SSP Safety Simplifier User manual

Safety Simplifier Manual

Design, programming, installation, maintenance and decommissioning of Safety Simplifier

Systems.

Safety Simplifier makes it easy to create safe and reliable industry and

workplace environments, using wireless safety communication.

Safety Simplifier can be customized with many different features and

functions to fit your application.

SSP North AB 30/08/2018 Manual V2f

This document is the original document

All rights of this documentation are reserved by SSP North AB (Safety System Products North AB).

Copies may be made for internal uses.

Source code from third-parties and/or open source software has been used for some parts of the

configuration software. The relevant license information available tough our home page

(www.sspn.se).

SSP North AB

Tullkammarvägen 14

439 31 Onsala

Sweden

www.sspn.se

SSP North AB 30/08/2018 Manual V2f

Table of Contents

1Introduction ..........................................................................................................10

1.1 This Manual ........................................................................................................10

1.1.1 Abbreviations ..................................................................................................................... 10

1.1.2 Symbols ............................................................................................................................. 10

1.2 Intended use of Safety Simplifier ........................................................................10

1.3 Contact ...............................................................................................................11

1.4 Who can implement Safety Simplifier..................................................................11

1.5 Warranty .............................................................................................................11

1.6 Maintenance and repairs ....................................................................................11

1.7 Disposal considerations ......................................................................................11

1.8 Safety Assessment .............................................................................................12

1.9 Safety communication ........................................................................................12

2The Safety Simplifier System overview and features ........................................13

2.1 Features .............................................................................................................14

2.1.1 Example input functions .................................................................................................... 14

2.1.2 Example Output Functions ................................................................................................ 14

2.1.3 Combined I/O..................................................................................................................... 14

2.1.4 Redundant Relay Outputs ................................................................................................. 15

2.1.5 I/O outputs for “non-safety” information............................................................................. 15

2.1.6 LED information ................................................................................................................. 15

3Safety Precautions when using Safety Simplifier ..............................................16

3.1 Safety information regarding I/O and relay outputs of Safety Simplifier...............19

3.1.1 The relay outputs ............................................................................................................... 19

3.1.2 Solid-state transistor outputs ............................................................................................. 20

3.1.3 Safety inputs ...................................................................................................................... 22

4Technical data Safety Simplifier..........................................................................23

4.1 Safety parameters according to 610508 .............................................................25

5Dimensions and mounting ..................................................................................26

6Safety Simplifier principle layout ........................................................................29

7Electrical Installation ...........................................................................................30

7.1 Making IO Connections.......................................................................................31

8Bus communication via radio and/or CAN-bus..................................................32

9Calculating PFH-d values ....................................................................................32

10 Calculating reaction time.....................................................................................34

11 Electrical diagrams for recommended connections of machines, PB:s and

safety devices.....................................................................................................................35

11.1 E-stop, Combo PB with indication could be used for reset, open, start, stop etc .35

11.2 E-stop, Combo PB with indication for Reset, Open, Start and Stop, Selectors....35

SSP North AB 30/08/2018 Manual V2f

11.3 Two-hand connection according to EN 574.........................................................36

11.4 Safety devices with OSSD outputs such as: RFID- sensor/Safety Gate sensor,

Scanners, Light beams and light curtains .............................................................................36

11.5 Safety Gate limit switches..................................................................................37

11.6 Relay outputs for contactors with feedback for supervision/monitoring ..............37

11.7 Relay outputs for machines and safety devices .................................................38

11.8 OSSD outputs for machines, contactors and safety devices ..............................38

11.9 The LED display menu.......................................................................................39

11.9.1 Navigation.......................................................................................................................... 39

11.9.2 Sub-menus ........................................................................................................................ 40

11.9.3 The menus......................................................................................................................... 41

11.9.3.1 N (first level)....................................................................................................................... 41

11.9.3.2 N (second level)................................................................................................................. 41

11.9.3.3 I/O (first level) .................................................................................................................... 42

11.9.3.4 I/O (second level)............................................................................................................... 43

11.9.3.5 U (first level)....................................................................................................................... 43

11.9.3.6 U (second level)................................................................................................................. 44

11.9.3.7 U (third level) ..................................................................................................................... 44

11.9.3.8 M (first level) ...................................................................................................................... 45

11.9.3.9 M (second level) ................................................................................................................ 45

11.9.3.10 (Radio) (first level) ........................................................................................................ 46

11.9.3.11 (Radio) (second level) .................................................................................................. 46

11.9.3.12 CAN (first level).................................................................................................................. 47

11.9.3.13 CAN (second level)............................................................................................................ 47

11.9.3.14 CAN (third level) ................................................................................................................ 48

11.9.4 Fatal error mode ................................................................................................................ 48

11.9.4.1 Fatal error codes................................................................................................................ 48

11.9.5 Configuration mode ........................................................................................................... 50

11.10 LED Display quick reference...............................................................................51

11.10.1 First level menu information .............................................................................................. 51

11.10.2 Second level menu information ......................................................................................... 51

11.10.3 Third level menu information ............................................................................................. 52

12 Introduction of the software Simplifier Manager................................................54

13 Simplifier Manager ...............................................................................................54

13.1 Notice .................................................................................................................54

13.2 Windows 7 and 10 ..............................................................................................54

13.3 Installation ..........................................................................................................54

13.3.1 External Tools .................................................................................................................... 54

13.3.1.1 Compiler ............................................................................................................................ 54

13.3.1.2 PDF Viewer........................................................................................................................ 54

13.3.1.3 Windows 7 USB Driver ...................................................................................................... 54

13.4 User Interface Layout .........................................................................................55

13.4.1 The Main Menu.................................................................................................................. 55

13.4.2 The Toolbar........................................................................................................................ 58

13.4.3 Documents......................................................................................................................... 58

13.4.4 The Toolbox ....................................................................................................................... 58

13.4.5 The Inspector..................................................................................................................... 58

13.4.6 The Project Manager ......................................................................................................... 58

13.5 Making your first program ..................................................................................58

13.5.1 Creating a Project .............................................................................................................. 58

13.5.2 Hardware Configuration..................................................................................................... 59

13.5.3 The Logic Editor................................................................................................................. 60

13.5.4 Navigation in the logic graph ............................................................................................. 61

SSP North AB 30/08/2018 Manual V2f

13.5.5 The Goal of this example................................................................................................... 61

13.5.6 Adding Function Blocks ..................................................................................................... 62

13.5.7 Moving Blocks.................................................................................................................... 63

13.5.8 Deleting Blocks .................................................................................................................. 63

13.5.9 Selecting Multiple Blocks................................................................................................... 63

13.5.10 Copy, Cut, and Paste......................................................................................................... 63

13.5.11 Connections....................................................................................................................... 63

13.5.12 Removing Connections ..................................................................................................... 64

13.5.13 Final steps ......................................................................................................................... 65

13.5.14 Checking and Compiling.................................................................................................... 65

13.5.15 Saving and loading projects .............................................................................................. 65

13.6 Expanding the program.......................................................................................66

13.6.1 Local Memories ................................................................................................................. 66

13.6.2 Adding Local Memories to the program ............................................................................ 67

13.6.3 Managing Pages................................................................................................................ 68

13.6.4 Adding more nodes ........................................................................................................... 70

13.6.5 Programming Node 2 ........................................................................................................ 70

13.6.6 Sending Information via Radio/CAN.................................................................................. 71

13.7 Online Mode .......................................................................................................74

13.8 Downloading Programs.......................................................................................77

13.8.1 Entering serial numbers..................................................................................................... 78

13.8.2 Download via USB............................................................................................................. 78

13.8.3 Download via radio with Simplifier Monitor........................................................................ 78

13.9 Passwords .........................................................................................................78

13.9.1 Opening a password protected project file ........................................................................ 79

13.9.2 Comments ......................................................................................................................... 79

13.9.3 The Comment property...................................................................................................... 79

13.9.4 The Comment block .......................................................................................................... 79

13.10 Designing systems with Radio or CAN communication.......................................80

13.10.1 Radio and CAN communication safety Notice .................................................................. 80

13.10.2 Radio ................................................................................................................................. 81

13.10.3 Selecting radio channel for radio communication.............................................................. 83

13.10.4 Designing systems that communicate via radio ................................................................ 84

13.10.4.1 Radio quality ...................................................................................................................... 84

13.10.5 Global and CAN Memories................................................................................................ 86

13.10.5.1 Choosing Memory Numbers.............................................................................................. 86

13.10.5.2 Timeout and StartUp test................................................................................................... 86

13.10.5.3 Best Practices.................................................................................................................... 88

13.10.5.4 Controlling outputs directly via radio or CAN..................................................................... 88

13.11 Input Functions ...................................................................................................89

13.11.1 Input States........................................................................................................................ 90

13.11.2 Input signal types............................................................................................................... 91

13.11.2.1 VDC ................................................................................................................................... 91

13.11.2.2 OSSD................................................................................................................................. 91

13.11.2.3 0V ...................................................................................................................................... 91

13.11.2.4 A, B, C, D Pulses ............................................................................................................... 91

13.11.2.5 Inverted A, B, C, D Pulses ................................................................................................. 91

13.11.3 Input properties.................................................................................................................. 91

13.11.3.1 Enable ERROR Output...................................................................................................... 92

13.11.3.2 StartUp Test ....................................................................................................................... 92

13.11.3.3 Filter ON (ms) .................................................................................................................... 92

13.11.3.4 Filter OFF (ms) .................................................................................................................. 92

13.11.3.5 Enable Simultaneity........................................................................................................... 92

13.11.3.6 Simultaneity (ms) ............................................................................................................... 92

13.11.3.7 Enable Zero Time .............................................................................................................. 93

13.11.3.8 Zero Time (ms) .................................................................................................................. 93

SSP North AB 30/08/2018 Manual V2f

13.11.3.9 Comment ........................................................................................................................... 93

13.11.3.10 Terminal Count............................................................................................................... 93

13.11.3.11 Pin Properties ................................................................................................................ 93

13.12 Output Functions ................................................................................................94

13.12.1 ERROR State .................................................................................................................... 95

13.12.2 Feedback ........................................................................................................................... 96

13.12.3 Output signal types ............................................................................................................ 96

13.12.3.1 VDC ................................................................................................................................... 96

13.12.3.2 0V ...................................................................................................................................... 96

13.12.3.3 OSSD................................................................................................................................. 96

13.12.3.4 A, B, C, D Pulses ............................................................................................................... 96

13.12.3.5 Inverted A, B, C, D Pulses ................................................................................................. 96

13.12.4 The Advanced Output function block................................................................................. 96

13.13 Fatal Errors.........................................................................................................97

13.14 Logic...................................................................................................................97

13.14.1 Logical Loops..................................................................................................................... 97

13.14.2 Unsafe and safe signals .................................................................................................... 98

13.15 Serial Communication for status information.......................................................99

13.15.1 Serial Encoding.................................................................................................................. 99

13.15.1.1 Format ............................................................................................................................. 100

13.15.2 Serial Decoding ............................................................................................................... 101

13.15.3 Serial communication via I/O Terminals .......................................................................... 102

13.15.4 Configuration for communication with other PLCs .......................................................... 103

13.15.4.1 Receiving signals from other PLCs ................................................................................. 103

13.15.4.2 Sending signals to other PLCs ........................................................................................ 103

13.15.4.3 Function blocks for communication with PLCs................................................................ 103

14 Function Block Reference .................................................................................104

14.1 Inputs................................................................................................................105

14.1.1 Two-Hand Device ............................................................................................................ 105

14.1.2 Status Input...................................................................................................................... 107

14.1.3 Selector Switch ................................................................................................................ 108

14.1.4 Advanced Input................................................................................................................ 109

14.1.5 Door Sensor......................................................................................................................111

14.1.6 Light Barrier ......................................................................................................................112

14.1.7 E Stop ...............................................................................................................................114

14.1.8 Push Button ......................................................................................................................115

14.2 Output...............................................................................................................116

14.2.1 Advanced Output ..............................................................................................................116

14.2.2 OSSD Output....................................................................................................................117

14.2.3 Relay Output.....................................................................................................................118

14.2.4 Status Output....................................................................................................................119

14.3 Memory ............................................................................................................120

14.3.1 Memory............................................................................................................................ 120

14.3.2 Reference ........................................................................................................................ 121

14.4 Function............................................................................................................122

14.4.1 Delay OFF ....................................................................................................................... 122

14.4.2 Delay ON ......................................................................................................................... 123

14.4.3 Single Reset .................................................................................................................... 124

14.4.4 Sequence Reset .............................................................................................................. 125

14.4.5 Stepping........................................................................................................................... 126

14.4.6 Internal Input.................................................................................................................... 127

14.5 Logic.................................................................................................................129

14.5.1 NOT ................................................................................................................................. 129

SSP North AB 30/08/2018 Manual V2f

14.5.2 AND ................................................................................................................................. 129

14.5.3 NAND............................................................................................................................... 130

14.5.4 OR ................................................................................................................................... 132

14.5.5 NOR................................................................................................................................. 133

14.5.6 XOR ................................................................................................................................. 134

14.5.7 XNOR .............................................................................................................................. 135

14.6 Latches.............................................................................................................136

14.6.1 T Latch ............................................................................................................................. 136

14.6.2 SR Latch .......................................................................................................................... 137

14.7 Signal Generators.............................................................................................138

14.7.1 Logic 1 ............................................................................................................................. 138

14.7.2 Logic 0 ............................................................................................................................. 138

14.7.3 Square Wave ................................................................................................................... 139

14.7.4 1Hz Blink.......................................................................................................................... 139

14.7.5 5Hz Blink.......................................................................................................................... 140

14.8 Debug...............................................................................................................142

14.8.1 Fatal Error........................................................................................................................ 142

14.8.2 CAN OK ........................................................................................................................... 143

14.8.3 Link OK ............................................................................................................................ 143

14.9 Advanced .........................................................................................................144

14.9.1 Unsafe & Safe.................................................................................................................. 144

14.10 Non-Safety........................................................................................................144

14.10.1 Serial Encoder ................................................................................................................. 144

14.10.2 Serial Decoder ................................................................................................................. 146

14.11 Miscellaneous...................................................................................................147

14.11.1 Comment ......................................................................................................................... 147

SSP North AB 30/08/2018 Manual V2f

Safety Simplifier

Introduction | System overview | Features | Safety

Precautions | I/O and Relay outputs | Technical data |

Installation | Bus communication | PFH-d-values |

Reaction time | Electrical diagrams | LED display

SSP North AB 30/08/2018 Manual V2f

1 Introduction

1.1 This Manual

This manual regards the design and use of Safety Simplifier systems.

The manual is valid until new documentation is published. The latest original instructions are available

at www.sspn.se.

The manual explains the function, the special safety design to consider for a safety system, the

calculation of safety values for Safety Simplifier as an element of safety and how to connect and install

the product.

Programming, downloading, updating and debugging Simplifier Systems is described in the software

part of this manual.

1.1.1 Abbreviations

CAN

Controller Area Network

Diagnostic coverage

ESPE

Electro-sensitive Protective Device

EUC

Equipment Under Control

MRT

Mean Repair Time

OSSD

Output Signal Switching Device

PCB

Print Circuit Board

PFH

Mean probability of failure on demand

PFH-d

Mean probability of dangerous failure on demand

Performance Level

PLC

Programmable Logic Controller

SFF

Safe Failure Fraction

SIF

Safety Instrumented Function

SIL

Safety Integrity Level

SSPN

Safety System Products North AB

USB

Universal Serial Bus

1.1.2 Symbols

Different symbols are used throughout this manual and it is important to understand the meaning of

each.

Warning!

This symbol indicates a situation that presents immediate danger, and if not

prevented will result in serious injury or death.

Caution!

This symbol indicates a situation that presents potential danger, and if not prevented

may result in injury or death.

Notice!

This symbol indicates a potential danger, which may lead to damage to property and

equipment if not prevented.

Note

This symbol indicates useful tips and information.

1.2 Intended use of Safety Simplifier

The Safety Simplifier is intended for use in machinery covered by the Machinery Directive 2006/42/EC

and for safety circuits according to ISO 13849-1 and IEC 61508 up to PL e, Cat. 4 and SIL 3. See

technical data and CE declaration for Safety Simplifier for more information on intended use.

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