Pepperl+Fuchs VAA-2E-G4-SN User manual

FACTORY AUTOMATION
INSTRUCTION MANUAL
AS-Interface Safety at Work
VAA-2E-G4-SN
Version 1.2

With regard to the supply of products, the current issue of the following document is applicable:
The General Terms of Delivery for Products and Services of the Electrical Industry, as published by
the Central Association of the "Elektrotechnik und Elektroindustrie (ZVEI) e.V.",
including the supplementary clause "Extended reservation of title".
We at Pepperl+Fuchs recognize a duty to make a contribution to the future.
For this reason, this printed matter is produced on paper bleached without the use of chlorine.

VAA-2E-G4-SN
Table of content
Date of issue 20.05.2005
3
Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
Pepperl+Fuchs Group • Tel.: Germany [phone] • USA [phone] • Singapore [phone] • Internet http://www.pepperl-fuchs.com
Table of content
Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1 Symbols used in this document . . . . . . . . . . . . . . . . . . . . . . 5
2 Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Connections, displays and control elements . . . . . . . . . 11
5 Power supply of the modules . . . . . . . . . . . . . . . . . . . . . . 16
6 Assignment of the connections . . . . . . . . . . . . . . . . . . . . 17
6.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.2 Connection examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7 Operating the modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.1 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.2 Addressing of the modules . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.3 Operation of the AS-Interface safety input modules . . . . . . . 23
8 Transfer time of safety-related information . . . . . . . . . . . 24
9 Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
10 Summary of the requirements for categories . . . . . . . . . 24

VAA-2E-G4-SN
Declaration of conformity
Date of issue 20.05.2005
4Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
Pepperl+Fuchs Group • Tel.: Germany [phone] • USA [phone] • Singapore [phone] • Internet http://www.pepperl-fuchs.com
Declaration of conformity
The AS-Interface safety slave for mechanical switches and SN/S1N
proximity switches VAA-2E-G4-SN was developed and manufactured
taking into consideration applicable European standards and regulations.
The manufacturer of the product, Pepperl+Fuchs GmbH in
D-68301 Mannheim, has a certified quality assurance program in
accordance with ISO 9001.
A corresponding declaration of conformity may be
requested from the manufacturer.
Note
ISO9001

VAA-2E-G4-SN
Symbols used in this document
Date of issue 20.05.2005
5
Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
Pepperl+Fuchs Group • Tel.: Germany [phone] • USA [phone] • Singapore [phone] • Internet http://www.pepperl-fuchs.com
1 Symbols used in this document
This symbol indicates a warning about a possible danger.
Failure to observe this warning may result in consequences
ranging from personal injury to death or from damage of
equipment to destruction.
This symbol warns of a possible fault. Failure to observe the
instructions given in this warning may result in developing a
fault or even complete failure of the device and any facilities
or systems connected to it.
This symbol brings important information to your attention.
Warnin
g
Attention
Note

VAA-2E-G4-SN
Safety
Date of issue 20.05.2005
6Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
Pepperl+Fuchs Group • Tel.: Germany [phone] • USA [phone] • Singapore [phone] • Internet http://www.pepperl-fuchs.com
2 Safety
2.1 Intended use
Protection of operating personnel and the system is only
ensured if the AS-Interface safety slave is used in
accordance with the usage for which it is properly intended.
The device can only be operated by trained professionals in
accordance with the available instruction manual.
It must only be used as a safety-oriented slave on an AS-
Interface line with a corresponding AS-Interface safety
monitor in accordance with the intended purpose.
The requirements for external cabling and selection of
connected sensors are based on both the functionality to be
fulfilled and the required category (EN 954-1/ISO 13849-1).
This category is determined either with the aid of risk
analysis (for example in accordance with EN 1050) or from
a C standard. The category of the safety monitor must
correspond at least to the category required by the
application.
The correct design of the desired safety function also
depends on the circuitry and programming of the safety
monitor. This also applies to the desired safety response
after a code malfunction or failure. See also the
documentation for the safety monitor and the section of
connection assignment. The safety function (including all
safety-related sensors) must be verified before the unit is
placed in service for the first time.
Warnin
g

VAA-2E-G4-SN
Safety
Date of issue 20.05.2005
7
Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
Pepperl+Fuchs Group • Tel.: Germany [phone] • USA [phone] • Singapore [phone] • Internet http://www.pepperl-fuchs.com
2.2 General Safety Instructions
Any other type of operation than what is described in this
manual places the safety and functionality of the device and
systems connected to it in question. Only professionals
trained in electronics are permitted to connect the device
and to perform maintenance tasks while operation.
If malfunctions cannot be eliminated, the device must be
taken out of operation and protected from being
inadvertently placed back info operation.
Repairs may only be performed at the manufacturer's
facility.
No changes and operations made to the device are
permitted and will render any warrantee claim void.
The operator is responsible for adhering to local safety
regulations and directives.
Warnin
g
Note

VAA-2E-G4-SN
General information
Date of issue 20.05.2005
8Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
Pepperl+Fuchs Group • Tel.: Germany [phone] • USA [phone] • Singapore [phone] • Internet http://www.pepperl-fuchs.com
3 General information
The Actuator Sensor Interface (AS-Interface) is established as a system
for networking primarily binary sensors and actuators on the lowest level
of the automation hierarchy. The high number of installed systems, simple
handling and the reliable operating behaviour make AS-Interface
promising for the area of machine safety as well.
System features
When used according to the intended purpose in combination with an
appropriately programmed AS-Interface Safety at Work safety monitor,
the AS-Interface safety slave described here makes it possible to operate
sensorcontrolled personal protection equipment up through Category 4 in
accordance with EN 954-1.
The safety monitor must be sufficient for the requirements of the system
specification "Specification of secure AS-Interface transfer" Version 2.01
dated May 12, 2000.
The slave is equipped with two safety-related inputs. A mechanical switch
in accordance with EN/IEC 60947-5-1 or a proximity switch of
Pepperl+Fuchs with defined behavior in case of a failure in accordance
with the SN/S1N Specification and EN/IEC 60947-5-3, Type S
(corresponding to Category 3 in accordance with EN 954-1/ISO 13849-1)
can be connected to each of these.

VAA-2E-G4-SN
General information
Date of issue 20.05.2005
9
Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
Pepperl+Fuchs Group • Tel.: Germany [phone] • USA [phone] • Singapore [phone] • Internet http://www.pepperl-fuchs.com
Principle of operation
The slave generates a code sequence internally. This code sequence is
monitored by a safety monitor (additional bus participant) for the correct
sequence.
Transferring the code sequence is affected by the status of externally
connected sensors.
Voltage
reference
AS-Interface
chip
AS-Interface
bus
Switch 1
Sensor 1
Sensor 2
Code-
generator
Comparator
voltage
monitoring
Switch 2
Comparator
Comparator
Comparator
Comparator

VAA-2E-G4-SN
General information
Date of issue 20.05.2005
10 Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
Pepperl+Fuchs Group • Tel.: Germany [phone] • USA [phone] • Singapore [phone] • Internet http://www.pepperl-fuchs.com
Information regarding the activation of the connected sensors (for
example with Emergency Stop activated, SN proximity switch muted,
code transfer is interrupted) is transferred as follows:
:
Code words 0000, XX00 and 00XX cause the safety monitor to bring the
system to a safe state (for example in Emergency Stop) without reporting
a malfunction. If a bit of a code word deviates from the target code word,
the safety monitor switches the system into the safe state and indicates a
malfunction in the slave.
An input circuit consists of two dynamically controlled comparators that
affect 2 of the 4 data inputs of the AS-Interface interface component. One
input for SN/S1N proximity switches and one input for mechanical position
switches each are switched logically in series.
Example: An Emergency Stop with two separate circuits (Fault detection
behaviour according to Category 4) assigns both module channels.
Activated input channel Code Data bit D4, D3, D2, D1
1
2
1 and 2
None
XX00
00XX
0000
XXXX
1.1
S+1
1.3
S-1
2.1
S-2
2.3
S+2
VAA-2E-G4-SN

VAA-2E-G4-SN
Connections, displays and control elements
Date of issue 20.05.2005
11
Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
Pepperl+Fuchs Group • Tel.: Germany [phone] • USA [phone] • Singapore [phone] • Internet http://www.pepperl-fuchs.com
4 Connections, displays and control elements
Connections
The sensor connections consist of cage clamp terminals.
Either one mechanical position switch or a SN/S1N proximity switch may
be connected to each channel.
Connections
1.1 Mechanical position switch 1 + S+1
1.2 Reserved RES
1.3 Mechanical position switch 1 + S-1
2.1 Mechanical position switch 2 + S-2
2.2 Reserved RES
2.3 Mechanical position switch 2 + S+2
3.1 SN/S1N proximity switch 1 + S+1
3.2 Proximity switch 1 emulation EM1
3.3 SN/S1N proximity switch 1 - L-1
4.1 SN/S1N proximity switch 2 - L-2
4.2 Proximity switch 2 emulation EM2
4.3 SN/S1N proximity switch 2 + L+2
Terminals 1.2 and 2.2 are reserved and must not be
assigned (used).
Each of the unassigned terminals should be wired as
follows:
Note

VAA-2E-G4-SN
Connections, displays and control elements
Date of issue 20.05.2005
12 Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
Pepperl+Fuchs Group • Tel.: Germany [phone] • USA [phone] • Singapore [phone] • Internet http://www.pepperl-fuchs.com
2 mechanical position switches (or one two-channel position switch)
1 mechanical position switch
Channel 1 Channel 2
1.1
3.1
1.2
3.2
1.3
3.3
2.1
4.1
2.2
4.2
2.3
4.3
L+1 EM1 L-1 L-2 EM2 L+2
S+1 RES S-1 S-2 RES S+2
Channel 1 Channel 2
1.1
3.1
1.2
3.2
1.3
3.3
2.1
4.1
2.2
4.2
2.3
4.3
L+1 EM1 L-1 L-2 EM2 L+2
S+1 RES S-1 S-2 RES S+2

VAA-2E-G4-SN
Connections, displays and control elements
Date of issue 20.05.2005
13
Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
Pepperl+Fuchs Group • Tel.: Germany [phone] • USA [phone] • Singapore [phone] • Internet http://www.pepperl-fuchs.com
2 SN/S1N proximity switches
1 SN/S1N proximity switch
Channel 1 Channel 2
1.1
3.1
1.2
3.2
1.3
3.3
2.1
4.1
2.2
4.2
2.3
4.3
L+1 EM1 L-1 L-2 EM2 L+2
S+1 RES S-1 S-2 RES S+2
Channel 1 Channel 2
1.1
3.1
1.2
3.2
1.3
3.3
2.1
4.1
2.2
4.2
2.3
4.3
L+1 EM1 L-1 L-2 EM2 L+2
S+1 RES S-1 S-2 RES S+2

VAA-2E-G4-SN
Connections, displays and control elements
Date of issue 20.05.2005
14 Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
Pepperl+Fuchs Group • Tel.: Germany [phone] • USA [phone] • Singapore [phone] • Internet http://www.pepperl-fuchs.com
Short-circuit terminals
The corresponding short-circuit terminals (#119797) are included with
delivery and must be adapted to match the application.
State as supplied
SN jumper
Mechanical position switch jumper

VAA-2E-G4-SN
Connections, displays and control elements
Date of issue 20.05.2005
15
Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
Pepperl+Fuchs Group • Tel.: Germany [phone] • USA [phone] • Singapore [phone] • Internet http://www.pepperl-fuchs.com
Displays
I1 Yellow LED, switching state of input channel 1 (independent of the sensor
technology)
I2 Yellow LED, switching state of input channel 2 (independent of the sensor
technology)
FAULT Red LED, AS-Interface communication error
PWR Green LED, AS-Interface power
The yellow LEDs I1 and I2 indicate the status of the
dynamic safety code, which is forwarded on to the safety
motor. Since the frequency of the safety code decreases
with the number of AS-Interface slaves that are connected,
the LEDs may flicker noticeably. This is a normal operating
state.
Note

VAA-2E-G4-SN
Power supply of the modules
Date of issue 20.05.2005
16 Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
Pepperl+Fuchs Group • Tel.: Germany [phone] • USA [phone] • Singapore [phone] • Internet http://www.pepperl-fuchs.com
5 Power supply of the modules
The SN module is connected to the AS-Interface via the
electromechanical EMS interface.

VAA-2E-G4-SN
Assignment of the connections
Date of issue 20.05.2005
17
Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
Pepperl+Fuchs Group • Tel.: Germany [phone] • USA [phone] • Singapore [phone] • Internet http://www.pepperl-fuchs.com
6 Assignment of the connections
6.1 General information
The attachable Emergency Stop or position switches must be
implemented as normally closed contacts. Interfaces in accordance with
the SN specification (Pepperl+Fuchs) are provided for the safety sensors.
The slave contains two redundantly structured input channels that are
independent of each other.
6.2 Connection examples
The following system requirements must be fulfilled to achieve a safety
category:
Category 2
Testing
• Connection of two independent mechanical switches of Category 2:
Since a short-circuit over the switch is not detected, the switches and
safety slaves must be tested regularly. The test intervals must be
adapted to the application. There are no special requirements for
cables or switches.
Channel 1
Channel 2
1.1
S+1
1.3
S-1
2.1
S-2
2.3
S+2
VAA-2E-G4-SN

VAA-2E-G4-SN
Assignment of the connections
Date of issue 20.05.2005
18 Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
Pepperl+Fuchs Group • Tel.: Germany [phone] • USA [phone] • Singapore [phone] • Internet http://www.pepperl-fuchs.com
Category 3
The occurrence of an error must not result in loss of the safety function
(Category 3).
• Connection of two independent mechanical switches of Category 3:
Since a short-circuit over the switch is not detected, the lines between
the safety slave and the switch must be laid with protection against
mechanical damage. The switch must be positively driven so that it is
not possible for the contacts to become fused together.
The following functional devices can be used in this application while
operating the AS-Interface safety slave together with a safety monitor
type VAS-1A-K12-U or VAS-2A-K12-U to meet the requirements of
Category 3:
Two channels dependent
Two channels independent
VAA-2E-G4-SN
1.1
S+1
1.3
S-1
2.1
S-2
2.3
S+2
mechanical
protected
mechanical
protected
Channel 2
Channel 1

VAA-2E-G4-SN
Assignment of the connections
Date of issue 20.05.2005
19
Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
Pepperl+Fuchs Group • Tel.: Germany [phone] • USA [phone] • Singapore [phone] • Internet http://www.pepperl-fuchs.com
• Connection of two separate SN proximity switches of Category 3/S:
Since a short-circuit between the proximity switch circuits cannot
always be detected, they should not be connected by a common multi
wire cable, unless a cross-circuit between the two proximity switch
inputs can be excluded by protected wire laying or similar means.
The following function devices can be used in this application while
operating the AS-Interface safety slave together with a safety monitor of
types VAS-1A-K12-U or VAS-2A-K12-U to meet the requirements of
Category 3:
Two channels dependent
Two channels independent
+
+
VAA-2E-G4-SN
3.1
L+1
3.3
L-1
4.3
L+2
4.1
L-2
Separation
Channel 1
Channel 2

VAA-2E-G4-SN
Assignment of the connections
Date of issue 20.05.2005
20 Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
Pepperl+Fuchs Group • Tel.: Germany [phone] • USA [phone] • Singapore [phone] • Internet http://www.pepperl-fuchs.com
Category 4
The occurrence of an error must not result in loss of the safety function.
An accumulation of errors must not result in loss of the safety function
• Connection of two dependent mechanical switches:
Since the short-circuit over the switch is not detected, the lines
between the safety slave and the switch must either be laid with
protection or must be designed as a four-wire line. The switch must be
positively driven so that it is not possible for the contacts to become
fused together.
VAA-2E-G4-SN
1.1
S+1
1.3
S-1
2.1
S-2
2.3
S+2
Safety related circuit
mechanicaly
protected
mechanicaly
protected
Channel 2
Channel 1
VAA-2E-G4-SN
1.1
S+1
1.3
S-1
2.1
S-2
2.3
S+2
Safety related circuit
four-wire line