Pepperl+Fuchs VAA-2E2A-KE1-S/E2 User manual

FACTORY AUTOMATION
Instruction Manual
AS-Interface Safety at Work
VAA-2E2A-KE1-S/E2
Version 1.0

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,
published by the Central Association of the "Elektrotechnik und Elektroindustrie (ZVEI) e.V.
in their most recent version as well as the supplementary clause: "Extended reservation of title".
We at Pepperl+Fuchs recognise 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-2E2A-KE1-S/E2
Table of contents
S
ubject 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
Date of Issue 2003-11-28
1
1 Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
2 Symbols used in this document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1.1 Non-secure outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1.2 Requirements for the safety monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1.3 Requirements for wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1.4 Switches or sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Transfer time of the safety-relevant information . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 PFD-calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 Working principles of the module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Safety related inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2 Non-secure outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5 Connections and displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
5.1 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.2 Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6 Interface properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
6.1 AS-Interface, auxiliary energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.2 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.2.2 Safety category . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.2.3 Cross fault monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.3 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7.1 Requirements for configuring the safety monitor . . . . . . . . . . . . . . . . . . . . . . 13
7.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7.3 Addressing modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7.4 Function test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7.5 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
8 Operation of AS-Interface safety modules . . . . . . . . . . . . . . . . . . . . . .14
9 Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
A Application examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
A.1 Category 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
A.2 Category 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
A.3 Category 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
B Summery of the requirements for categories . . . . . . . . . . . . . . . . . . . 20

VAA-2E2A-KE1-S/E2
Declaration of conformity
S
ubject 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
Date of Issue 2003-11-28
2
1 Declaration of conformity
The AS-Interface safety module VAA-2E2A-KE1-S/E2 with 2 safety-related inputs for
mechanical switches and 2 non-safety related outputs was developed and manufac-
tured in observance of applicable European standards and regulations.
The manufacturer of the product, Pepperl+Fuchs GmbH in D-68307 Mannheim, has
a certified quality assurance program in accordance with ISO 9001.
A corresponding declaration of conformity can be requested from the
manufacturer.
ISO 9001

VAA-2E2A-KE1-S/E2
Symbols used in this document
S
ubject 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
Date of Issue 2003-11-28
3
2 Symbols used in this document
This symbol warns of danger.
In the event the warning is ignored, the consequences may range from
personal injury to death of persons or from damage to destruction of
equipment.
This symbol warns of a possible fault.
Failure to observe may result in damage to the device or systems and
installations connected to it up to and including compete lack of proper
functionality.
This symbol brings important information to your attention.

VAA-2E2A-KE1-S/E2
Safety
S
ubject 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
Date of Issue 2003-11-28
4
3 Safety
3.1 Intended use
The AS-Interface safety module described here, when used properly in combination
with an AS-Interface safety monitor programmed appropriately, allows for operation
of sensor-controlled devices for protection of persons up to Category 4 according to
EN 954-1 or up to SIL 3 according to EN/IEC 61508.
3.1.1 Non-secure outputs
3.1.2 Requirements for the safety monitor
The module must only be used in a proper manner as a safety-related slave on an
AS-Interface line with the corresponding AS-i safety monitor. The AS-Interface safety
monitor must meet the requirements of the system specification "Specification of safe
AS-Interface transfer" Version 2.01 dated May12, 2000.
All components must be evaluated for functionality according to this safety standard
for the evaluation of a safety-related function.
The correct execution of the desired safety function also depends on the wiring and
programming of the safety monitor. This also applies to the desired safety response
after a code malfuntion or failure. See also the documentation for the safety monitor.
The safety function (including all safety-related sensors) must be tested before it is
placed in service the first time.
3.1.3 Requirements for wiring
The requirements of EN/IEC 60204-1 (or similar standard) must always be observed.
The requirements for external wiring and the selection of sensors that are connected
are based on both the functionality to be provided as well as the required category
(EN 954-1/ISO 13849-1 or EN/IEC 61508). The category can be determined by
means of a risk analysis (for example as described by EN1050) or can be derived
from a C standard. The category or SIL of the safety monitor must at least correspond
to the category or SIL required by the application.
Protection of operating personnel and the system is not ensured if the
module is not used in accordance with its intended purpose.
The outputs must not be used for safety-related functions.

VAA-2E2A-KE1-S/E2
Safety
S
ubject 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
Date of Issue 2003-11-28
5
3.1.4 Switches or mechanical contacts
The switches must either be of the forced-opening variety or must have a defined fail-
ure behaviour. Combinations of switches that ensure comparable safety (error behav-
iour analysis) can be used.
3.2 General safety instructions
The module can only be operated by trained professionals in accordance with the
available instruction manual (see section 8).
Connecting modules and performing maintenance tasks while the devices are con-
nected to a power source must only be performed by trained electrical specialists.
If malfunctions cannot be eliminated, the module must be taken out of operation and
protected from being inadvertently placed back in operation.
Repairs must only be performed directly by the manufacturer.
Making changes to or tampering with the device is not permitted and will render the
warranty void.
When operating the device, care must be taken to ensure that the requirements for
installation of a housing in IP20 are also maintained.
3.3 Transfer time of the safety-relevant information
The transfer time depends essentially on the monitor. The corresponding documen-
tation and the switch-off times of the actuators must be observed.
3.4 PFD-calculation
To calculate the PFD (probability of failure on demand) of a safety-related function, all
PFD values of all components used in this function must be taken into consideration.
The AS-Interface safety slave does not make any significant contribution to the PFD
or PDH (probability of dangerous failure per hour) of the overall system.
For the PFD or PFH-values of other components, especially of the safety monitor,
please refer to the relevant documentation.
Any type of operation other than what is described in the instructions
places the safety and functionality of the module and connected sys-
tems in question.
The plant management is responsible for heeding local safety regula-
tions.

VAA-2E2A-KE1-S/E2
Working principles of the module
S
ubject 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
Date of Issue 2003-11-28
6
4 Working principles of the module
4.1 Safety related inputs
The module generates a code sequence internally. This code sequence is monitored
by a safety monitor (an additional bus station) for the correct sequence.
.
Figure 4.1: Code generation
The transfer of the code sequence is affected by the status of the externally connect-
ed mechanical switch.
Information on the activation of the connected mechanical switches (e. g. for emer-
gency stop button activated, code transfer interrupted) is transferred as follows:
Code words 0000, XX00 and 00XX cause the safety monitor to bring the system to a
secure state (for example with the emergency stop button) without reporting a mal-
function. If a bit of a code word deviates from the nominal code word, the safety mon-
itor switches the system into the secure state and signals a malfunction of the slave.
The two input channels of the safety module are independent of each other. Param-
eters can be set in the safety monitor for monitoring the synchronicity of the two inputs
for two-channel applications. For more information, see also the application examples
in Appendix A.
Activated input channel Code
DI3 DI2 DI1 DI0
1XX00
200XX
1 and 2 0 0 0 0
none X X X X

VAA-2E2A-KE1-S/E2
Working principles of the module
S
ubject 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
Date of Issue 2003-11-28
7
.
Figure 4.2: Example: An emergency off button with two separate circuits is assigned to both module inputs.
4.2 Non-secure outputs
The outputs are designed according to the AS-Interface standard. These are switched
to positive potential (PNP technology).
The state of the outputs is set according to the operating mode, which in turn is ad-
justed by parameter on the AS-Interface master, either switched by the master or de-
rived from the states of the inputs. For a more detailed description, see section 6.3.

VAA-2E2A-KE1-S/E2
Connections and displays
S
ubject 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
Date of Issue 2003-11-28
8
5 Connections and displays
.
5.1 Connections
Safety related inputs Outputs and others
Designation Description Designation Description
S1+ Mechanical switch 1+ O1 Output 1+
S1+- Mechanical switch 1- O-1 Output 1-
S2+ Mechanical switch 2+ O2 Output 2+
S2- Mechanical switch 2- O-2 Output 2-
ASi+ AS-Interface +
ASi- AS-Interface -
AUX+ Auxiliary power UAUX +
AUX- Auxiliary power UAUX -
++
1
1
2
2
S
FAULT
AUX
PWR
ADDR
OUT
01
AS-i AS-i
01 02
AUX AUX
02
S
S+1 S-1 S+2 S-2

VAA-2E2A-KE1-S/E2
Connections and displays
S
ubject 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
Date of Issue 2003-11-28
9
5.2 Displays
Designation Description Designation Description
S1 Yellow LED,
switching state of input
circuit 1
PWR Green LED,
AS-Interface power
S2 Yellow LED,
switching state of input
circuit 2
FAULT Red LED,
AS-Interface communica-
tion error
AUX Green LED,
auxiliary power
OUT1 Yellow LED,
switching state of
output 1, UAUX + switched
through with active LED
OUT2 Yellow LED,
switching state of
output 2, UAUX + switched
through with active LED

VAA-2E2A-KE1-S/E2
Interface properties
S
ubject 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
Date of Issue 2003-11-28
10
6 Interface properties
6.1 AS-Interface, auxiliary energy
In case of the KE1-series all interfaces are connected via removable terminals. Thus
also AS-Interface and auxiliary energy. The cable has to meet the minimum require-
ments for AS-Interface (e.g. AS-Interface flat band cable, VAZ-FK-S-YE for AS-Inter-
face and VAZ-FK-S-BK for auxiliary energy).
6.2 Inputs
6.2.1 General
In this case the switches are also connected to removable terminals. One or more me-
chanical switches, switched in series, can be connected per channel.
.
Figure 6.1: 2 mechanical switches (or one two-channel switch)
.
Figure 6.2: 1 mechanical switch
If only one single-channel switch is used, input 1 must be used for this purpose. If in-
put 2 is to remain unswitched, it must be jumpered.

VAA-2E2A-KE1-S/E2
Interface properties
S
ubject 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
Date of Issue 2003-11-28
11
6.2.2 Safety category
The module contains two input channels independent of each other and redundantly
structured that individually meet the requirements of Category 4 according to
EN 954-1.
6.2.3 Cross fault monitoring
The inputs are monitored for cross fault with each other. Cross fault monitoring is ca-
pable of detecting low-resistance cross faults between the two inputs caused by a me-
tallic connection.
6.3 Outputs
The outputs are designed according to the AS-Interface standard. These are switched
to positive potential (PNP technology).
The outputs can be operated in two modes:
1. The outputs are controlled directly by the corresponding data bits of the AS-Inter-
face master.
2. The output signals of the AS-Interface master are linked with the secure inputs. The
outputs are turned on if the master turns them on or if the inputs are in a secure
state.
This operating mode is used to control signal lights that must display the state of
the inputs without the master being involved.
.
Figure 6.3: Output modes

VAA-2E2A-KE1-S/E2
Interface properties
S
ubject 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
Date of Issue 2003-11-28
12
Modes and logic table of the outputs
The modes are selected by the Master with parameter bit P0:
1) 0 corresponds to an open switch (secure state). 1 means closed switch.
X means any state that has no effect on the outputs.
2) 1 means outputs are turned on, 0 means outputs are voltage-free.
P0 S1 / S2 1) DO0 / DO1 2) OUT1 / OUT2 Mode
1X / X 0 / 0 0 / 0 Outputs independent of
inputs
X / X 1 / 1 1 / 1
0
0 / 0 X / X 1 / 1
Open switch at the input
sets the corresponding
output
1 / 1 0 / 0 0 / 0 When the switches are
closed on the input, the
master controls the output
1 / 1 1 / 1 1 / 1

VAA-2E2A-KE1-S/E2
Commissioning
S
ubject 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
Date of Issue 2003-11-28
13
7 Commissioning
7.1 Requirements for configuring the safety monitor
On measures related to the safety monitor that are required for organisation, please
refer to the safety monitor documentation.
7.2 Installation
For installation of the module a suitable top hat DIN rail in accordance with DIN 50022
is recommended.
7.3 Addressing modules
Addressing of the module is performed by means of a manual addressing device or
with an AS-Interface master. If a manual addressing device is used, it should be con-
nected and addressed to the addressing socket of the module (identified with ADDR)
using the addressing cable included with delivery. Addresses from 1 to 31 can be as-
signed. The state as supplied is address 0.
7.4 Function test
Function tests must be performed as part of the installation. Because of the cross fault
monitoring of the secure inputs, there is no need for a test for short circuits in the wir-
ing. The function test covers all faults present at the time of installation.
7.5 Operating modes
No operating modes can be switched for the inputs. The parameters in the AS-Inter-
face can affect the behaviour of the outputs. For a more detailed description of con-
necting peripheral devices, consult section 5.

VAA-2E2A-KE1-S/E2
Certificates
S
ubject 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
Date of Issue 2003-11-28
14
8 Operation of AS-Interface safety modules
The safety function of the module is determined by how the monitor is programmed.
Please observe the corresponding documentation. Depending on the safety category,
regular function tests may not be required.
9 Certificates
Approvals according to EN 954-1/ISO 13849-1 and EN/IEC 61508.

VAA-2E2A-KE1-S/E2
Application examples
S
ubject 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
Date of Issue 2003-11-28
15
A Application examples
A.1 Category 2
The safety function(s) must be tested at appropriate intervals of time by the machine
control system. Loss of the safety function will be detected by the test. The test inter-
vals must be adjusted to match the application.
Connecting two independent mechanical position switches of Category 2:
.
The examples listed here correspond to our understanding of the cate-
gories according to EN 954-1 and should not be seen as binding.

VAA-2E2A-KE1-S/E2
Application examples
S
ubject 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
Date of Issue 2003-11-28
16
A.2 Category 3
Occurrence of a fault must not result in a loss of the safety function.
Connecting two dependent mechanical position switches per channel (2 safety func-
tions)
Example 1
.
Example 2
If the possibility of a dangerous failure (short circuit) of the switch cannot be excluded,
these switches must be doubled and switched in series.
.

VAA-2E2A-KE1-S/E2
Application examples
S
ubject 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
Date of Issue 2003-11-28
17
Example 3
If the possibility of a short circuit in the wiring cannot be excluded with the switches,
both channels are required to achieve a Category 3 safety function.
.
.
Parameters can be set for the following function modules to achieve safety category
3 in this application while the AS-Interface safety module is in operation on a safety
monitor (for example VAS-1A-K12 or VAS-2A-K12):
Example 1 and 2:
Example 3:
Dual channel independent
Dual channel dependent
Dual channel force-guided
The function module 'two-channel independent' must not be used
in example 3.

VAA-2E2A-KE1-S/E2
Application examples
S
ubject 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
Date of Issue 2003-11-28
18
A.3 Category 4
Occurrence of a fault and an accumulation of faults must result in a loss of the safety
function.
Example 1
Connecting a dual-channel mechanical position switch.
The safety function must be tested to detect a dangerous accumulation of faults. The
test intervals must be adjusted to match the application.
.
Example 2
If it is not possible to exclude a dangerous failure (short circuit) for the switches, two
dependent mechanical switches must be used for each channel. The safety function
must be tested to detect a dangerous accumulation of faults. The test intervals must
be adjusted to match the application.
.