Elobau EloProg User manual

eloProg - Vers. 1.0

eloProg

Configurable safety system

Manual

Product description

Doc.-No. 350HB002en

Last updated: 05/20111 (Vers. 1.0)

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eloProg - Vers. 1.0

CONTENTS

INTRODUCTION................................................................................................................................................5

Contents of this handbook............................................................................................................................. 5

Important safety instructions ......................................................................................................................... 5

Abbreviations and symbols ........................................................................................................................... 6

Applicable standards..................................................................................................................................... 6

OVERVIEW ........................................................................................................................................................7

PRODUCT COMPOSITION ...............................................................................................................................8

INSTALLATION .................................................................................................................................................9

Mechanical fastening..................................................................................................................................... 9

Calculation of safety distance of an ESPE connected to eloProg............................................................... 10

Electrical connections.................................................................................................................................. 10

Instructions concerning connection cables............................................................................................. 11

USB input................................................................................................................................................ 12

eloProg memory stick (350EPS )............................................................................................................ 13

MULTIPLE LOAD function.................................................................................................................. 13

RESTORE function............................................................................................................................. 13

EXAMPLE OF CONNECTION OF eloProg TO THE MACHINE CONTROL SYSTEM.......................... 18

CHECKLIST AFTER INSTALLATION......................................................................................................... 18

OPERATING DIAGRAM..................................................................................................................................19

SIGNALS..........................................................................................................................................................20

INPUTS ....................................................................................................................................................... 20

MASTER ENABLE.................................................................................................................................. 20

NODE SEL.............................................................................................................................................. 20

RESTART_FBK ...................................................................................................................................... 21

OUTPUTS ................................................................................................................................................... 22

OUT STATUS ......................................................................................................................................... 22

OUT TEST .............................................................................................................................................. 22

OSSD (485EPB, 485EPE08A02, 485EPA02, 485EPA04)..................................................................... 22

SAFETY RELAYS (485EPR02, 485EPR04) .......................................................................................... 23

Characteristics of the output circuit......................................................................................................... 23

485EPR02/485EPR04 internal contacts................................................................................................. 23

Wiring example 485EPR02 / 485EPB .................................................................................................... 24

Switching operation timing diagram........................................................................................................ 24

TECHNICAL FEATURES.................................................................................................................................25

GENERAL SYSTEM CHARACTERISTICS............................................................................................ 25

Safety level parameters...................................................................................................................... 25

General data....................................................................................................................................... 25

Enclosure............................................................................................................................................ 26

485EPB module.................................................................................................................................. 26

485EPE08A02 module....................................................................................................................... 26

485EPE08 - 485EPE16 modules ....................................................................................................... 27

485EPA02 - 485EPA04 modules ....................................................................................................... 27

485EPR02 - 485EPR04 modules....................................................................................................... 27

MECHANICAL DIMENSIONS..................................................................................................................... 28

SIGNALS..................................................................................................................................................... 29

485EPB................................................................................................................................................... 29

485EPE08A02 ........................................................................................................................................ 30

485EPE08............................................................................................................................................... 31

485EPE16............................................................................................................................................... 32

485EPA02............................................................................................................................................... 33

485EPA04............................................................................................................................................... 34

485EPR02 / 485EPR04.......................................................................................................................... 35

TROUBLESHOOTING................................................................................................................................ 36

485EPB................................................................................................................................................... 36

485EPE08A02 ........................................................................................................................................ 37

485EPE08............................................................................................................................................... 38

485EPE16............................................................................................................................................... 39

485EPA02 / 485EPA04........................................................................................................................... 40

eloProg - Vers. 1.0

eloProg safety designer SOFTWARE...........................................................................................................41

Installing the software.................................................................................................................................. 41

PC HARDWARE requirements............................................................................................................... 41

PC SOFTWARE requirements................................................................................................................ 41

How to install the configuration software ................................................................................................ 41

Fundamentals ......................................................................................................................................... 42

Standard tool bar .................................................................................................................................... 43

Create a new project (configure the eloProg system)............................................................................. 44

EDIT CONFIGURATION (composition of the various modules) ............................................................ 45

Change user parameters........................................................................................................................ 45

OBJECTS - OPERATOR - CONFIGURATION tool bars ....................................................................... 46

Creating the diagram (Figure 29)............................................................................................................ 47

Example of a project............................................................................................................................... 48

Project validation ................................................................................................................................ 48

Project report...................................................................................................................................... 48

Connect to eloProg............................................................................................................................. 49

Sending the configuration to the eloProg ........................................................................................... 49

Configuration LOG.............................................................................................................................. 49

Upload system configuration.............................................................................................................. 50

Disconnecting System........................................................................................................................ 50

MONITOR (I/O status in real time - table).......................................................................................... 50

MONITOR (I/O status in real time - graphic)...................................................................................... 51

Password protection ............................................................................................................................... 52

Level 1 password................................................................................................................................ 52

Level 2 password................................................................................................................................ 52

Password Change .............................................................................................................................. 52

TESTING the system.............................................................................................................................. 53

OBJECT FUNCTION BLOCKS................................................................................................................... 54

OUTPUT OBJECTS................................................................................................................................ 54

OSSD (safety outputs)........................................................................................................................ 54

STATUS (signal output)...................................................................................................................... 54

INPUT OBJECTS.................................................................................................................................... 55

E-STOP (emergency stop)................................................................................................................. 55

E-GATE (safety gate device).............................................................................................................. 56

ENABLE (enable key)......................................................................................................................... 58

ESPE (optoelectronic safety light curtain / laser scanner) ................................................................. 59

FOOTSWITCH (safety pedal)............................................................................................................. 60

MOD-SEL (safety selector)................................................................................................................. 62

PHOTOCELL (safety photocell) ......................................................................................................... 62

TWO-HAND safety control ................................................................................................................. 64

SENSOR............................................................................................................................................. 65

S-MAT (safety mat)............................................................................................................................. 66

SWITCH.............................................................................................................................................. 67

COMMENTS....................................................................................................................................... 68

OPERATOR FUNCTION BLOCKS............................................................................................................. 68

LOGICAL OPERATORS......................................................................................................................... 68

AND.................................................................................................................................................... 68

NAND.................................................................................................................................................. 69

NOT.................................................................................................................................................... 69

OR ...................................................................................................................................................... 69

NOR.................................................................................................................................................... 70

XOR.................................................................................................................................................... 70

XNOR ................................................................................................................................................. 70

MULTIPLEXER................................................................................................................................... 71

MEMORY OPERATORS........................................................................................................................ 71

D FLIP FLOP (max number = 8) ........................................................................................................ 71

SR FLIP FLOP.................................................................................................................................... 72

USER RESTART MANUAL (max number = 8 with RESTART MONITORED).................................. 72

USER RESTART MONITORED (max number = 8 with RESTART MANUAL)................................. 72

COUNTER OPERATORS....................................................................................................................... 73

COUNTER (max number = 8)............................................................................................................ 73

eloProg - Vers. 1.0

TIMER OPERATORS (max number = 8)................................................................................................ 73

CLOCKING......................................................................................................................................... 73

MONOSTABLE................................................................................................................................... 74

PASSING MAKE CONTACT.............................................................................................................. 75

DELAY................................................................................................................................................ 76

MUTING OPERATORS (max number = 4)............................................................................................. 77

"Concurrent" MUTING........................................................................................................................ 77

MUTING “L”........................................................................................................................................ 78

"Sequential" MUTING......................................................................................................................... 79

MUTING “T”........................................................................................................................................ 80

SPECIAL APPLICATIONS...................................................................................................................... 81

Output delay with manual................................................................................................................... 81

ACCESSORIES AND SPARE PARTS............................................................................................................82

EC DEclaration of conformity........................................................................................................................83

eloProg - Vers. 1.0

INTRODUCTION

Contents of this handbook

This handbook describes how to use the eloProg programmable safety module and its expansion

units ("SLAVES");

it includes:

• a description of the system

• method of installation

• connections

• signals

• troubleshooting

• use of the configuration SW

Important safety instructions

This safety alert symbol indicates a potential personal safety hazard. Failure to comply with

instructions bearing this symbol could pose a very serious risk to personnel.

ÎThis symbol indicates an important instruction.

The eloProg is built to the following safety levels: SIL 3, SILCL 3, PL e, Cat. 4, Type 4 in

accordance with the applicable standards.

However, the definitive SIL and PL of the application will depend on the number of safety

components, their parameters and the connections that are made, as per the risk analysis.

Read the "Applicable Standards" section carefully.

Perform an in-depth risk analysis to determine the appropriate safety level for your specific

application, on the basis of all the applicable standards.

Always test the complete system whenever new safety components are added (see the

"TESTING the system" section).

The ambient temperature in the place where the system is installed must be compatible with

the operating temperature parameters stated on the product label and in the specifications.

For all matters concerning safety, if necessary, contact your country's competent safety

authorities or the competent trade association.

eloProg - Vers. 1.0

Abbreviations and symbols

350EPS = eloProg memory stick: for basic module 485EPB (accessory)

350EPT = eloProg t-fitting

350EPKS = eloProg configuration software

OSSD = Output Signal Switching Device: solid state safety output

MTTFd= Mean Time to Dangerous Failure

PL = Performance Level

PFHd= Probability of a dangerous failure per Hour

SIL = Safety Integrity Level

SILCL = Safety Integrity Level Claim Limit

SW = Software

Applicable standards

eloProg complies with the following European Directives:

• 2006/42/EC "Machinery Directive"

• 2004/108/EC "Electromagnetic Compatibility Directive"

• 2006/95/EC "Low Voltage Directive"

and is built to the following standards:

CEI EN 61131-2 Programmable controllers, part 2:

Equipment requirements and tests

ISO 13489-1 Safety of machinery:

Safety related parts of control systems. General principles for design

EN 61496-1 Safety of machinery: Electro-sensitive protective equipment. Part 1: General

requirements and tests.

IEC 61508-1 Functional safety of electrical/electronic/programmable electronic safety-related

systems: General requirements.

IEC 61508-2 Functional safety of electrical/electronic/programmable electronic safety-related

systems: Requirements for electrical/electronic/programmable electronic safety-

related systems.

IEC 61508-3 Functional safety of electrical/electronic/programmable electronic safety-related

systems: Software requirements.

IEC 61784-3 Digital data communication for measurement and control: Functional safety field

buses.

IEC 62061 Safety of machinery. Functional safety of safety-related electrical, electronic and

programmable electronic control systems

Table 1

eloProg - Vers. 1.0

OVERVIEW

eloProg is a modular safety controller. It consists of a master unit (485EPB), which can be

configured using the configuration software graphic interface, and a number of expansion

units connected via the proprietary bus.

The master unit can also be used as a stand-alone device. It has 8 safety inputs and 2

independent programmable dual channel outputs.

ÎThe following expansions are available:

ÎI/O expansion (485EPE08A02)

Îinput expansions (485EPE08 and 485EPE16)

Îoutput expansions (485EPA02 and 485EPA04)

Îguided contact safety relay output modules (485EPR02 and 485EPR04)

Îdiagnostic connections to the main field buses:

485EPFPD (PROFIBUS), 485EPFCO (CanOpen), 485EPFDN (DeviceNet).

eloProg is capable of monitoring the following safety sensors and commands:

optoelectronic sensors (safety light curtains, scanners, safety photocells), mechanical

switches, safety mats, emergency stops, two-hand controls,all managed by a single

flexible and expandable device.

The system must consist of just one Master 485EPB and a number of electronic

expansions that can range from 0 to a maximum of 7, not more than 4 of the same type.

There is no limit to the number of relay modules that can be installed.

With 7 expansions, the system can have up to 72 inputs and 8 dual channel safety

outputs. The MASTER and its SLAVE units communicate via the 5-way bus sensor,

physically arranged on the rear panel of each unit.

The configuration software is capable of creating complex logics, using logical operators

and safety functions such as muting, timer, counters, etc.

All this is performed through an easy and intuitive graphic interface.

The configuration performed on the PC is sent to the basic module via USB connection;

the file resides in the basic module and can also be saved on the memory chip 350EPS

(accessory). The configuration can therefore quickly be copied to another basic module.

ÎThe eloProg system is certified to the maximum safety level envisaged by the applicable

industrial safety standards (SIL 3, SILCL 3, PL e, Cat. 4).

eloProg - Vers. 1.0

PRODUCT COMPOSITION

The basic module 485EPB is supplied with:

• CD-ROM containing the free configuration software SW and PDF handbook.

ÎNB: the rear panel connector (t-fitting350EPT) and memory stick (350EPS) can be ordered

separately as accessories.

The expansion units are supplied with:

• Multilingual Installation sheet.

• Rear panel connector 350EPT (t-fitting),

(not present in the 485EPR02 and 485EPR04 which are connected via terminal blocks

only).

ÎNB: to install an expansion unit (excluding relays) you will need the t-fitting supplied with the

unit plus another t-fitting for the connection to the basic module. This can be ordered

separately as an accessory.

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eloProg - Vers. 1.0

Calculation of safety distance of an ESPE connected to eloProg

Any Electro-sensitive Protective Equipment device connected to eloProg, must be positioned at a

distance equal to or greater than the minimum safety distance Sso that the dangerous point can

be reached only after stopping the dangerous movement of the machine.

The european standard:

- ISO 13855:2010- (EN 999:2008) Safety of machinery - Positioning of safeguards with respect to

the approach speeds of parts of the human body.1

provides the elements to calculate the proper safety distance.

Carefully read the installation manual of each device for specific information on the correct

positioning.

Remember that the total response time depends on:

eloProg response time + ESPE response time + response time of the machine (i.e. the time

taken by the machine to stop the dangerous movement from the moment in which the stop

signal is transmitted).

Electrical connections

The modules are provided with terminal blocks for the

electrical connections. Each unit can have 8, 16 or 24

terminals.

Each module also has a rear panel plug-in connector

(for communication with the master and with the other

expansion units).

The 485EPR02 and 485EPR04 are connected via

terminal blocks only.

Install safety units in an enclosure with a protection class of at least IP54.

The supply voltage to the units must be 24Vdc ±20% (PELV, in compliance with the

standard EN 60204-1 (Chapter 6.4)).

Do not use the eloProg to supply external devices.

The same ground connection (0VDC) must be used for all system components.

1"Describe the methods that designers can use to calculate the minimum safety distance from a specific dangerous point

for the safety devices, particularly Electro-sensitive devices (eg. light curtains), safety-mats or pressure sensitive floors and

bimanual control. It contains a rule to determine the placement of safety devices based on approach speed and the

stopping time of the machine, which can reasonably be extrapolated so that it also includes the interlocking guards without

guard locking."

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