DOLD Safemaster Pro User manual

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Configurable safety system SAFEMASTER PRO
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C
CO ON NF FI IG GU UR RA AB BL LE E S SA AF FE ET TY Y S SY YS ST TE EM M
S
SA AF FE EM MA AS ST TE ER R P PR RO O
CONTENTS
INTRODUCTION ............................................................................................................................5
Contents of this handbook...........................................................................................................5
Important safety instructions .......................................................................................................5
Abbreviations and symbols .........................................................................................................6
Applicable standards...................................................................................................................6
OVERVIEW ....................................................................................................................................7
Control unit and I/O expansion modules......................................................................................8
Speed monitoring modules UG6917 ...........................................................................................8
Fieldbus modules........................................................................................................................8
BusExtender module UG6918.....................................................................................................9
PRODUCT COMPOSITION..........................................................................................................10
INSTALLATION............................................................................................................................10
Mechanical fastening.............................................................................................................10
Electrical connections ...............................................................................................................11
USB input..............................................................................................................................11
SAFEMASTER PRO Memory chip OA6911..........................................................................12
MULTIPLE LOAD function.................................................................................................12
RESTORE function ...........................................................................................................12
Connection terminals.............................................................................................................13
Instructions concerning connection cables. .......................................................................13
Connection terminals, control unit UG6911.10 ......................................................................14
Connection terminals, Input/Output module UG6916.10........................................................14
Connection terminals, input module UG6913.16 with 16 inputs.............................................15
Connection terminals, input module UG6913.12 with 12 inputs.............................................16
Connection terminals, input module UG6913.08 with 8 inputs...............................................16
Connection terminals, output module OSSD UG6912.04 with 4 OSSD.................................17
Connection terminals, output module OSSD UG6912.02 with 2 OSSD.................................17
Connection terminals, output module relay UG6912.28 with 2 OSSD ...................................18
Connection terminals, output module relay UG6912.14 with 1 OSSD ...................................18
Connection terminals, output module relay UG6914.04/000..................................................19
Connection terminals, output module relay UG6914.04/008..................................................19
Connection terminals, Speed monitoring module UG6917 ....................................................20
Encoder connections (RJ45) Speed monitoring module UG6917..........................................20
Connection terminals, BusExtender module UG6918............................................................20
EXAMPLE OF CONNECTION TO THE MACHINE CONTROL SYSTEM..............................21
Calculation of safety distance of an ESPE connected to SAFEMASTER PRO......................22
CHECKLIST AFTER INSTALLATION.......................................................................................22
PROJECT development DIAGRAM ............................................................................................23
SIGNALS......................................................................................................................................24
INPUTS.....................................................................................................................................24
MASTER ENABLE................................................................................................................24
NODE SEL............................................................................................................................24
PROXIMITY INPUT FOR SPEED CONTROLLER ................................................................24
RESTART_FBK ....................................................................................................................25
OUTPUTS.................................................................................................................................26
OUT STATUS .......................................................................................................................26
OUT TEST ............................................................................................................................26
OSSD (control unit UG6911.10, input/output module UG6916.10)........................................26
OSSD (output module OSSD UG6912.02, UG6912.04) with 2/4 OSSD................................26
SAFETY RELAYS (output module relay UG6912.14, UG6912.28 with 1/2 OSSD)................27
Characteristics of the output circuit....................................................................................27

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Internal contacts diagram..................................................................................................28
Example: connection static OSSD outputs from control unit UG6911.10
to output module
relay UG6912.14 with 1 OSSD
2)
....................................................................................28
Switching operation timing diagram...................................................................................29
TECHNICAL FEATURES.............................................................................................................30
GENERAL SYSTEM CHARACTERISTICS...............................................................................30
Safety level parameters.........................................................................................................30
General data .........................................................................................................................30
Enclosure..............................................................................................................................32
Mechanical dimensions.........................................................................................................32
Control unit UG6911.10 ............................................................................................................33
Input/output module UG6916.10 IO...........................................................................................34
Input modules UG6913.08 - UG6913.16 with 8 / 16 inputs........................................................35
Input modules UG6913.13 with 12 inputs..................................................................................35
Output modules OSSD UG6912.02 - UG6912.04 with 2/4 OSSD .............................................36
Output module relay UG6912.14 - UG6912.28 with 1/2 OSSD..................................................37
Output module relay UG6914.04/000 - UG6914.04/008............................................................38
Speed monitoring module UG6917...........................................................................................40
BusExtender module UG6918...................................................................................................41
Cable for BusExtender Module UG6918 ...................................................................................41
Visualisations..............................................................................................................................42
Control unit UG6911.10 ............................................................................................................42
Input/output module UG6916.10 ...............................................................................................43
Input modules UG6913.08, UG6913.12, UG6913.16, with 8, 12 and 16 inputs.........................44
Output module UG6912.02, UG6912.04, with 2 or 4 OSSD......................................................45
Output module relay UG6912.14/ UG6912.28 with 1/2 OSSD...................................................46
Output module relay UG6914.04/000, UG6914.04/008.............................................................47
Speed monitoring module UG6917/002, UG6917/x02, UG6917/xx2.........................................48
BusExtender module UG6918...................................................................................................49
Troubleshooting..........................................................................................................................50
Control unit UG6911.10 ............................................................................................................50
Input/output module UG6916.10 ...............................................................................................51
Input module UG6913.08, UG6913.12, UG6913.16 with 8, 12 or 16 inputs...............................52
Output modules UG6912.02 / UG6912.04 with 2/4 OSSD.........................................................53
Output module relay UG6914.04/000, UG6914.04/008.............................................................54
Speed monitoring module UG6917/002, UG6917/x02, UG6917/xx2.........................................55
BusExtender module UG6918...................................................................................................56
SAFEMASTER PRO DESIGNER SOFTWARE............................................................................57
Installing the software ...............................................................................................................57
PC HARDWARE requirements..............................................................................................57
PC SOFTWARE requirements ..............................................................................................57
How to install SAFEMASTER PRO DESIGNER....................................................................57
Fundamentals...........................................................................................................................58
Standard tool bar ......................................................................................................................59
Create a new project (configure the SAFEMASTER PRO system)........................................60
EDIT CONFIGURATION (composition of the various units) ..................................................61
Change user parameters.......................................................................................................61
OBJECTS - OPERATOR - CONFIGURATION tool bars .......................................................61
Creating the diagram (Figure 16) ..............................................................................................62
Use of mouse right button.........................................................................................................63
ON BLOCK INPUT / OUTPUT...........................................................................................63
ON BLOCK OPERATORS ................................................................................................63
ON Input / Output TERMINALS.........................................................................................63
ON CONNECTION (WIRES).............................................................................................63
Print logic diagram ....................................................................................................................64
Example of a project..............................................................................................................65

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Project validation.......................................................................................................................65
Project report ...........................................................................................................................66
Connect to SAFEMASTER PRO...............................................................................................67
Sending the configuration to the SAFEMASTER PRO ..........................................................67
Download a configuration from a SAFEMASTER PRO .........................................................67
Configuration LOG ................................................................................................................68
System composition..............................................................................................................68
Disconnecting System...............................................................................................................68
Error codes from SAFEMASTER PRO Designer.......................................................................69
MONITOR (I/O status in Textual)..............................................................................................70
MONITOR (I/O status in real time - textual - graphic)................................................................71
Password protection..................................................................................................................72
Level 1 password..................................................................................................................72
Level 2 password..................................................................................................................72
Password Change.................................................................................................................72
TESTING the system................................................................................................................73
OBJECT FUNCTION BLOCKS....................................................................................................74
OUTPUT OBJECTS..................................................................................................................74
OSSD (safety outputs) ..........................................................................................................74
RELAY (safety output)...........................................................................................................75
STATUS (signal output) ........................................................................................................76
FIELDBUS PROBE...............................................................................................................76
INPUT OBJECTS......................................................................................................................77
E-STOP (emergency stop)....................................................................................................77
E-GATE (safety gate device).................................................................................................78
SINGLE E-GATE (Safety gate device) ..................................................................................79
LOCK FEEDBACK................................................................................................................80
ENABLE (enable key) ...........................................................................................................81
ESPE (optoelectronic safety light curtain / laser scanner) .....................................................82
FOOTSWITCH (safety pedal)................................................................................................83
MOD-SEL (safety selector)....................................................................................................84
PHOTOCELL (safety photocell) ............................................................................................85
TWO-HAND (bimanual control).............................................................................................86
SENSOR...............................................................................................................................87
S-MAT (safety mat)...............................................................................................................88
SWITCH................................................................................................................................89
ENABLING GRIP SWITCH ...................................................................................................90
TESTABLE SAFETY DEVICE...............................................................................................92
SOLID STATE DEVICE.........................................................................................................93
FIELDBUS INPUT.................................................................................................................94
LLO, LL1...............................................................................................................................95
NETWORK IN.......................................................................................................................95
SPEED CONTROL TYPE FUNCTION BLOCKS.......................................................................96
SPEED CONTROL................................................................................................................96
WINDOW SPEED CONTROL...............................................................................................99
STAND STILL .....................................................................................................................101
STAND STILL AND SPEED CONTROL..............................................................................103
TEXT BLOCKS.......................................................................................................................105
COMMENTS.......................................................................................................................105
TITLE..................................................................................................................................105
OPERATOR FUNCTION BLOCKS ............................................................................................106
LOGICAL OPERATORS.........................................................................................................106
AND....................................................................................................................................106
NAND..................................................................................................................................106
NOT....................................................................................................................................106
OR ......................................................................................................................................107

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NOR....................................................................................................................................107
XOR....................................................................................................................................107
XNOR .................................................................................................................................108
LOGICAL MACRO ..............................................................................................................108
MULTIPLEXER...................................................................................................................109
MEMORY OPERATORS.........................................................................................................110
D FLIP FLOP (max number = 16)........................................................................................110
SR FLIP FLOP....................................................................................................................110
T FLIP FLOP.......................................................................................................................110
USER RESTART MANUAL (max number = 16 USER RESTART at all) .............................111
USER RESTART MONITORED (max number = 16 USER RESTART at all) ......................111
MACRO RESTART MANUAL (max number = 16 USER RESTART at all)..........................111
MACRO RESTART MONITORED (max number = 16 USER RESTART at all)...................112
GUARD LOCK OPERATORS.................................................................................................112
GUARD LOCK.................................................................................................................112
COUNTER OPERATORS.......................................................................................................114
COUNTER (max number = 16)........................................................................................114
TIMER OPERATORS (max number = 16)...............................................................................114
CLOCKING.........................................................................................................................114
MONOSTABLE...................................................................................................................115
MONOSTABLE_B...............................................................................................................116
PASSING MAKE CONTACT...............................................................................................117
DELAY................................................................................................................................117
DELAY LINE .......................................................................................................................118
MUTING OPERATORS (max number = 4)..............................................................................120
"Concurrent" MUTING.........................................................................................................120
MUTING “L” ........................................................................................................................121
"Sequential" MUTING..........................................................................................................122
MUTING “T” ........................................................................................................................123
MUTING OVERRIDE (max number = 4) .............................................................................123
Miscellany (special function Blocks)........................................................................................125
Serial output........................................................................................................................125
Network...............................................................................................................................126
RESET UG6911..................................................................................................................129
INTERPAGE IN / OUT ........................................................................................................129
RESET UG6911..................................................................................................................129
SPECIAL APPLICATIONS......................................................................................................130
Combination of Two Hand with other safety functions.........................................................131
SIMULATOR ..............................................................................................................................132
Schematic Simulation..........................................................................................................132
Graphic Simulation..............................................................................................................133
ACCESSORIES AND SPARE PARTS.......................................................................................137
Liability......................................................................................................................................138
Declaration of conformity.........................................................................................................139

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INTRODUCTION
Contents of this handbook
This handbook describes how to use the SAFEMASTER PRO programmable safety integrated
controller and its expansion units;
It includes:
• a description of the system
• method of installation
• connections
• signals
• troubleshooting
• use of the configuration software
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.

This symbol indicates an important instruction.
SAFEMASTER PRO 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.
Programming/configuration of the Mosaic is the sole responsibility of the installer or user.
The device must be programmed/configured in accordance with the application-specific risk
analysis and all the applicable standards.
Always test the complete system whenever new safety components are added (see the
"TESTING the system" section).
Reference should be made to the handbooks and the relative product and/or application
standards to ensure correct use of devices connected to the Mosaic within the specific
application.
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.

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Abbreviations and symbols
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
Applicable standards
SAFEMASTER PRO 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:
DIN EN 61131-2
Programmable controllers, part 2:
Equipment requirements and tests
DIN EN ISO 13849-1
Safety of machinery:
Safety related parts of control systems. General principles for design
DIN EN 61496-1
Safety of machinery: Electro-sensitive protective equipment. Part 1: General
requirements and tests.
DIN EN 61508-1
Functional safety of electrical/electronic/programmable electronic safety-
related systems: General requirements.
DIN EN 61508-2
Functional safety of electrical/electronic/programmable electronic safety-
related systems: Requirements for electrical/electronic/programmable
electronic safety-related systems.
DIN EN 61508-3
Functional safety of electrical/electronic/programmable electronic safety-
related systems: Software requirements.
DIN EN 61784-3
Digital data communication for measurement and control: Functional safety
fieldbuses.
DIN EN 62061
Safety of machinery. Functional safety of safety-related electrical, electronic
and programmable electronic control systems
Table 1

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OVERVIEW
SAFEMASTER PRO is a configurable safety system. It consists of a control unit
UG6911.10, which can be configured using the SAFEMASTER PRO DESIGNER graphic
interface, and a number of expansion modules connected to the control unit UG6911.10
via the proprietary IN-RAIL-BUS.
The control unit UG6911.10 can also be used as a stand-alone device. It has 8 safety
inputs and 2 independent programmable dual channel outputs.

The following expansions are available: input/output module (UG6916.10), input modules
(UG6913.08, UG6913.12 and UG6913.16), output modules OSSD (UG6912.02 and
UG6912.04) with dual channel semiconductor outputs, output modules relays with guided
contact safety relays (UG6914.04/000, UG6914.04/008, UG6912.14 und UG6912.28), and
several speed monitoring modules (UG6917/xx2).

The BusExtender module UG6918 allows a decentralized system with module connection at
great distance.

For diagnostic over the main fieldbus, following fieldbus modules are available:
UG6951 (CanOpen), UG6952 (PROFIBUS), UG6954 (PROFINET), UG6955 (Ethernet IP),
UG6956 (EtherCAT) and UG6957 (Universal Serial BUs).
For more detailed information, consult the fieldbus manual on the SAFEMASTER PRO Designer
CD-ROM
SAFEMASTER PRO 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 control unit UG6911.10 and a number of electronic
expansions that can range from 0 to a maximum of 14, not more than 4 of which of the
same type. There is no limit to the number of relay units that can be installed.
With 14 expansions, the system can have up to 128 inputs, 16 dual channel safety outputs
and 16 Status outputs. The CONTROL UNIT and its SLAVE units communicate via the 5-
pole IN-RAIL-BUS (proprietary bus), physically arranged on the rear panel of each unit.
Furthermore 8 inputs and 16 outputs probe controllable (by Fieldbus) are available.
The SAFEMASTER PRO DESIGNER 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 control unit UG6911.10 via USB
connection; the file resides in the control unit UG6911.10 and can also be saved on the
proprietary OA6911 memory chip (accessory). The configuration can therefore quickly be
copied to another control unit UG6911.10 unit.

The SAFEMASTER PRO system is certified to the maximum safety level envisaged by the
applicable industrial safety standards (SIL 3, SILCL 3, PL e, Cat. 4).

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Control unit and I/O expansion modules
• The control unit UG6911.10 and the I/O Expansion module UG6916.10 have 8 safety inputs, 2
independent programmable dual channel safety outputs (OSSD), 2 status outputs and 4 test
outputs to monitor the presence of short-circuits on the inputs.
• The input modules UG6913.08, UG6913.12 and UG6913.16 have respectively 8, 12 or 16
inputs. The modules UG6913.08 and UG6913.16 has 4 test outputs to monitor the presence of
short-circuits on the inputs. The module UG6913.12 has 8 test outputs and can control up to 4-
wire safety maps.
• The output modules UG6912.02 and UG6912.04 has respectively 2 or 4 independent
programmable dual channel safety outputs (OSSD) and 2 or 4 status outputs.
• The relays output modules UG6912.14 and UG6912.28 provide the system with 2 and 4 N.O.
guided contact safety relay outputs, respectively, with the related external relay feedback (N.C.
contact).
They are not connected over the proprietary IN-RAIL-BUS but directly to the OSSD outputs
from I/O modules with OSSD output.
• The relays output modules UG6914.04/000 and UG6914.04/008 are safety units provided with 4
independent safety relay outputs and the corresponding 4 inputs for the external feedback
contacts (EDM).
There are two possible output settings (configured using the SAFEMASTZER PRO Designer
configuration software).
• The speed monitoring modules UG6917 can be used to control the following (up to PLe):
-Two pairs of connection contacts (2 N.O. contacts per output with 2 corresponding feedback
inputs).
-Four independent single connection contacts (1 N.O. contact per output with 1
corresponding feedback input).
Only the UG6914.04/008 module has 8 programmable status outputs.
Speed monitoring modules UG6917
• The speed monitoring modules UG6917 can be used to control the following (up to PLe):
-Zero speed, Max. speed, Speed range;
-Direction of movement, rotation/translation;
Up to 4 speed thresholds can be set for each logic output (axis).
Each unit incorporates two logic outputs that can be configured using the SAFEMASTZER
PRO Designer configuration software and is thus capable of controlling up to two independent
axes.
Fieldbus modules
• The fieldbus modules UG6951, UG6952, UG6954, UG6955, UG6956 and UG6957 permit the
connection to the most commonly used industrial fieldbus systems for diagnostics and data
transmission.
UG6957 permits connection to devices with a USB port.