EUCHNER MSC User manual

EN
Operating Instructions
Installation and use
Modular Safety Control System MSC

Operating Instructions
Modular Safety Control System MSC
2(Translation of the original operating instructions) 2121331-04-04/19
Contents
1. About this document............................................................................................. 7
1.1. Scope............................................................................................................................................7
1.2. Target group ..................................................................................................................................7
1.3. Key to symbols...............................................................................................................................7
1.4. Supplementary documents ..............................................................................................................7
1.5. Exclusion of liability and warranty.....................................................................................................7
2. Introduction.......................................................................................................... 8
2.1. Contents of this manual...................................................................................................................8
2.2. Important safety precautions ...........................................................................................................8
2.3. Abbreviations and symbols ..............................................................................................................9
2.4. Applicable standards.......................................................................................................................9
3. Overview ............................................................................................................ 10
4. Layout of the product ......................................................................................... 12
5. Installation ......................................................................................................... 13
5.1. Mechanical fastening.....................................................................................................................13
5.2. Calculation of the safety distance for an item of ESPE connected to the MSC system ........................14
5.3. Electrical connections ...................................................................................................................14
5.3.1. Information in relation to connecting cables .......................................................................15
5.3.1.1. Base unit MSC-CB ...............................................................................................15
5.3.2. USB connection ...............................................................................................................16
5.3.3. MSC configuration memory (M-A1).....................................................................................16
5.3.3.1. MULTIPLE LOAD function......................................................................................16
5.3.3.2. RESTORE function...............................................................................................17
5.3.3.3. Module FI8FO2....................................................................................................17
5.3.3.4. Module FI8..........................................................................................................18
5.3.3.5. Module FM4........................................................................................................18
5.3.3.6. Module FI16........................................................................................................19
5.3.3.7. Module AC-FO4 ...................................................................................................20
5.3.3.8. Module AC-FO2 ...................................................................................................20
5.3.3.9. Modules SPM0 – SPM1 – SPM2 ...........................................................................21
5.3.4. Encoder connections with RJ45 plug connector (SPM1, SPM2)............................................21
5.3.4.1. Module AZ-FO4 ...................................................................................................23
5.3.4.2. Module AZ-FO4O8 ...............................................................................................23
5.3.4.3. Module O8..........................................................................................................24
5.3.4.4. Module O16........................................................................................................24
5.3.4.5. Module AH-FO4SO8.............................................................................................25
5.3.5. Example for the connection of the MSC system to the machine control ................................25
5.4. Check list after installation.............................................................................................................26
6. Flow chart .......................................................................................................... 27
7. Signals............................................................................................................... 28
7.1. Inputs ..........................................................................................................................................28
7.1.1. MASTER_ENABLE ............................................................................................................28
7.1.2. NODE_SEL ......................................................................................................................28

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Operating Instructions
Modular Safety Control System MSC
EN
7.1.3. Proximity switch input on speed monitoring modules SPM...................................................29
7.1.4. RESTART_FBK .................................................................................................................30
7.2. Outputs........................................................................................................................................31
7.2.1. OUT_STATUS...................................................................................................................31
7.2.2. OUT_TEST ......................................................................................................................31
7.2.3. OSSD (MSC-CB, FI8FO2)...................................................................................................31
7.2.4. OSSD (AC-FO2, AC-FO4) ...................................................................................................32
7.2.5. OSSD (AH-FO4SO8)..........................................................................................................33
7.2.6. Safety relays (AZ-FO4, AZ-FO4O8) .....................................................................................34
8. Technical data .................................................................................................... 35
8.1. General system settings................................................................................................................35
8.1.1. Safety-related parameters ................................................................................................35
8.1.2. General data....................................................................................................................35
8.1.3. Housing ..........................................................................................................................36
8.1.4. Module MSC-CB ...............................................................................................................36
8.1.5. Module FI8FO2 ................................................................................................................36
8.1.6. Modules FI8 – FI16 ..........................................................................................................36
8.1.7. Module FM4 ....................................................................................................................36
8.1.8. Modules AC-FO2 – AC-FO4................................................................................................37
8.1.9. Module AH-FO4SO8..........................................................................................................37
8.1.10. Modules SPM0 – SPM1 – SPM2........................................................................................38
8.1.11. Modules AZ-FO4 – AZ-FO4O8 ............................................................................................38
8.1.12. Modules O8 – O16...........................................................................................................38
8.2. Mechanical dimensions .................................................................................................................39
8.3. Signals ........................................................................................................................................40
8.3.1. Base unit MSC-CB (Figure 14) ..........................................................................................40
8.3.2. Module FI8FO2 (Figure 15) ...............................................................................................41
8.3.3. Module FI8 (Figure 16) .....................................................................................................42
8.3.4. Module FM4 (Figure 17) ...................................................................................................43
8.3.5. Module FI16 (Figure 18) ...................................................................................................44
8.3.6. Module AC-FO2 (Figure 19) ..............................................................................................45
8.3.7. Module AC-FO4 (Figure 20) ..............................................................................................46
8.3.8. Module AZ-FO4 (Figure 21) ...............................................................................................47
8.3.9. Module AZ-FO4F08 (Figure 22) .........................................................................................48
8.3.10. Module O8 (Figure 23) .....................................................................................................49
8.3.11. Module O16 (Figure 24) ...................................................................................................50
8.3.12. Modules SPM0, SPM1, SPM2 (Figure 25) ..........................................................................51
8.3.13. Module AH-FO4SO8 (Figure 26) ........................................................................................52
8.4. Fault diagnostics ..........................................................................................................................53
8.4.1. Base unit MSC-CB (Figure 27) ..........................................................................................53
8.4.2. Module FI8FO2 (Figure 28) ...............................................................................................54
8.4.3. Module FI8 (Figure 29) .....................................................................................................55
8.4.4. Module FM4 (Figure 30) ...................................................................................................56
8.4.5. Module FI16 (Figure 31) ...................................................................................................57
8.4.6. Modules AC-FO2/AC-FO4 (Figure 32) ................................................................................58
8.4.7. Module AZ-FO4 (Figure 33) ...............................................................................................59
8.4.8. Module AZ-FO4O8 (Figure 34) ..........................................................................................60
8.4.9. Module O8 (Figure 35) .....................................................................................................61
8.4.10. Module O16 (Figure 36) ...................................................................................................62
8.4.11. Modules SPM0, SPM1, SPM2 (Figure 37) ..........................................................................63
8.4.12. Module AH-FO4SO8 (Figure 38) ........................................................................................64
9. Software EUCHNER Safety Designer.................................................................... 65
9.1. Installing the software ...................................................................................................................65
9.1.1. PC hardware – requirements .............................................................................................65
9.1.2. PC software – requirements..............................................................................................65

Operating Instructions
Modular Safety Control System MSC
4(Translation of the original operating instructions) 2121331-04-04/19
9.1.3. EUCHNER Safety Designer is installed as follows................................................................65
9.1.4. General ...........................................................................................................................66
9.1.5. Default toolbar.................................................................................................................66
9.1.6. Menu bar.........................................................................................................................67
9.1.7. Creating a new project (configuring MSCB system) .............................................................68
9.1.7.1. Changing configuration (layout of the various modules) ..........................................69
9.1.7.2. Editing user parameters ......................................................................................69
9.1.8. Tool windows for ITEMS, OPERATOR, CONFIGURATION .......................................................69
9.1.9. Preparing the diagram......................................................................................................70
9.1.9.1. Using the right mouse button ...............................................................................71
9.1.10. Example for a project.......................................................................................................72
9.1.10.1. Project validation.................................................................................................73
9.1.10.2. Printing project report .........................................................................................74
9.1.10.3. Connecting to MSC .............................................................................................75
9.1.10.4. Sending the configuration to the MSC system........................................................75
9.1.10.5. Downloading a configuration file (project) from MSC-CB..........................................75
9.1.10.6. Configuration log.................................................................................................75
9.1.10.7. System layout.....................................................................................................76
9.1.10.8. Disconnecting the system....................................................................................76
9.1.10.9. Monitor (real-time I/O status – text form)...............................................................77
9.1.10.10. Monitor (real-time I/O status – text – graphic) ........................................................78
9.1.11. Password protection ........................................................................................................79
9.1.11.1. Password level 1.................................................................................................79
9.1.11.2. Password level 2.................................................................................................79
9.1.11.3. Password change................................................................................................79
9.1.12. Checking the system........................................................................................................80
9.2. Item-specific function blocks..........................................................................................................81
9.2.1. Output items....................................................................................................................81
9.2.1.1. Safety outputs (OSSD).........................................................................................81
9.2.1.2. Safety output (SINGLE_OSSD)..............................................................................82
9.2.1.3. Signal output (STATUS) ........................................................................................84
9.2.1.4. Fieldbus sensor (FIELDBUS PROBE) ......................................................................85
9.2.1.5. Relay [RELAY] .....................................................................................................85
9.2.1.6. Usage of the automatic start (A) or manual start (B) (category 2) ............................87
9.2.2. Input items ......................................................................................................................89
9.2.2.1. Emergency stop (E-STOP) ....................................................................................89
9.2.2.2. Interlock (INTERLOCK) .........................................................................................91
9.2.2.3. Single-channel interlock (SINGLE INTERLOCK)........................................................93
9.2.2.4. Guard locking monitoring (LOCK FEEDBACK) .........................................................94
9.2.2.5. Key-operated switch (KEY LOCK SWITCH)..............................................................95
9.2.2.6. Optoelectronic safety light grid or safety laser scanner (ESPE) ...............................97
9.2.2.7. Safety footswitch (FOOTSWITCH)..........................................................................99
9.2.2.8. Operating mode selection (MOD-SEL)..................................................................101
9.2.2.9. Light barrier (PHOTOCELL).................................................................................102
9.2.2.10. Two-hand control (TWO-HAND) ............................................................................104
9.2.2.11. NETWORK_IN....................................................................................................105
9.2.2.12. SENSOR...........................................................................................................106
9.2.2.13. Pressure sensitive mat (S-MAT)...........................................................................108
9.2.2.14. Switch (SWITCH) ...............................................................................................110
9.2.2.15. Enabling switch (ENABLING SWITCH) ..................................................................111
9.2.2.16. Table – Mode 1 (device with 2 NO + 1 NC)..........................................................112
9.2.2.17. Table – Mode 2 (device with 2 NO + 1 NC)..........................................................112
9.2.2.18. Testable safety device (TESTABLE SAFETY DEVICE) .............................................113
9.2.2.19. Semiconductor output (SOLID STATE DEVICE) .....................................................115
9.2.2.20. Fieldbus input (FIELDBUS INPUT) ........................................................................116
9.2.2.21. LL0 – LL1.........................................................................................................116
9.2.2.22. Comments........................................................................................................116
9.2.2.23. Title .................................................................................................................116
9.3. Function blocks for speed monitoring...........................................................................................117

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2121331-04-04/19 (Translation of the original operating instructions)
Operating Instructions
Modular Safety Control System MSC
EN
9.3.1. Speed monitoring (SPEED CONTROL) ..............................................................................118
9.3.2. Speed range monitoring (WINDOW SPEED CONTROL).......................................................121
9.3.3. Standstill monitoring (STAND STILL) ................................................................................123
9.3.4. Speed/standstill monitoring (STAND STILL AND SPEED CONTROL) ....................................125
9.4. Function blocks in the "OPERATOR" window...................................................................................128
9.4.1. Logical operators...........................................................................................................128
9.4.1.1. AND .................................................................................................................128
9.4.1.2. NAND...............................................................................................................128
9.4.1.3. NOT .................................................................................................................128
9.4.1.4. OR ...................................................................................................................129
9.4.1.5. NOR.................................................................................................................129
9.4.1.6. XOR .................................................................................................................129
9.4.1.7. XNOR ...............................................................................................................130
9.4.1.8. Logical macro...................................................................................................130
9.4.1.9. MULTIPLEXER ...................................................................................................131
9.4.2. Memory operators .........................................................................................................132
9.4.2.1. D FLIP FLOP (max. number = 16) .......................................................................132
9.4.2.2. T FLIP FLOP (max. number = 16)........................................................................132
9.4.2.3. SR FLIP FLOP (max. number = 16) .....................................................................132
9.4.2.4. Manual restart (USER RESTART MANUAL)
(max. number = 16, including other RESTART operators) ....................................133
9.4.2.5. Monitored restart (USER RESTART MONITORED)
(max. number = 16, including other RESTART operators) ....................................133
9.4.2.6. Macro manual restart (MACRO RESTART MANUAL)
(max. number = 16, including other RESTART operators) ....................................133
9.4.2.7. Macro monitored restart (MACRO RESTART MONITORED)
(max. number = 16, including other RESTART operators) ....................................134
9.4.3. Guard lock logic (GUARD LOCK) (max. number = 4)..........................................................135
9.4.3.1. GUARD LOCK....................................................................................................135
9.4.4. COUNTER operators ......................................................................................................137
9.4.4.1. Counter (COUNTER) (max. number = 16) ............................................................137
9.4.5. TIMER operators (max. number = 32)..............................................................................139
9.4.5.1. MONOSTABLE...................................................................................................139
9.4.5.2. MONOSTABLE_B...............................................................................................140
9.4.5.3. Passing make contact (PASSING MAKE CONTACT)...............................................141
9.4.5.4. Delay (DELAY) ...................................................................................................142
9.4.5.5. Delay line (DELAY LINE) .....................................................................................143
9.4.5.6. Clock generation (CLOCKING) ............................................................................144
9.4.6. The MUTING function......................................................................................................145
9.4.7. MUTING operators (max. number = 4) .............................................................................145
9.4.7.1. Simultaneous muting (MUTING "Con")..................................................................145
9.4.7.2. MUTING "L".......................................................................................................147
9.4.7.3. "Sequential" MUTING..........................................................................................148
9.4.7.4. MUTING "T".......................................................................................................150
9.4.7.5. MUTING OVERRIDE............................................................................................151
9.5. Other function blocks ..................................................................................................................153
9.5.1. Serial output (SERIAL OUTPUT) (max. number = 4) ...........................................................153
9.5.1.1. Network (NETWORK) (max. number = 1) .............................................................154
9.5.1.2. Reset (RESET)...................................................................................................158
9.5.1.3. Interpage In/Out................................................................................................158
9.5.2. Special applications .......................................................................................................159
9.5.2.1. Output delay with manual operating mode ...........................................................159
9.6. Simulator ...................................................................................................................................160
9.6.1. Schematic simulation .....................................................................................................161
9.6.2. Administration of the graphic simulation...........................................................................163
9.6.2.1. Application example for the graphic simulation ....................................................166
9.6.3. MSC error codes ...........................................................................................................168
9.6.4. Error log file ..................................................................................................................169

Operating Instructions
Modular Safety Control System MSC
6(Translation of the original operating instructions) 2121331-04-04/19
10. Ordering information and accessories............................................................... 170
11. Inspection and service ...................................................................................... 170
12. Service ............................................................................................................ 170
13. Declaration of conformity ................................................................................. 170

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Operating Instructions
Modular Safety Control System MSC
EN
1. About this document
1.1. Scope
These operating instructions are valid for the Modular Safety Control System MSC. These operating instructions and any
brief instructions enclosed form the complete user information for your device.
1.2. Target group
Design engineers and installation planners for safety devices on machines, as well as setup and servicing staff possessing
special expertise in handling safety components.
1.3. Key to symbols
Symbol/depiction Meaning
Printed document
Internet
www Document is available for download at www.euchner.de
DANGER
WARNING
CAUTION
Safety precautions
Danger of death or severe injuries
Warning about possible injuries
Caution slight injuries possible
NOTICE
Important!
Notice about possible device damage
Important information
Tip! Tip/useful information
1.4. Supplementary documents
The overall documentation for this device consists of the following documents:
Document title (document number) Contents
Operating Instructions Safety Relays and Control Systems MSC
(2121331) This document
Internet
www
Possibly brief instructions enclosed Item-specific information about deviations or additions
Internet
www
Important!
Always read all documents to gain a complete overview of safe installation, setup and use of the
device. The documents can be downloaded from www.euchner.de. For this purpose enter the doc.
no. in the search box.
1.5. Exclusion of liability and warranty
In case of failure to comply with the conditions for correct use stated above, or if the safety regulations are not followed,
or if any servicing is not performed as required, liability will be excluded and the warranty void.

Operating Instructions
Modular Safety Control System MSC
8(Translation of the original operating instructions) 2121331-04-04/19
2. Introduction
2.1. Contents of this manual
The usage of the programmable safety system MSC and the related extension modules ("SLAVES") is described in this manual.
It covers:
ÌSystem description
ÌInstallation procedure
ÌConnections
ÌSignals
ÌTroubleshooting
ÌUsage of the configuration software
2.2. Important safety precautions
WARNING
ÌMSC achieves the following safety levels: SIL 3, SILCL 3, PL e, cat. 4, type 4 as per the applicable
standards.
However the final SIL and PL safety categories for the application are dependent on the number of
safety components, their parameters and the connections made, as per the risk analysis.
ÌRead the section "Applicable standards" carefully.
ÌUndertake a comprehensive risk analysis to determine the corresponding safety level for the spe-
cific application based on the applicable standards.
ÌThe programming/configuration of the MSC system is the sole responsibility of the installer or the
user.
ÌThis programming/configuration must correspond to the application-specific risk analysis and all
applicable standards.
ÌAfter programming/configuration and installation of the MSC system and all related devices, a
complete application safety check must be undertaken (see section “Checking the system” on
page 80).
ÌAfter adding new safety components, the complete system must always be checked (see section
“Checking the system” on page 80).
ÌEUCHNER is not liable for these processes or for the related risks.
ÌTo ensure the correct usage of the modules connected to the MSC system within the stated appli-
cation, reference should be made to the operating instructions/manuals and the related product
and/or application standards.
ÌThe ambient temperature in the installation location for the system must match the operating tem-
perature parameters stated on the product label and in the specifications.
ÌIn the event of safety-related questions, if necessary contact the responsible safety authorities in
your country or the responsible specialist association.

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2121331-04-04/19 (Translation of the original operating instructions)
Operating Instructions
Modular Safety Control System MSC
EN
2.3. Abbreviations and symbols
Abbreviations and symbols
M-A1 Memory card for MSC-CB (accessory)
MSCB Proprietary bus for extension modules
EUCHNER
Safety Designer (SWSD) MSC configuration software for Windows
OSSD Output Signal Switching Device
MTTFDMean Time to Dangerous Failure
PL Performance Level (according to EN ISO 13849-1)
PFHDProbability of Dangerous Failure per Hour
SIL Safety Integrity Level (according to EN 61508)
SILCL Safety Integrity Level Claim Limit (according to EN 62061)
SW Software
2.4. Applicable standards
MSC complies with the following European directives:
Ì2006/42/EC "Machinery Directive"
Ì2014/30/EU "EMC Directive"
Ì2006/95/EC "Low Voltage Directive"
and corresponds to the following standards:
EN IEC 61131-2 Programmable controllers – Part 2: Equipment requirements and tests
EN ISO 13489-1 Safety of machinery. Safety related parts of control systems. General principles for design
EN IEC 61496-1 Safety of machinery. Electro-sensitive protective equipment. Part 1: General requirements and tests.
EN IEC 61508-1 Functional safety of electrical/electronic/programmable electronic safety-related systems: General requirements.
EN IEC 61508-2 Functional safety of electrical/electronic/programmable electronic safety-related systems: Requirements for electrical/electronic/programma-
ble electronic safety-related systems.
EN IEC 61508-3 Functional safety of electrical/electronic/programmable electronic safety-related systems: Software requirements
EN IEC 61784-3 Industrial communication networks: Functional safety fieldbuses
EN IEC 62061 Safety of machinery. Functional safety of safety-related electrical, electronic and programmable electronic control systems
Table 1: Applicable standards

Operating Instructions
Modular Safety Control System MSC
10 (Translation of the original operating instructions) 2121331-04-04/19
3. Overview
MSC is a modular safety system and comprises a base unit (MSC-CB), which can be configured using the graphic user
interface in EUCHNER Safety Designer and various extension modules that can be connected to MSC-CB via the proprietary
MSCB bus.
The base unit MSC-CB, which can also be used as a standalone device, has 8 safety inputs and 2 separate, programmable
dual-channel outputs.
Important!
ÌThe following extension modules are available: FI8FO2 with inputs and outputs, FI8, FM4, FI16,
SPM0,SPM1 and SPM2 only with inputs, AC-FO2 and AC-FO4 only with outputs, also O8, O16
and AH-FO4SO8 with monitoring outputs, as well as AZ-FO4 and AZ-FO4O8 with positively driv-
en safety relays. Extension modules for connection to the commonest industrial fieldbus systems
for diagnostics are also available: CE-PR (PROFIBUS), CE-CO (CanOpen), CE-DN (DeviceNet),
CE-EI (ETHERNET/IP), CE-EI2 (ETHERNET/IP-2PORT), CE-PN (Profinet), CE-EC (ETHERCAT), CE-
MR (Modbus RTU), CE-MT (Modbus/TCP).
MSC makes it possible to monitor the following safety sensors and command switches:
Optoelectronic sensors (safety light grids, scanners, safety light barriers), mechanical switches, safety mats, emergency
stop buttons, two-hand controls, which are all managed via one single, flexible device that can be expanded.
The system is only allowed to comprise a single base unit MSC-CB and a maximum of 14 electronic extension modules, of
which not more than four are allowed to be of the same type.
With 14 extension modules the system can have up to 128 inputs, 16 dual-channel safety outputs and 32 status outputs.
The modules AZ-FO4/AZ-FO4O8 have four 1-channel outputs. The greater the number of AZ-FO4/AZ-FO4O8 modules used,
the fewer dual-channel outputs are available.
The communication between the base unit (MASTER) and the extension modules (SLAVES) is via the MSCB 5-way bus (pro-
prietary bus from EUCHNER) on the rear side of every module.
In addition, 8 inputs and 16 outputs are available and can be controlled using sensors (via the fieldbus).
The number of inputs in the system can be increased using the MSC extension modules FI8, FI16 and FM4 such that more
external devices can be connected. FM4 also provides 8 outputs of type OUT_TEST.
With the extension modules AC-FO2 and AC-FO4, the MSC system has 2 or 4 OSSD pairs to control devices connected
downstream of the MSC system.
AH-FO4SO8 is a safety module with 4 single-channel high-current safety outputs and 4 associated inputs for external device
monitoring contacts (EDM). The module is also equipped with 8 programmable signal outputs.
FI8FO2 has 8 inputs and 2 OSSD outputs.
The extension modules in the CE series make it possible to connect the commonest industrial fieldbus systems for diagnos-
tics and data transmission. CE-EI, CE-EI2, CE-PN, CE-MT and CE-EC also have an Ethernet connection. CE-US makes
it possible to connect devices with a USB port.
CE-CI1, CE-CI2 are modules in the MSC family that make it possible to connect MSC-CB to extension modules further
away (<50 m). Two CE-CI modules are connected at the required distance using a screened cable (can be ordered from
EUCHNER or as per the table for the cable technical data).
The following can be monitored (up to PLe) using the extension modules for speed monitoring SPM0, SPM1 and SPM2:
ÌStandstill, overspeed, speed range
ÌMovement direction, rotary motion/ linear movement
Up to 4 speed limits can be defined for each logical output (axis).
Each module has two logical outputs that can be configured via EUCHNER Safety Designer. In this way up to two independent
axes can be monitored.