the logic...
Page 123: Logic Programming – Function Blocks
Chapter 9 Logic programming – Function blocks Logic programming – Function blocks General description The function logic of the MELSEC-WS safety controller is programmed by using function blocks. These function blocks are certified for use in safety-relevant functions if all safety standards are observed during implementation. The following sections provide information on important aspects of using function blocks in the MELSEC-WS safety controller.
Page 124 Chapter 9 Logic programming – Function blocks Take delays into account that are caused by CPU markers and jump addresses with logic loop backs! A loop back signal is an input signal that is connected to an output of a function block with the same or higher function block index (the function block index is displayed at the top of each function block).
Page 125: Function Block Overview
Chapter 9 Logic programming – Function blocks Function block overview The MELSEC-WS safety controller uses function blocks to define the safety-oriented logic. There are logic function blocks and application-specific function blocks. The following table lists all function blocks available in the CPU modules: Table 19: Logic Overview of the CPU...
Page 126: Function Block Properties
Chapter 9 Logic programming – Function blocks A configuration can encompass a maximum of 255 function blocks. The logic execution time is a multiple of 4 ms and depends on the number and type of function blocks used. Therefore, the number and type of function blocks in your application should be kept as low as possible.
Page 127: Input And Output Signal Connections Of Function Blocks
Chapter 9 Logic programming – Function blocks Input and output signal connections of function blocks 9.5.1 Function block input connections Possible sources for function block inputs are all input elements listed in the input selection tree of the logic editor as well as the outputs of function blocks. 9.5.2 Inversion of input connections The input connections of some function blocks can be configured as inverted.
Page 128: Function Block Output Connections
Chapter 9 Logic programming – Function blocks 9.5.3 Function block output connections Function blocks provide various output signal connections for connecting to physical outputs or to other function blocks. The output of a function block can be connected to several subordinate function blocks, but not to several output elements (physical outputs or EFI outputs).
Page 129: Fault Present Output
Chapter 9 Logic programming – Function blocks 9.5.4 Fault present output Various function blocks dispose of the Fault present diagnostics output. In order to use it, activate the Use fault present checkbox on the I/O settings tab of the function block properties.
Page 130: Timer Values And Logic Execution Time
Chapter 9 Logic programming – Function blocks Timer values and logic execution time Note The following has to be observed when selecting time monitoring functions for the discrepancy time, synchronization time, pulse duration, muting time, etc.: The times  have to be greater than the logic execution time, ...
Page 131 Chapter 9 Logic programming – Function blocks 9.7.2 Function block diagram Figure 100: Function block diagram for the AND function block General description The output is High if all evaluated inputs are High. Up to eight inputs are evaluated. Example: If eight emergency stop buttons are attached to the inputs of the function block, the output would become Low as soon as one of the emergency stop buttons is pressed.
Page 132 Chapter 9 Logic programming – Function blocks Truth table for AND evaluation with eight inputs Table 24: Input 1 Input 2 Input 3 Input 4 Input 5 Input 6 Input 7 Input 8 Output 1 Truth table for AND evaluation with eight inputs 9.7.3 Function block diagram Figure 101:...
Page 133: Xor (Exclusive Or)
Chapter 9 Logic programming – Function blocks Truth table for OR evaluation with two inputs Table 27: Input 1 Input 2 Output 1 Truth table for OR evaluation with two inputs Truth table for OR evaluation with eight inputs Table 28: Input 1 Input 2 Input 3...
Page 134: Xnor (Exclusive Nor)
Chapter 9 Logic programming – Function blocks 9.7.5 XNOR (exclusive NOR) Function block diagram Figure 103: Function block diagram for the Exclusive NOR (XNOR) function block General description The output is High only if both inputs are equivalent (have the same value: both inputs High or both inputs Low).
Page 135: Rs Flip-Flop
Chapter 9 Logic programming – Function blocks Function block parameters Table 31: Parameter Possible values Parameters for the multiple release function block Number of inputs 1 to 7 (without Release input) Invert input x Each input of this function block can be inverted (see section 9.5.2) Invert Release Truth table...
Page 136: Jk Flip-Flop
Chapter 9 Logic programming – Function blocks Truth table for the RS Flip-Flop function block The following applies for the truth table in this section:  “0” means logic Low.  “1” means logic High.  “n–1” references the preceding value. ...
Page 137: Multiple Memory
Chapter 9 Logic programming – Function blocks Truth table for the JK Flip-Flop function block The following applies for the truth table in this section:  “0” means logic Low.  “1” means logic High.  “↑” means that a rising edge has been detected at the input. ...
Page 138: Clock Generator
Chapter 9 Logic programming – Function blocks Function block parameters Table 37: Parameter Possible values Parameters for the multiple memory function block Number of inputs 1 to 7 (without Latch input) Invert input x Each input of this function block can be inverted (see section9.5.2).
Page 139: Event Counter (Up, Down And Up And Down)
Chapter 9 Logic programming – Function blocks Parameters of the function block Table 39: Parameter Possible values Parameters of the Clock Stopping mode  Immediately generator function block  After last clock Clock period (cycle duration) 2 to 65535 Duration = Parameter value × Logic execution time Pulse time 1 to 65534 Duration = Parameter value ×...
Page 140 Chapter 9 Logic programming – Function blocks Inputs Up and Down A rising edge (Low to High) at the Up input increases the value of the internal counter by “1”. A rising edge (Low to High) at the Down input decreases the value of the internal counter by “1”.
Page 141 Chapter 9 Logic programming – Function blocks Reload value and Counter reload The Counter reload parameter determines what happens when the counter value reaches “0”. If this parameter is configured to Automatic and the internal counter equals “0”, the Underflow output becomes High for the duration of the logic execution time.
Page 142: Fast Shut Off And Fast Shut Off With Bypass
Chapter 9 Logic programming – Function blocks 9.7.12 Fast shut off and Fast shut off with bypass Function block diagram Figure 112: Function block diagram for the Fast shut off and Fast shut off with bypass function blocks General description The Fast shut off and Fast shut off with bypass function block is used to minimize the response time of a safety switching path within the MELSEC-WS safety controller.
Page 143 Chapter 9 Logic programming – Function blocks Always consider the total response time of the entire safety function! The response time of the Fast shut off function block is not the same as the total ATTENTION response time of the entire safety function. The total response time includes multiple parameters outside of this function block.
Page 144 Chapter 9 Logic programming – Function blocks  Choose the number of inputs which you would like to attach to the function block.  Then click the Parameter tab and choose the zone by checking the boxes. Figure 116: Parameter settings dialog for the Fast shut off function block If only AND logic is needed, leave the Zone 2 AND function block inputs unchecked.
Page 145 Chapter 9 Logic programming – Function blocks At this point, the selected inputs and outputs are linked to each other such that the output cannot be moved to another position and the inputs must stay on the WS0- XTIO module in the hardware configuration. The elements which are linked are shown in the hardware configuration in orange.
Page 146 Chapter 9 Logic programming – Function blocks  The Bypass input has an on-delay of 3 logic cycles to compensate delays due to logic processing time and transmission time of the FLEXBUS+. The delay ensures that the I/O module has received the bypass signal before it is used for the further logic processing in the Fast shut off function block.
Page 147: Edge Detection
Chapter 9 Logic programming – Function blocks 9.7.13 Edge detection Function block diagram one bypass conditions Figure 120: Function block diagram for the Edge detection function block General description The Edge detection function block is used to detect a positive (rising) or negative (falling) edge of the input signal.
Page 148: Binary Encoder
Chapter 9 Logic programming – Function blocks 9.7.14 Binary encoder Function block diagram Figure 122: Function block diagram for the Binary encoder function block General description The Binary encoder function block encodes depending on the current configuration a one-out-of-N (one-hot) or a priority code to a binary code (Output A = 2 , Output B = 2 Output C = 2 ).
Page 149 Chapter 9 Logic programming – Function blocks Priority-to-binary (input 1 dominant) In this mode, all outputs are set to Low, if input 1 is High, regardless of the other inputs. If input 1 is Low, the function block behaves as in Priority mode. If all inputs are Low at the same time, all outputs are set to Low and Fault present becomes High.
Page 150 Chapter 9 Logic programming – Function blocks Output Output Output Fault Input 8 Input 7 Input 6 Input 5 Input 4 Input 3 Input 2 Input 1 present Table 48: Truth table for the Binary encoder function block with 8 inputs in Priority mode Table 49: Fault Input 2...
Page 151: Binary Decoder
Chapter 9 Logic programming – Function blocks 9.7.15 Binary decoder Function block diagram Figure 123: Function block diagram for the Binary decoder function block General description The Binary decoder function block decodes dependent on the current configuration a binary code to a one-out-of-N (one-hot) or to a priority code. Up to 5 inputs can be configured.
Page 152 Chapter 9 Logic programming – Function blocks Truth tables for the Binary decoder function block The following applies for the truth table in this section:  “0” means logic Low.  “1” means logic High. Table 52: Input A Output 2 Output 1 Truth table for the Binary decoder with 1 input in One...
Page 153 Chapter 9 Logic programming – Function blocks Evaluation of more than three inputs If 4 or 5 inputs are used, up to four Binary decoder function blocks can be combined in order to encode binary codes with values from 0 to 31. Figure 124: Combination of four Binary decoder function blocks...
Page 154: Log Generator
Chapter 9 Logic programming – Function blocks 9.7.16 Log generator Function block diagram Figure 125: Function block diagram for the Log generator function block General description The Log generator function block monitors up to eight inputs. If at one of these inputs an edge is detected according to the configuration, the function block sets the corresponding output to High for the duration of the logic execution time and adds a user defined text message to the diagnostics history.
Page 155 Chapter 9 Logic programming – Function blocks To configure the Log generator function block, proceed as follows:  Connect input elements to the function block. Double click on the function block to open the configuration dialog and click then on the I/O settings tab. Figure 127: I/O settings for the Log generator function block...
Page 156: Routing 1:N
Chapter 9 Logic programming – Function blocks  Then click the Message assignment tab. Assign the desired message to each used input and choose the input condition that must be fulfilled for the related message to be sent (rising edge, falling edge or rising and falling edge). The message assignment can not be exported or imported.
Page 157: Routing N:n
Chapter 9 Logic programming – Function blocks 9.7.18 Routing N:N Function block diagram Figure 131: Function block diagram for the Routing N:N function block General description The Routing N:N function block passes up to eight input signals parallel to up to eight outputs.
Page 158: Application-Specific Function Blocks
Chapter 9 Logic programming – Function blocks Application-specific function blocks 9.8.1 Reset Function block diagram Figure 132: Function block diagram for the Reset function block General description The Reset function block can be used to fulfill the normative requirements for safety applications on acknowledging a manual safety stop and the subsequent request to restart the application.
Page 159: Restart
Chapter 9 Logic programming – Function blocks Ensure that the transitions of the signals for resetting fulfill the requirements! In case of a short-circuit to High (to 24 V DC) at a physical input, the evaluated signal ATTENTION can have a pulse when the signal is reset due to the short-circuit detection. If such a pulse can result in a dangerous state in the machine, the following points have to be observed: ...
Page 160 Chapter 9 Logic programming – Function blocks Restart required output The Restart required output shows by pulsing at 1 Hz that the function block expects a valid restart pulse at the Restart input so that the Enable output can become High. This is the case if the Release condition fulfilled output is High, i.e.
Page 161: Off-Delay Timer
Chapter 9 Logic programming – Function blocks 9.8.3 Off-delay timer Function block diagram Figure 136: Function block diagram for the Off-delay timer function block General description The Off-delay timer function block delays the switching-off of the output signal by a configurable duration.
Page 162: Adjustable Off-Delay Timer
Chapter 9 Logic programming – Function blocks 9.8.4 Adjustable off-delay timer Function block diagram Figure 138: Function block diagram for the Adjustable off-delay timer function block General description The Adjustable off-delay timer function block delays the switching-off of the Enable output by an adjustable duration.
Page 163: On-Delay Timer
Chapter 9 Logic programming – Function blocks 9.8.5 On-delay timer Function block diagram Figure 140: Function block diagram for the On-delay timer function block General description The On-delay timer function block delays the switching-on of the output signal by a specified duration.
Page 164: Adjustable On-Delay Timer
Chapter 9 Logic programming – Function blocks 9.8.6 Adjustable on-delay timer Function block diagram Figure 142: Function block diagram for the Adjustable on-delay timer function block General description The Adjustable on-delay timer function block delays the switching-on of the Enable output by an adjustable duration.
Page 165: Edm (External Device Monitoring)
Chapter 9 Logic programming – Function blocks 9.8.7 EDM (External device monitoring) Function block diagram Figure 144: Function block diagram for the EDM function block General description The EDM (External device monitoring) function block allows to control an external device (e.g. a contactor) and to check on the basis of its feedback signal whether it has switched as expected.
Page 166: Valve Monitoring
Chapter 9 Logic programming – Function blocks The EDM error and Fault present outputs become Low, if a signal sequence is detected that sets Output 1 and Output 2 to High. Alternatively an error can also be reset with the aid of the Error reset input (from firmware V3.02).
Page 167 Chapter 9 Logic programming – Function blocks Parameters of the function block Table 70: Parameter Possible values Parameters of the Valve Reset condition  Manual reset monitoring function block  Auto reset Continuous monitoring  No when valve is active ...
Page 168 Chapter 9 Logic programming – Function blocks Feedback error, Directional error and Fault present Generally it is expected that the Feedback 1/2 input always takes the inverted value of the related Control input before the configured Max. switch-on feedback delay ) or Max.
Page 169 Chapter 9 Logic programming – Function blocks Sequence/timing diagrams Figure 147: Sequence/timing diagram for single valve in manual reset mode Figure 148: Sequence/timing diagram for double valve in manual reset mode Figure 149: Sequence/timing diagram for directional valve...
Page 170: User Mode Switch
Chapter 9 Logic programming – Function blocks 9.8.9 User mode switch Function block diagram Figure 150: Function block diagram for the User mode switch function block General description The User mode switch function block selects an output depending on an input value. Output x is High if Input x is High.
Page 171 Chapter 9 Logic programming – Function blocks Truth table for the User mode switch function block The truth table uses the following designations: “0” means logic Low. “1” means logic High. Table 72: Inputs Outputs Truth table for the User Fault present mode switch function block More than one input High or no input...
Page 172: Switch Synchronization
Chapter 9 Logic programming – Function blocks 9.8.10 Switch synchronization Function block diagram Figure 152: Function block diagram for the Switch synchronization function block General description The Switch synchronization function block was designed to improve the integration of SICK safety scanners (e.g. S3000). It monitors the input signals for changes. If a change of any input signal has been detected, the function block “freezes”...
Page 173 Chapter 9 Logic programming – Function blocks Cascading mode – with cascade input Several Switch synchronization function blocks can be combined to a cascade so that all outputs will be switched at precisely the same time. By cascading multiple Switch synchronization function blocks it is possible to synchronize more than six inputs.
Page 174 Chapter 9 Logic programming – Function blocks Sequence/timing diagrams Figure 154: Sequence/timing diagram for the Switch synchronization function block without cascading Figure 155: Sequence/timing diagram for the Switch synchronization function block with cascading...
Page 175: Error Output Combination
Chapter 9 Logic programming – Function blocks 9.8.11 Error output combination Function block diagram Figure 156: Function block diagram for the Error output combination function block General description The Error output combination function block was designed to improve the integration of SICK safety scanners (e.g.
Page 176: Ramp Down Detection
Chapter 9 Logic programming – Function blocks 9.8.12 Ramp down detection Function block diagram Figure 158: Function block diagram for the Ramp down detection function block General description The Ramp down detection function block checks whether a connected drive has been stopped, meaning that for a configurable time no pulses have been detected from the encoder system (e.g.
Page 177 Chapter 9 Logic programming – Function blocks Parameters of the function block Table 76: Parameter Possible values Parameters of the Ramp Number of incremental inputs  1 single encoder input down detection function block  1 pair of encoder inputs ...
Page 178 Chapter 9 Logic programming – Function blocks Figure 161: Signal pattern for zero pulse encoders It must be ensured by the design of your system that the minimum duration of the encoder pulses t and t must both be always higher than the logic execution time. high Take all possible tolerances into account, e.g.
Page 179 Chapter 9 Logic programming – Function blocks  Determine the time between signal changes for the speed limit: Signal frequency for release = 0.25 Hz × 4 teeth/revolution = 1 Hz Max. input pattern period = 1/1 Hz × 185°/360° = 514 ms Time between signal changes = 514 ms + 10 ms = 524 ms ...
Page 180 Chapter 9 Logic programming – Function blocks Logic example Figure 162: Logic example for the Ramp down detection function block Sequence/timing diagrams Figure 163: Sequence/timing diagram for the Ramp down detection function block Figure 164: Sequence/timing diagram for the Ramp down detection function block with plausibility check...
Page 181: Frequency Monitor
Chapter 9 Logic programming – Function blocks 9.8.13 Frequency monitor Function block diagram Figure 165: Logic connections for the frequency monitor function block General description Using the frequency monitor function block the frequency or the period duration of up to two signals can be monitored separately. Optionally it is also possible to monitor the pulse duration (thigh).
Page 182 Chapter 9 Logic programming – Function blocks Pay attention to the accuracy of the monitoring! The minimum duration for the pulse duration t and the minimum duration of the ATTENTION high space between pulses t on the pulse generator signals must be greater than the logic execution time.
Page 183 Chapter 9 Logic programming – Function blocks  (3) The pulse duration measured is too short: The pulse duration monitoring is activated (Average value of the pulse duration is not 0) and the time between the last rising edge and the last falling edge on the Frequency x input is less than Average value of the pulse duration —...
Page 184 Chapter 9 Logic programming – Function blocks  the Frequency 1 error output is high or  the Frequency 2 error output is high or  the Frequency 1 constant high output is high or  the Frequency 2 constant high output is high. The Frequency x error, Frequency x constant high and Fault present outputs change to low again if the Enable x output changes to high, i.e.
Page 185: Start Warning
Chapter 9 Logic programming – Function blocks 9.8.14 Start warning Function block diagram Figure 170: Function block diagram for the Start warning function block General description Many machines must be equipped with a start warning mechanism, e.g. if the machine operator can not see all dangerous areas from one location because of the size of the machine.
Page 186 Chapter 9 Logic programming – Function blocks For restrictions to this rule that apply in forward/backward locked mode see below. Note 5. If the release time has expired and no transition to inch mode has occurred, the function block will transit back to Waiting for start mode and a complete start sequence is required again.
Page 187 Chapter 9 Logic programming – Function blocks Waiting time The Waiting time parameter defines the time between the first rising edge of the Inch forward or Inch backward input and the start of the Release time. Release time After the Waiting time has expired, the Release time begins. During the Release time a rising edge on one of the Inch forward/Inch backward inputs will start the machine (depending on the setting of the Direction switching parameter).
Page 188 Chapter 9 Logic programming – Function blocks Reset A falling edge on the Reset input restarts the start sequence. An active inch mode is stopped and the function block back goes into Waiting for start mode. The Enable output as well as the Forward active and the Backward active output will become Low while the Startup active output will become High.
Page 189 Chapter 9 Logic programming – Function blocks Sequence/timing diagrams Figure 172: Sequence/timing diagram for the Start warning function block in Not locked mode Figure 173: Sequence/timing diagram for the Start warning function block in Locked mode  The start sequence is started by a rising edge of the Inch forward input. Note ...
Page 190: Function Blocks For Dual Channel Evaluation
Chapter 9 Logic programming – Function blocks Function blocks for dual channel evaluation The MELSEC-WS safety controller supports applications up to SIL3 (in accordance with IEC 62061) and Performance Level (PL) e (in accordance with EN/ISO 13849-1). Possible sources for function block inputs are one or two safety signals connected locally to the MELSEC-WS safety controller.
Page 191: Dual-Channel Evaluation (1 Pair) And Discrepancy Time
Chapter 9 Logic programming – Function blocks 9.9.2 Dual-channel evaluation (1 pair) and discrepancy time Note This section relates to the Safety gate monitoring, Emergency stop, Light curtain monitoring, Magnetic switch, Two hand control type IIIA and Two hand control type IIIC function blocks.
Page 192 Chapter 9 Logic programming – Function blocks The following truth table describes the discrepancy conditions for the dual-channel equivalent and the dual-channel complementary input evaluation: Table 81: Evaluation Input Input Discrepancy Evaluation Enable output Discrepancy Dual-channel evaluation type timer status error output Equivalent Inactive...
Page 193: Double Dual-Channel Evaluation (2 Pair Synchronization Evaluation) And Synchronization Time
Chapter 9 Logic programming – Function blocks  If signals from tested sensors are connected to WS0-XTDI or WS0-XTIO modules, the discrepancy time should be at least the set Test gap (ms) plus the Max. off-on delay (ms), because a signal change at the module input can be delayed for this time.
Page 194 Chapter 9 Logic programming – Function blocks The following truth table describes the synchronization conditions for double dual- channel evaluations (2 pairs): Table 82: Status of the Status of the Synchronization Synchronization Enable Synchronization Double dual-channel dual-channel dual-channel timer status output error output evaluation (synchronization...
Page 195: Emergency Stop
Chapter 9 Logic programming – Function blocks Figure 178: Sequence/timing diagram for the Safety gate monitoring function block, Category 4, dual-channel equivalent (2 pairs) without function test 9.9.4 Emergency stop Function block diagram Figure 179: Function block diagram for the Emergency stop function block General description The Emergency stop function block allows the implementation of an emergency stop...
Page 196: Magnetic Switch
Chapter 9 Logic programming – Function blocks Parameters of the function block Table 83: Parameter Possible values Parameters of the Emergency stop function  Single-channel Inputs block  Dual-channel equivalent  Dual-channel complementary Discrepancy time 0 = disabled, 10 to 30,000 ms in 10 ms steps. If enabled, the value has to be greater than the logic execution time.
Page 197: Light Curtain Monitoring
Chapter 9 Logic programming – Function blocks 9.9.6 Light curtain monitoring Function block diagram Figure 181: Function block diagram for the Light curtain monitoring function block General description The Light curtain monitoring function block allows the implementation of a semiconductor protective device functionality with ESPE. The internal logic of the Light curtain monitoring function block corresponds to the functionality of the Emergency stop function block, however with a limited parameter selection.
Page 198: Safety Gate Monitoring
Chapter 9 Logic programming – Function blocks 9.9.7 Safety gate monitoring Function block diagram Figure 182: Function block diagram for the Safety gate monitoring function block General description The function block can be used for the evaluation of dual-channel switches. 1 pair or 2 pairs can be selected.
Page 199 Chapter 9 Logic programming – Function blocks Function test In some applications, safeguarding devices require cyclic physical testing in order to verify that the device continues to operate properly. If the Safety gate monitoring function block is configured with the Function test required parameter, the input signal(s) must change once per machine cycle in a way that no enable condition exists anymore and back (e.g.
Page 200: Tolerant Dual Channel Monitor
Chapter 9 Logic programming – Function blocks 9.9.8 Tolerant dual channel monitor Function block diagram Figure 185: Logic connections for the tolerant dual channel monitor function block General description The Tolerant dual channel monitor function block can be used to evaluate switches and sensors.
Page 201 Chapter 9 Logic programming – Function blocks Function block parameters Table 87: Parameters Possible values Parameters for the tolerant dual channel monitor Input mode  Equivalent function block  Complementary Evaluation mode  Dual channel  Dual channel/AND mode Max. time for AND 0 = infinite, 1 to 60000 s mode Discrepancy time on...
Page 202 Chapter 9 Logic programming – Function blocks Figure 186: State diagram for the tolerant dual channel monitor function block Discrepancy time An optional discrepancy time can be defined. The discrepancy time defines how long the two inputs are allowed to have discrepant values after a change in one of the two inputs without this situation resulting in an error.
Page 203 Chapter 9 Logic programming – Function blocks Fault present and resetting errors The Fault present output is a combined error output and changes to high if one of the following cases occurs:  The discrepancy time on switching on is activated and has elapsed or ...
Page 204 Chapter 9 Logic programming – Function blocks Figure 189: Sequence/timing diagram for the tolerant dual channel monitor function block — AND mode Off-delay Using the off-delay, briefly switching off one or both inputs can be ignored and the Release output remains high. If one or both of the inputs is/are still switched off after the off-delay has elapsed, then the Release output changes to low.
Page 205: Two-Hand Control Type Iiia
Chapter 9 Logic programming – Function blocks 9.9.9 Two-hand control type IIIA Function block diagram Figure 191: Function block diagram for the Two-hand control type IIIA function block General description The Two-hand control type IIIA function block is a predefined function block for two- hand control sensors for which discrepancy time monitoring on equivalent inputs is required.
Page 206 Chapter 9 Logic programming – Function blocks In the hardware configuration the used inputs must be configured as single channel signals, i.e. no dual channel input evaluation on the safety I/O module. Parameters of the function block Table 90: Parameter Possible values Parameters of the Two-hand Discrepancy time pair 1...
Page 207: Multi Operator (Multiple Two-Hand Control)
Chapter 9 Logic programming – Function blocks 9.9.11 Multi operator (multiple two-hand control) Function block diagram Figure 194: Function block diagram for the Multi operator function block General description The Multi operator function block is used to monitor simultaneous operation of up to three two-hand controls.
Page 208 Chapter 9 Logic programming – Function blocks The Enable output changes to High, if …  all Release inputs are High and stay High, and  each activated Operator input has changed to Low at least once (this may occur at different times as well) after the MELSEC-WS safety controller has changed from the Stop state to the Run state or after a rising or a falling edge (depending on the configuration) has been detected at the Cycle request input, and...
Page 209: Overview And General Description
Chapter 9 Logic programming – Function blocks 9.10 Function blocks for Parallel muting, Sequential muting and Cross muting 9.10.1 Overview and general description Muting is the automatic temporary suppression of safety-oriented area monitoring using electro-sensitive protective equipment (ESPE) while certain objects, e.g. pallets with material, are moved into the hazardous area.
Page 210 Chapter 9 Logic programming – Function blocks The general safety regulations and protective measures have to be observed! If you use muting, be sure to observe the following information about the correct use of ATTENTION muting:  Access to the hazardous area has to be detected reliably by the ESPE or be excluded through other measures.
Page 211 Chapter 9 Logic programming – Function blocks Figure 196: Safety when mounting the muting sensors  Always position the muting sensors in such a way that only the material is detected and not the conveyance means (pallet or vehicle). Figure 197: Detection of material during muting ...
Page 212: Parameters Of The Function Blocks
Chapter 9 Logic programming – Function blocks  When an override input is configured, test pulse outputs may not be used for the configuration of the safety inputs.  Separate lines have to be used for the sensor signals A1 and A2 (B1 and B2). ...
Page 213 Chapter 9 Logic programming – Function blocks Direction detection Direction detection is used when the transported material has to be moved in a specific direction. The direction depends on the sequence in which the muting sensors are activated. If direction detection is disabled, the material to be transported can be moved in both directions in order to fulfill the muting conditions.
Page 214 Chapter 9 Logic programming – Function blocks Muting total time The Muting total time is used in order to limit the maximum duration of the muting sequence. If the set value for the Muting total time is exceeded, the Muting error and Fault present outputs change to High and the Enable output changes to Low.
Page 215 Chapter 9 Logic programming – Function blocks Sequence monitoring Sequence monitoring is used to define a special mandatory sequence in which the muting sensors have to be High. Table 93 shows the valid sequence for muting sensor input signals. This parameter is only available for configurations with four muting sensors, for example for parallel muting or sequential muting.
Page 216 Chapter 9 Logic programming – Function blocks Note A reset button can also be suitable for the override function. Check the requirements of your application in order to ensure that the safety-relevant logic fulfils the requirements of the local, regional, national and international regulations. Table 94 provides information about the Override required output and when Override is possible under the shown conditions and when not.
Page 217 Chapter 9 Logic programming – Function blocks During an override cycle, the Enable output is set to High as during a valid muting sequence. The number of permissible override cycles is limited in order to prevent excessive use of the override function. The number of permissible override cycles depends on the value for the total muting time.
Page 218 Chapter 9 Logic programming – Function blocks The following timer functions are influenced by the value of the Conveyor input: Table 96: Monitoring function Effect of the Conveyor input Effects of the conveyor belt  If a belt stop is detected, these timer functions pause. monitoring on the timer Monitoring of the functions...
Page 219: Information On Wiring
Chapter 9 Logic programming – Function blocks 9.10.3 Information on wiring If muting functions are to be implemented, possible errors in the wiring have to be taken into consideration. If certain signal combinations are to be transferred in a common wire, additional precautions have to be taken in order to ensure that the respective signals are correct.
Page 220: State Transition From Stop To Run
Chapter 9 Logic programming – Function blocks 9.10.4 State transition from Stop to Run If the MELSEC-WS safety controller changes from the Stop state to the Run state, the following behavioural patterns can be realized, depending on the state of the muting sensors and of the OSSDs of the sensors (e.g.
Page 221: Parallel Muting
Chapter 9 Logic programming – Function blocks 9.10.6 Parallel muting Function block diagram Figure 199: Function block diagram for the Parallel muting function block Representation of the application Figure 200 shows an example of the placement of sensors for Parallel muting. Figure 200: Muting with two parallel sensor pairs...
Page 222 Chapter 9 Logic programming – Function blocks Where … = Distance between the sensors (layout symmetrical to the detection area of the ESPE) = Length of material in conveyor direction = Velocity of the material (e.g. of the conveyor belt) = Set total muting time [s] = Response time of the light curtain or the muting sensors IN Light curtain...
Page 223: Sequential Muting
Chapter 9 Logic programming – Function blocks 9.10.7 Sequential muting Function block diagram Figure 202: Function block diagram for the Sequential muting function block Representation of the application Figure 203 shows an example of the placement of sensors using the Sequential muting function block.
Page 224 Chapter 9 Logic programming – Function blocks Equations and prerequisites for calculating the distance:  v × 2 × T IN Muting sensor v × t > L < L < T IN Light curtain IN Muting sensor Where … = Distance between the inner sensors (layout symmetrical to the detection area of the ESPE) = Distance between the outer sensors (layout symmetrical to the detection...
Page 225 Chapter 9 Logic programming – Function blocks 9.10.8 Cross muting direction of movement only forwards or backwards – Function block diagram Figure 205: Function block diagram for the Cross muting function block with optional input C1 Representation of the application Figure 206 shows an example of the sensor layout for the Cross muting function block.
Page 226 Chapter 9 Logic programming – Function blocks Where … = Minimum distance between the detection line of the ESPE and the detection by A1, A2 = Distance between the two detection lines of the sensors (sensors activated/sensors clear) = Length of material in conveyor direction = Maximum distance between C1 and the detection line of A1, A2 = Velocity of the material (e.g.
Page 227 Chapter 9 Logic programming – Function blocks 9.10.9 Cross muting material transport in both directions – Function block diagram Figure 208: Function block diagram for the Cross muting function block Representation of the application The sensors can be located as follows in the case of muting applications with one crossed sensor pair where the material has to be moved in both directions.
Page 228 Chapter 9 Logic programming – Function blocks Where … = Minimum distance between the detection line of the ESPE and the detection by A1, A2 = Distance between the two detection lines of the sensors (sensors activated/sensors clear) = Length of material in conveyor direction = Velocity of the material (e.g.
Page 229: Function Blocks For Press Contact Monitoring
Chapter 9 Logic programming – Function blocks 9.11 Function blocks for press contact monitoring 9.11.1 Overview and general description For press applications there are two complementary types of function blocks offered. This section describes the contact monitoring function blocks, which provide signals for the press cycle control function blocks.
Page 230 Chapter 9 Logic programming – Function blocks Parameters of the function block Table 107: Parameter Possible values Parameters of the Eccentric Dynamic cam input  With press contact function block  Without Min. reset pulse time  100 ms  350 ms Reset input ...
Page 231 Chapter 9 Logic programming – Function blocks Top output and Upstroke output The Top output is typically used to stop the press and is connected to another complementary press function block, e.g. Press setup or Press single stroke. The Upstroke output is typically connected to another complementary press function block, e.g.
Page 232 Chapter 9 Logic programming – Function blocks Figure 213: Press cycle for the Eccentric press contact function block with Dynamic cam on upstroke If there is a falling edge of the Dynamic cam input when the Upstroke cam input is Low, i.e.
Page 233 Chapter 9 Logic programming – Function blocks Contact monitoring The input signals for the Overrun cam input, Upstroke cam input and the Drive released input have to accord with Figure 215 and the following rules. Figure 215: Contact monitoring with the Eccentric press contact function block (1) The overrun must begin during the upstroke phase: The rising edge at the...
Page 234 Chapter 9 Logic programming – Function blocks In order to fulfill the safety standards it may be necessary to use tested switches for the cam input signals, each with different test sources. To use different test sources for the cam signals, the Overrun cam, Upstroke cam and Dynamic cam need to be connected to different WS0-XTDI or WS0-XTIO modules.
Page 235: Universal Press Contact
Chapter 9 Logic programming – Function blocks Disable monitoring Using this optional input it is possible to deactivate the monitoring functionality under certain conditions in order to prevent the function block to go into an error state. This can be useful for certain operating modes, e.g. during the setup of the machine or when the press moves backwards.
Page 236 Chapter 9 Logic programming – Function blocks Parameters of the function block Table 108: Parameter Possible values Parameters of the Universal Overrun cam input  With press contact function block  Without BDC input  With  Without Number of BDC signals per cycle ...
Page 237 Chapter 9 Logic programming – Function blocks If the Reset input is disabled, an error can be reset only by stopping the logic execution, e.g. by a power cycle or by changing the system state from the Run state to the Stop state and back to the Run state with the Setting and Monitoring Tool.
Page 238 Chapter 9 Logic programming – Function blocks Figure 219: Press cycle for the Universal press contact function block with falling edge of BDC before TDC A second rising edge of the BDC input does not restart the upstroke phase. This is the case if Number of BDC signals per cycle is 0-2 (e.g.
Page 239 Chapter 9 Logic programming – Function blocks TDC monitoring There must be exactly one TDC pulse per cycle. A violation of this rule can be detected only if the Overrun cam input is enabled and/or the BDC input is enabled and the parameter Number of BDC signals per cycle is set to 1 (e.g eccentric press).
Page 240 Chapter 9 Logic programming – Function blocks BDC and Overrun cam monitoring If BDC and Overrun cam are enabled, the BDC input signals must accord with Figure 223 and the following rules. Figure 223: Contact monitoring with the Universal press contact function block with BDC enabled (1) The beginning of the BDC (Low-High transition) must be close to 180°...
Page 241 Chapter 9 Logic programming – Function blocks Additionally, the number of BDC signals (Low-High-Low) must be according to the configured value, i.e. either exactly one or any value between 0 and 2. 0 BDC signals per cycle 1 BDC signal per cycle 2 BDC signals per cycle Figure 224: Timing diagrams for 0, 1 and 2 BDC signals per cycle...
Page 242 Chapter 9 Logic programming – Function blocks Overrun monitoring If the Overrun cam input is enabled, the Universal press contact function block monitors the overrunning of the press, i.e. it checks whether the Overrun cam cam is left although the press is expected to have stopped. The Drive released input signal must then accord with Figure 225 and the following rule.
Page 243: Function Blocks For Press Cycle Control
Chapter 9 Logic programming – Function blocks 9.12 Function blocks for press cycle control 9.12.1 Press setup Function block diagram Figure 226: Function block diagram for the Press setup function block General description The Press setup function block is generally used together with the Universal press contact or the Eccentric press contact function block in order to set up the press and in order to provide the information of the Top output as input for this function block.
Page 244 Chapter 9 Logic programming – Function blocks Input signals of the function block The Press setup function block supports the following input signals: Start/Release The Start/Release input signal is used to indicate the beginning and the end of the press movement. A rising edge (Low to High) at the Start/Release input signals a start of the press.
Page 245 Chapter 9 Logic programming – Function blocks Restart input If the Restart interlock parameter has been set to Without, a Restart signal is not required in order to restart the press after any kind of stop. The Restart interlock parameter can also be set to the following values: ...
Page 246: Press Single Stroke
Chapter 9 Logic programming – Function blocks 9.12.2 Press single stroke Function block diagram Figure 228: Function block diagram for the Press single stroke function block General description The Press single stroke function block is generally used together with the Universal press contact or the Eccentric press contact function block in order to provide the information of the Top and Upstroke outputs as input for this function block.
Page 247 Chapter 9 Logic programming – Function blocks Ensure that the transitions of the signals for restarting fulfill the requirements of the safety standards and regulations! ATTENTION In case of a short-circuit to High (to 24 V DC) at a physical input, the evaluated signal can have a pulse when the signal is reset due to the short-circuit detection.
Page 248 Chapter 9 Logic programming – Function blocks Release 3 (safety) The Release 3 (safety) input signal is an optional signal. The Enable output can only change from Low to High if Release 3 (safety) is High. If Release 3 (safety) is Low and Upstroke is Low, the Enable output is set to Low and a restart sequence has to occur in accordance with the settings.
Page 249 Chapter 9 Logic programming – Function blocks Restart input If the Restart interlock parameter has been set to Without, a Restart signal is not required in order to restart the press after any kind of stop. The Restart interlock parameter can also be set to the following values: ...
Page 250: Press Automatic
Chapter 9 Logic programming – Function blocks 9.12.3 Press automatic Function block diagram Figure 232: Function block diagram for the Press automatic function block General description The Press automatic function block is used in connection with press applications in which the workpieces are moved automatically to and from the press, but where occasionally access to the press is required, for example to change a tool.
Page 251 Chapter 9 Logic programming – Function blocks Input parameters and input signals of the function block Stop request The Stop request parameter determines the Stop state of the Press automatic function block. If this parameter is configured as When Start/Release input is Low, the Start/Release input signal is used to control the Enable output directly.
Page 252 Chapter 9 Logic programming – Function blocks Release 1 (static) The input signal Release 1 (static) is mandatory. The Enable output always changes immediately to Low, if Release 1 (static) is Low. If this function block is used together with a press contact function block (e.g. Eccentric press contact or Universal press contact), its enable signal must be connected with the Release 1 (static) input of this function block.
Page 253: N-Break (Press With N-Psdi Mode)
Chapter 9 Logic programming – Function blocks 9.12.4 N-break (press with N-PSDI mode) Function block diagram Figure 234: Function block diagram for the N-break function block General description The N-break function block is used for press applications with Presence-Sensing Device Initiation (PSDI) mode. Conform to the safety regulations for PSDI mode! The requirements for PSDI mode are specified in local, regional, national and ATTENTION...
Page 254 Chapter 9 Logic programming – Function blocks Parameters of the function block Table 112: Parameter Possible values Parameters of the N-break Number of breaks 1 to 8 function block Mode  Standard  Sweden Max. Up-Stroke muting time 0 = disabled, 1 to 7200 s. The Upstroke input is available only if the value is not set to 0.
Page 255 Chapter 9 Logic programming – Function blocks Requirements for the start sequence If the Enable output changes to Low because of one of the following conditions, a complete start sequence can be necessary:  Release 1 (static) is Low,  the Unexpected PSDI output is High, while Cycle = 0 and there is no active upstroke muting and no stop at the top dead center, ...
Page 256 Chapter 9 Logic programming – Function blocks PSDI time monitoring The PSDI time monitoring parameter specifies the required time both for a complete start sequence and for a cycle start sequence. If the PSDI time monitoring is exceeded, the PSDI timeout output changes to High. In this case, a complete start sequence is necessary so that the Enable output can return to High (e.g.
Page 257 Chapter 9 Logic programming – Function blocks Exclude any danger during the upstroke movement of the press! If you use upstroke muting, you must ensure that during the upstroke period no ATTENTION hazards are present, e.g. by the up movement itself. Figure 238: Sequence/timing diagram for Upstroke muting in...
Page 258 Chapter 9 Logic programming – Function blocks Release 1 (static) The input signal Release 1 (static) is mandatory. The Enable output always changes immediately to Low, if Release 1 (static) is Low. If this function block is used together with a press contact function block (e.g. Eccentric press contact or Universal press contact), its Enable output must be connected with the Release 1 (static) input of this function block.
Page 259 Chapter 9 Logic programming – Function blocks If Restart interlock has been set to Always and upstroke muting is active, the Enable output remains High until the Top input becomes High, thus indicating that the press cycle has been completed. In this case, a complete restart sequence is required. If Restart interlock has been set to Deactivation on upstroke (only for PSDI) and the Upstroke input is High, the Enable output remains High until Top becomes High, thus indicating that the press cycle has been completed.
Page 260 Chapter 9 Logic programming – Function blocks Unexpected PSDI The Unexpected PSDI output is High when a valid start sequence has been carried out and the PSDI input changes from High to Low while no muting is active and no break is expected.
Page 261: User Defined Function Blocks
Chapter 9 Logic programming – Function blocks 9.13 User defined function blocks 9.13.1 Grouped function block Function block diagram Figure 241: Function block diagram for the Grouped function block You can select groups of function blocks in order to create a single grouped function block.
Page 262 Chapter 9 Logic programming – Function blocks  Click on Group. The Edit Function Block Details dialog opens. Figure 243: Edit Function Block Details dialog for the Grouped function block  Enter a name for the new grouped function block. Note Do not enter the same name used in any existing grouped function block for the new grouped function block.
Page 263 Chapter 9 Logic programming – Function blocks The content of the new grouped function block is stored on a new page. In the example, the name of the new grouped function block is Machine 1. The worksheet for the grouped function block is displayed orange. Figure 246: New logic editor page for the new grouped function block...
Page 264 Chapter 9 Logic programming – Function blocks The inputs and outputs that have been added to the grouped function block will appear on the function block itself in the main program and devices can be attached to them. Once a device is attached, it will be displayed in the logic of the grouped function block when the view is switched to external view.
Page 265: Customized Function Block
Chapter 9 Logic programming – Function blocks 9.13.2 Customized function block Once a grouped function block is created, it is possible to lock and import it into the function block selection field for use in future project files. The resulting function block is called a Customized function block.
Page 266 Chapter 9 Logic programming – Function blocks  If you want to assign another icon to your new customized function block, you have two possibilities: – Click on Browse... to choose a user defined icon. – Or click on Select... to open the Select Icon dialog. You can choose the icon from a fixed library.
Page 267 Chapter 9 Logic programming – Function blocks How to edit a customized function block:  Open the customized function block’s page by clicking on its tab,  Click on Edit... in the toolbar. You will be prompted for confirmation. If you click on Yes, the customized function block will be transformed to a grouped function block which can be edited (see Section 9.13.1).
Page 268: Simulation Of The Configuration
Chapter 9 Logic programming – Function blocks 9.14 Simulation of the configuration Within the logic editor, it is possible to simulate the programmed logic offline. Inputs can be set to High or Low and the resulting switching of the outputs can be monitored. Additionally the timer and counter values of the used function blocks are displayed on the function blocks while the simulation is running.
Page 269 Chapter 9 Logic programming – Function blocks Figure 256: Simulation mode started, simulation off While the simulation is running you can set an input to High by clicking on it. High inputs will be displayed green with a blue frame. Another click will set the input back to Low again.
Page 270: Force Mode
Chapter 9 Logic programming – Function blocks 9.15 Force mode In force mode you can set the inputs in the MELSEC-WS logic program to High or Low via Setting and Monitoring Tool independently of the values of the actual physical inputs while the MELSEC-WS safety controller is in the Run state.
Page 271 Chapter 9 Logic programming – Function blocks  Go to the Logic editor view and click on the Start force mode button. A dialog is opened where you can enter the time after which the force mode will be automatically left if no actions are taken. Figure 258: Dialog window when starting force mode...
Page 272 Chapter 9 Logic programming – Function blocks How to force an input:  Click on an input with the left mouse button. A context menu with the following options will appear: – Force low...: The MELSEC-WS safety controller will evaluate the input independently of its actual physical value as Low.
Page 273 Chapter 9 Logic programming – Function blocks Termination of the force mode The force mode can be terminated in the following ways:  manually through the user  automatically after the defined time delay  automatically after 30 seconds if the MELSEC-WS safety controller detects an error (e.g.
Page 274: I/O Modules
Chapter 10 I/O modules I/O modules 10.1 Dual channel evaluation and discrepancy time monitoring Dual channel evaluation The safety I/O modules, e.g. WS0-XTIO or WS0-XTDI, can carry out a dual-channel evaluation when predefined input elements from the Elements window (e.g. RE27, C4000, …) are connected to them.
Page 275 Chapter 10 I/O modules The following truth table describes the discrepancy conditions for the dual-channel equivalent and the dual-channel complementary input evaluation: Table 114: Dual-channel evaluation Input A Input B Status of the Safety I/O Evaluation Discrepancy Discrepancy (I1, I3, (I2, I4, dual-channel module input in...
Page 276: On-Off Filter And Off-On Filter
Chapter 10 I/O modules 10.2 ON-OFF filter and OFF-ON filter Several unintentional brief signal changes occur when opening or closing a component fitted with contacts as the result of the bouncing of the contacts. As this may influence the evaluation of the input, you can use the ON-OFF filter for falling edges (i.e.
Page 277: Transferring The System Configuration
Chapter 11 Transferring the system configuration Transferring the system configuration Initially, the configuration of the MELSEC-WS safety controller only exists as a project, meaning as a MELSEC-WS configuration file. The configuration has to be transferred to the memory plug via the CPU. The memory plug and the CPU module communicate via an internal interface.
Page 278: Verification Of The Configuration
Chapter 11 Transferring the system configuration 11.3 Verification of the configuration After the configuration has been downloaded to the safety controller, the MELSEC- WS safety controller can be verified. To this purpose, the downloaded configuration data are read back from the safety controller and compared with the project data. If they match, the data are displayed in a report.
Page 279 Chapter 11 Transferring the system configuration  The Upload and verify result window is opened. Click Yes below at the question Set device to verified? if the displayed configuration is the expected configuration. The system is then considered to be verified. Figure 263: Setting a device to verified.
Page 280 Chapter 11 Transferring the system configuration If the verification is completed successfully, a project report is created subsequently that you can print and save. The query whether the device is to be marked as verified is displayed in the lower part of the report window.
Page 281: Activating The Write Protection Of The Configuration In The Safety Controller
Chapter 11 Transferring the system configuration 11.4 Activating the write protection of the configuration in the safety controller A verified configuration can be protected against accidental changes by activating the write protection. The write protection can be set and deactivated in the Setting and Monitoring Tool by using the lock symbol in the Hardware configuration to the left of the CPU module.
Page 282: Device States Of The Melsec-Ws Safety Controller
Chapter 12 Device states of the MELSEC-WS safety controller Device states of the MELSEC-WS safety controller The MELSEC-WS safety controller knows different device states during operation. Some device states require a user intervention, e.g. the state transition from Stop to Run or vice versa using the Setting and Monitoring Tool.
Page 283: Changing The Device State
Chapter 12 Device states of the MELSEC-WS safety controller 12.1 Changing the device state Specific state changes in the MELSEC-WS safety controller are carried out manually in the Setting and Monitoring Tool. These changes in the device state are:  change from Stop to Run ...
Page 284: Technical Commissioning
Chapter 13 Technical commissioning Technical commissioning The configuration of the MELSEC-WS safety controller has to be completed before you begin with the technical commissioning. 13.1 Wiring and voltage supply When connecting the MELSEC-WS safety controller, observe the technical data in the Safety Controller User’s Manual! ATTENTION ...
Page 285: Technical Test And Commissioning
Chapter 13 Technical commissioning 13.3 Technical test and commissioning The machine or system that is protected by a MELSEC-WS safety controller may only be started up after a successful technical check of all safety functions. The technical test may only be performed by qualified safety personnel. The technical test includes the following test items: ...
Page 286: Troubleshooting
Chapter 14 Troubleshooting Troubleshooting In case of an error please refer to the Safety Controller User’s Manual. There you will find a list of LED error displays, error codes, error causes and rectification measures. Error codes and error messages can also be displayed in the Diagnostics view if you are connected to the MELSEC-WS safety controller.
Page 287: Annex
Chapter 15 Annex Annex 15.1 Example application reports 15.1.1 Example application Newspaper palletizer...
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Page 298: Example Application Wood Scanner
Chapter 15 Annex 15.1.2 Example application Wood scanner...
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Page 307: Example Application Ramp Down Detection
Chapter 15 Annex 15.1.3 Example application Ramp down detection...
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Page 315: List Of Function Block Status In Simulation Mode
Chapter 15 Annex 15.2 List of function block status in simulation mode Table 117 lists the function block status displayed in the FB Preview window. Table 117: Function block status List of function block status Bottom dead center (BDC) left first time in simulation mode Bottom dead center (BDC) reached first time Bottom dead center (BDC) left second time...
Page 316: Precautions
Chapter 15 Annex 15.3 Precautions (1) Edit a CSV file exported from Setting and Monitoring tool in a text editor.
Page 317: Sick Contact
Chapter 15 Annex 15.4 SICK contact More representatives and agencies in all major industrialnations at www.sick.com Australia Norge Phone +61 3 9497 4100 Phone +47 67 81 50 00 1800 33 48 02 – tollfree E-Mail austefjord@sick.no E-Mail sales@sick.com.au Österreich Belgium/Luxembourg Phone +43 (0)22 36 62 28 8-0 E-Mail office@sick.at...
Page 318 MELCO does not warrant or guarantee the design, 1. Limited Warranty and Product Support. specify, manufacture, construction or installation of a. Mitsubishi Electric Company ("MELCO") warrants that the materials, construction criteria, functionality, use, for a period of eighteen (18) months after date of...
Page 319 h. These terms and conditions constitute the entire well as damages of a pecuniary nature, the agreement between Customer and MELCO with disclaimers and limitations contained in these terms respect to warranties, remedies and damages and shall apply to all three types of damages to the fullest supersede any other understandings, whether written extent permitted by law.
Page 320 Microsoft, Windows, Windows NT, and Windows Vista are registered trademarks of Microsoft Corporation in the United States and other countries. Pentium is a trademark of Intel Corporation in the United States and other countries. Ethernet is a trademark of Xerox Corporation. All other company names and product names used in this manual are trademarks or registered trademarks of their respective companies.
Page 322 SICK AG Tel. +49 7681 202-0 http://www.sick.com SH(NA)-080856ENG-E(1408)MEE MODEL: SW1DNN-WS0ADR-B-O-E MODEL CODE: 13JU67 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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