Mitsubishi MELSEC-WS0-CPU0 User manual

Safety Controller
User's Manual
-WS0-CPU0
-WS0-CPU1
-WS0-CPU3
-WS0-XTDI
-WS0-XTIO
-WS0-4RO

This document is protected by the law of copyright, whereby all rights established
therein remain with the company Mitsubishi Electric Corporation. Reproduction of this
document or parts of this document is only permissible within the limits of the legal
determination of Copyright Law. Alteration or abridgement of the document is not
permitted without the explicit written approval of the company Mitsubishi Electric
Corporation.
Precautions regarding warranty and specifications
MELSEC-WS series products are jointly developed and manufactured by Mitsubishi
and SICK AG, Industrial Safety Systems, in Germany.
Note that there are some precautions regarding warranty and specifications of
MELSEC-WS series products.
<Warranty>
The gratis warranty term of the product shall be for one (1) year after the date of
delivery or for eighteen (18) months after manufacturing, whichever is less.
The onerous repair term after discontinuation of production shall be for four (4) years.
Mitsubishi shall mainly replace the product that needs a repair.
It may take some time to respond to the problem or repair the product depending on
the condition and timing.
<Specifications>
General specifications of the products differ.
MELSEC-WS MELSEC-Q MELSEC-QS
Operating ambient temperature -25 to 55°C*1 0 to 55°C 0 to 55°C
Operating ambient humidity 10 to 95%RH 5 to 95%RH 5 to 95%RH
Storage ambient temperature -25 to 70°C -25 to 75°C -40 to 75°C
Storage ambient humidity 10 to 95%RH 5 to 95%RH 5 to 95%RH
*1 When the WS0-GCC100202 is included in the system, operating ambient temperature will
be 0 to 55 °C.
EMC standards that are applicable to the products differ.
MELSEC-WS MELSEC-Q, MELSEC-QS
EMC standards EN61000-6-2, EN55011 EN61131-2

1
SAFETY PRECAUTIONS 
(Read these precautions before using this product.)
Before using this product, please read this manual and the relevant manuals carefully and pay full
attention to safety to handle the product correctly.
In this manual, the safety precautions are classified into two levels: " WARNING" and " CAUTION".
Under some circumstances, failure to observe the precautions given under " CAUTION" may lead to
serious consequences.
Observe the precautions of both levels because they are important for personal and system safety.
Make sure that the end users read this manual and then keep the manual in a safe place for future
reference.
[Design Precautions]
WARNING
When the MELSEC-WS safety controller detects a fault in the external power supply or itself, it
turns off the outputs. Configure an external circuit so that the connected devices are powered off
according to the output status (off) of the MELSEC-WS safety controller. Incorrect configuration
may result in an accident.
When a load current exceeding the rated current or an overcurrent caused by a load short-circuit
flows for a long time, it may cause smoke and fire. To prevent this, configure an external safety
circuit, such as a fuse.
For safety relays, configure an external circuit using a device such as a fuse or breaker to protect
a short-circuit current.
When changing data and operating status, and modifying program of the running MELSEC-WS
safety controller from the PC, configure a safety circuit in the sequence program or external to the
MELSEC-WS safety controller to ensure that the entire system operates safely.
Before operating the MELSEC-WS safety controller, read the relevant manuals carefully and
determine the operating procedure so that the safety can be ensured.
Furthermore, before performing online operations for the MELSEC-WS safety controller from the
PC, determine corrective actions to be taken for communication errors caused by failure such as a
poor contact.
Create an interlock program using a reset button to prevent the MELSEC-WS safety controller
from restarting automatically after the safety function is activated and the safety controller turns off
the outputs.

2
CAUTION
Ensure that an entire system using the MELSEC-WS safety controller meets the requirements for
the corresponding safety category.
The life of safety relays in the safety relay output module depends on the switching condition
and/or load. Configure a system satisfying the number of switching times of the safety relays in
the module.
Do not install the communication cables together with the main circuit lines or power cables. Keep
a distance of 100 mm or more between them.
Failure to do so may result in malfunction due to noise.
If a mechanical switch such as a relay is connected to an input terminal of a safety I/O module,
consider contact bounce.
Observe the protective notes and measures.
Observe the following items in order to ensure proper use of the MELSEC-WS safety controller.
When mounting, installing and using the MELSEC-WS safety controller, observe the standards
and directives applicable in your country.
The national/international rules and regulations apply to the installation, use and periodic
technical inspection of the MELSEC-WS safety controller, in particular.
Machinery Directive 2006/42/EC
EMC Directive 2004/108/EC
Provision and Use of Work Equipment Directive 89/655/EC
Low-Voltage Directive 2006/95/EC
The work safety regulations/safety rules
Manufacturers and owners of the machine on which a MELSEC-WS safety controller is used
are responsible for obtaining and observing all applicable safety regulations and rules.
The notices, in particular the test notices of this manual (e.g. on use, mounting, installation or
integration into the existing machine controller), must be observed.
The test must be carried out by specialized personnel or specially qualified and authorized
personnel and must be recorded and documented and retraced at any time by third parties.
The external voltage supply of the device must be capable of buffering brief mains voltage
failures of 20 ms as specified in EN 60204.
The modules of the MELSEC-WS safety controller conform to Class A, Group 1, in accordance
with EN 55011. Group 1 encompasses all the ISM devices in which intentionally generated
and/or used conductor-bound RF energy that is required for the inner function of the device
itself occurs.
The MELSEC-WS safety controller fulfils the requirements of Class A (industrial
applications) in accordance with the “Interference emission” basic specifications.
The MELSEC-WS safety controller is therefore only suitable for use in an industrial environment
and not for private use.

3
[Installation Precautions]
WARNING
Do not use the MELSEC-WS safety controller in flammable gas atmosphere or explosive gas
atmosphere. Doing so may result in a fire or explosion due to such as an arc caused by switching
the relays.
CAUTION
Use the MELSEC-WS safety controller in an environment that meets the general specifications in
this manual. Failure to do so may result in electric shock, fire, malfunction, or damage to or
deterioration of the product.
Latch the module onto the DIN mounting rail. Incorrect mounting may cause malfunction, failure or
drop of the module.
To ensure full electromagnetic compatibility (EMC), the DIN mounting rail has to be connected to
functional earth (FE).
Ensure that the earthling contact is positioned correctly. The earthling spring contact of the
module must contact the DIN mounting rail securely to allow electrical conductivity.
Shut off the external power supply (all phases) used in the system before mounting or removing
the module.
Failure to do so may result in damage to the product.
Do not directly touch any conductive part of the module.
Doing so can cause malfunction or failure of the module.
The MELSEC-WS safety controller is only suitable for mounting in a control cabinet with at least
IP 54 degree of protection.
Failure to meet the installation method may cause the module to fail or malfunction due to the
deposition of dust or the adhesion of water.

4
[Wiring Precautions]
WARNING
Shut off the external power supply (all phases) used in the system before wiring.
Failure to do so may result in electric shock or damage to the product.
The system could start up unexpectedly while you are connecting the devices.
CAUTION
Individually ground the GND wires of the MELSEC-WS safety controller with a ground resistance
of 100 Ωor less.
Failure to do so may result in electric shock or malfunction.
Check the rated voltage and terminal layout before wiring to the module, and connect the cables
correctly.
Connecting a power supply with a different voltage rating or incorrect wiring may cause a fire or
failure.
Tighten the terminal screw within the specified torque range.
Undertightening can cause short circuit, fire, or malfunction. Overtightening can damage the
screw and/or module, resulting in drop, short circuit, or malfunction.
Prevent foreign matter such as dust or wire chips from entering the module.
Such foreign matter can cause a fire, failure, or malfunction.
Mitsubishi MELSEC-WS safety controllers must be installed in control cabinets. Connect the main
power supply to the MELSEC-WS safety controller through a relay terminal block.
Wiring and replacement of an external power supply must be performed by maintenance
personnel who is familiar with protection against electric shock. (For wiring methods, refer to
Chapter 7.)
Place the cables in a duct or clamp them.
If not, dangling cable may swing or inadvertently be pulled, resulting in damage to the module or
cables or malfunction due to poor contact.

5
[Startup and Maintenance Precautions]
WARNING
Do not touch any terminal while power is on.
Doing so will cause electric shock.
Shut off the external power supply (all phases) used in the system before cleaning the module or
retightening the terminal screws. Failure to do so may result in electric shock.
Tighten the terminal screw within the specified torque range. Undertightening can cause short
circuit, fire, or malfunction.
Overtightening can damage the screw and/or module, resulting in drop, short circuit, or
malfunction.
Safety-oriented devices must be suitable for safety related signals.
A function interruption of safety outputs results in a loss of the safety functions so that the risk of
serious injury exists.
Do not connect any loads that exceed the rated values of the safety outputs.
Wire the MELSEC-WS safety controller so that 24 V DC signals cannot unintentionally contact
safety outputs.
Connect the GND wires of the power supply to earth so that the devices do not switch on when
the safety output line is applied to frame potential.
Use suitable components or devices that fulfill all the applicable regulations and standards.
Actuators at the outputs can be wired single-channeled. In order to maintain the respective Safety
Integrity Level the lines have to be routed in such a manner that cross circuits to other live signals
can be excluded, for example by routing them within protected areas such as in a control cabinet
or in separate sheathed cables.

6
CAUTION
Before performing online operations (Force mode) for the running MELSEC-WS safety controller
from the PC, read the relevant manuals carefully and ensure the safety.
The online operations must be performed by qualified personnel, following the operating
procedure determined at designing.
Fully understand the precautions described in the Safety Controller Setting and Monitoring Tool
Operating Manual before use.
Do not disassemble or modify the modules.
Doing so may cause failure, malfunction, injury, or a fire.
Mitsubishi does not warrant any products repaired or modified by persons other than Mitsubishi or
FA Center authorized by Mitsubishi.
Shut off the external power supply (all phases) used for the MELSEC-WS safety controller before
mounting or removing the module.
Failure to do so may cause the module to fail or malfunction.
After the first use of the product, do not mount/remove the module from/to the DIN mounting rail,
and the terminal block to/from the module more than 50 times (IEC 61131-2 compliant)
respectively.
Exceeding the limit of 50 times may cause malfunction.
Before handling the module, touch a grounded metal object to discharge the static electricity from
the human body.
Failure to do so may cause the module to fail or malfunction.
[Disposal Precautions]
CAUTION
When disposing of this product, treat it as industrial waste.
Disposal of the product should always occur in accordance with the applicable country-specific
waste-disposal regulations (e.g. European Waste Code 16 02 14).

7
CONDITIONS OF USE FOR THE PRODUCT 
(1) Although MELCO has obtained the certification for Product's compliance to the international safety
standards IEC61508, ISO13849-1 from TUV Rheinland, this fact does not guarantee that Product will
be free from any malfunction or failure. The user of this Product shall comply with any and all
applicable safety standard, regulation or law and take appropriate safety measures for the system in
which the Product is installed or used and shall take the second or third safety measures other than
the Product. MELCO is not liable for damages that could have been prevented by compliance with
any applicable safety standard, regulation or law.
(2) MELCO prohibits the use of Products with or in any application involving, and MELCO shall not be
liable for a default, a liability for defect warranty, a quality assurance, negligence or other tort and a
product liability in these applications.
1) power plants,
2) trains, railway systems, airplanes, airline operations, other transportation systems,
3) hospitals, medical care, dialysis and life support facilities or equipment,
4) amusement equipments,
5) incineration and fuel devices,
6) handling of nuclear or hazardous materials or chemicals,
7) mining and drilling,
8) and other applications where the level of risk to human life, health or property are elevated.