Wieland samos PRO COMPACT User manual

samos ® PRO
samos ®PRO COMPACT-Hardware
Manual
Doc. no. BA000966
Last Update: 08/2017 [8151]

Info
Wieland Electric GmbH | BA000966 | 08/2017 [8151]
2
Info
810920587
Copyright
This document is copyright-protected. The rights derived from this copyright are reserved for
Wieland Electric. Reproduction of this document or parts of this document is only permissible
within the limits of the statutory provision of the Copyright Act. Any modification or abridg-
ment of the document is prohibited without the express written agreement of Wieland Electric.
samos is a registered trademark of WIELAND Electric GmbH
Allen-Bradley, CompactBlock Guard I/O, CompactLogix, ControlFLASH, ControlLogix, DH+,
FactoryTalk, FLEX, GuardLogix, Kinetix, Logix5000, MicroLogix, PanelBuilder, PanelView,
PhaseManager, PLC-2, PLC-3, PLC-5, POINT I/O, POINT Guard I/O, Rockwell Automation,
Rockwell Software, RSBizWare, RSFieldbus, RSLinx, RSLogix 5000, RSNetWorx, RSView, SLC,
SoftLogix, Stratix, Stratix 2000, Stratix 5700, Stratix 6000, Stratix 8000, Stratix 8300, Studio
5000, Studio 5000 Logix Designer, SynchLink, and Ultra are registered trademarks of Rockwell
Automation, Inc.
ControlNet, DeviceNet, and EtherNet/IP are registered trademarks of ODVA, Inc.
TwinCAT is a registered trademark of Beckhoff Automation GmbH.
EtherCAT is a registered trademark and a patented technology licensed by Beckhoff Automa-
tion GmbH.
Microsoft, Windows 98, Windows NT, Windows 2000, Windows XP, Windows 7, Windows 8,
Windows 8.1, Windows 10 and .NET Framework are registered trademarks of the Microsoft
Corporation.
Any other product or trade names listed in this manual are the trademarks or registered trade-
marks of the respective owners.
Subject to change.
Subject to technical changes for reasons of continued development.

Table of Contents
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Table of Contents
1
About this manual
7
1.1
Function of this document
7
1.2
Target group
7
1.3
Information depth
8
1.4
Scope of validity and applicable documents
8
1.5
Abbreviations used
9
1.6
Symbols/icons and writing style/spelling standard used
10
2
Safety
11
2.1
Qualified persons
11
2.2
Areas of application of the device
11
2.3
Proper use
12
2.4
General safety information and protective measures
13
2.5
Environmentally friendly behavior
14
2.5.1
Disposal
14
2.5.2
Sorting of materials
14
3
Product description
15
3.1
System properties
15
3.2
System setup
16
3.3
Version, compatibility, and features
18
3.4
Controller module SP-COP1
19
3.4.1
Description
19
3.4.2
Display elements, interfaces, and terminal description
19
3.4.3
Internal circuits
22
3.4.4
Limited short-circuit detection in the input circuits
22
3.4.5
Deactivating the test pulses at the outputs
23
3.4.6
Single-channel use of outputs
23
3.5
Controller module SP-COP2-EN
24
3.5.1
Description
24
3.5.2
Display elements, interfaces, and terminal description
24
3.5.3
Internal circuits
26
3.5.4
Limited short-circuit detection in the input circuits
26
3.5.5
Deactivating the test pulses at the outputs
27
3.5.6
Single-channel use of outputs
27

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3.6
Controller module SP-COP2-ENI
28
3.6.1
Description
28
3.6.2
Display elements, error codes, and terminal description
28
3.7
SP-COP-CARD1 removable storage
29
3.7.1
Description
29
3.7.2
Files on the removable storage
30
3.8
SP-SDIO input/output expansion module
32
3.8.1
Description
32
3.8.2
Display elements and terminal assignment
33
3.8.3
Internal circuits
34
3.8.4
Deactivating the test pulses at the outputs
35
3.8.5
Single-channel use of outputs
35
3.9
SP-SDI input/output expansion module
36
3.9.1
Description
36
3.9.2
Display elements and terminal assignment
37
3.9.3
Internal circuits
38
3.10
SP-DIO input/output expansion module
39
3.10.1
Description
39
3.10.2
Display elements and terminal assignment
40
3.10.3
Internal circuits
41
4
Connecting devices
43
4.1
Safety command devices and electromechanical safety switches
45
4.1.1
Emergency stop button
45
4.1.2
Electromechanical safety switch without lock
45
4.1.3
Electromechanical safety switch with lock
46
4.1.4
Enable switch
47
4.1.5
Two-hand control
47
4.1.5.1
Type IIIA
47
4.1.5.2
Type IIIC
48
4.1.6
Safety mats and bumper
48
4.1.7
Connection of multiple safety mats/bumpers
50
4.1.8
Mode selection switch
50
4.1.9
Potential-free contacts
51
4.2
Contactless safety sensors
52
4.2.1
Magnetic safety switches
52
4.2.1.1
Magnetic safety switches with equivalent inputs
52
4.2.1.2
Magnetic safety switches with complementary inputs
52
4.2.2
Inductive safety switches
52
4.2.3
Transponder switches
53

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4.3
Testable single-beam safety light barriers
54
4.3.1
Testable type 2 single-beam safety light barriers
54
4.3.2
Testable type 4 single-beam safety light barriers
54
4.3.3
Customer-specific testable single-beam safety light barriers
55
4.3.4
Information on installing testable single-beam safety light barriers
55
4.4
ESPE – Electro-sensitive protective equipment
57
4.5
Motion monitoring
57
4.6
Safety outputs
58
5
Special functions
59
5.1
Muting
59
6
Installing/removing
60
6.1
Installing modules on hat rail
60
6.2
Removing modules from the hat rail
64
7
Electrical installation
66
7.1
Requirements for electrical installation
66
7.2
Internal wiring of the supply voltage
68
8
Configuration
69
9
Commissioning
70
9.1
Total acceptance of the application
70
9.2
Tests before initial commissioning
70
10
Diagnostics
71
10.1
What to do in the event of an error
71
10.2
Error statuses
71
10.3
Error displays in the status LEDs, error messages, troubleshooting
measures
72
10.3.1
Device state and LED displays in the controller modules
73
10.3.2
Device state and LED displays in the safe input/output modules
75
10.3.3
Device state and LED displays in the standard input/output modules
76
10.4
Support
78
10.5
Expanded diagnostics
78
11
Maintenance
79
11.1
Regular testing of the safety equipment by qualified persons
79
11.2
Replacing devices
80
11.2.1
Safety measures when replacing devices
80

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12
Technical data
81
12.1
System response times
81
12.1.1
Minimum switch-off time
83
12.1.2
Response time of the state flag
83
12.1.3
Default values for non-secure or secure data
83
12.2
Safety technology reference values
84
12.2.1
Controller modules without I/O expansion
84
12.2.2
Controller modules with safe I/O expansions
85
12.3
Data sheet
86
12.3.1
Controller module
86
12.3.2
Safe input/output expansion module
90
12.3.3
Safe input expansion module
93
12.3.4
Standard input/output expansion module
95
12.4
Dimensional drawings
97
12.4.1
Controller module
97
12.4.2
Input/output expansion modules
98
12.4.3
WKFN 2.5 E/35 GO-URL Level terminal
98
13
Order data
99
13.1
Hardware modules and accessories
99
13.2
Modules for contact expansion
101
13.3
Other safety-related products
101
14
Appendix
102
14.1
Declaration of Conformity
102
14.2
Checklist for manufacturers
106
14.3
Complete list of error messages
107

About this manual
Wieland Electric GmbH | BA000966 | 08/2017 [8151]
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About this manual
887957259
Please read this section and the Safety [ch. 2, p. 11] section carefully before documenting or
working with the modular samosPRO COMPACT ##safety control the corresponding sa-
mosPRO modules.
Function of this document
888316683
There are three manuals for the samosPRO system with clearly delineated areas of application
as well as installation instructions and brief instructions for each module.
•
This hardware manual
describes in-detail all modules that can be used with a SP-COPx
controller module and their functions. Use the hardware manual mainly for planning sa-
mosPRO safety controls.
This manual will guide
technical personnel of the machine manufacturer
and/or
machi-
ne operator
on safe installation, electric installation, commissioning, and maintenance of
the modular samosPRO safety control.
These manual does
not
provide instructions for operating the machine into which the sa-
fety control is or will be integrated. Instructions on how to operate the machine are provi-
ded for this purpose.
• The
software manual
describes the software-supported configuration and parameterizati-
on of the samosPRO safety control. In addition, the software manual contains a description
of the important diagnostic functions for operation and detailed information for identifying
and eliminating errors. Use the software manual mainly when configuring, commissioning
and operating samosPRO safety controls.
• The
gateway manual
describes in-detail the samosPRO gateways and their functions.
• Each module contains the
installation instructions/brief instructions
. These instructions
provide information on the fundamental technical specifications of the modules and con-
tain simple installation instructions. Use the installation instructions/brief instructions when
installing the samosPRO safety control.
This manual contains original operating instructions in accordance with the Machinery Directi-
ve.
Target group
888318219
This manual is targeted toward
designers
,
developers,
and
operators
of systems that are to
be safeguarded by a modular samosPRO safety control.
It is also targeted toward persons integrating a samosPRO safety control into a machine,
commissioning it for the first time, or maintaining such a system.
1
1.1
1.2

About this manual
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Information depth
888319755
This manual contains information on the modular samosPRO safety control with respect to the
following topics:
• Installation
• Electrical installation
• Hardware commissioning
• Maintenance
• Error diagnostics and error elimination
• Item numbers
• Conformity and approval
Furthermore, specialized technical knowledge that is not provided in this document is required
when designing and using Wieland safety equipment.
Essentially, governmental and legal regulations must be adhered to when operating the modu-
lar samosPRO safety control.
Downloads are provided at the following link
Also consult our website on the Internet. At the following link http://www.wielandinc.com/,
you will find:
• the samosPLAN 6 software
• The samosPRO manuals available for display and printing in various languages:
– This hardware manual (BA000966)
– The software manual (BA000968)
– The gateway manual (BA000970)
Scope of validity and applicable documents
888321291
This manual is valid for all samosPRO safety control modules that are operated in connection
with SP-COPx and samosPLAN 6 controller modules.
Table 1: Overview of the samosPRO documentation
Document
Title
Item number
Software manual
samosPLAN 6 software
BA000968
Hardware manual
samosPRO hardware
BA000966
Gateway manual
samosPRO gateways
BA000970
Operating instruc-
tions
SP-COPx
(Controller modules of the modular samosPRO sa-
fety controller)
BA000978
Operating instruc-
tions
SP-SDI/SP-SDIO
(Exte
nded modules of the modular samosPRO safety
controller)
BA000515
Operating instruc-
tions
SP-DIO
(Extended modules of the modular samosPRO safety
controller)
BA001033
Operating instruc-
tions
SP-PROFIBUS-DP
(samosPRO-PROFIBUS-DP gateway)
BA000572
Operating instruc-
tions
SP-CANopen
(samosPRO-CANopen gateway)
BA000683
Operating instruc-
tions
SP-EN-ETC
(samosPRO EtherCAT gateway)
BA000959
1.3
1.4

About this manual
Wieland Electric GmbH | BA000966 | 08/2017 [8151]
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Abbreviations used
888322827
Contactless
safety de-
vice
Contactless Safety Device
EDM
External Device Monitoring
PFHD
Probability of Dangerous Failure per Hour
OSSD
Output Signal Switching Device
SIL
Safety Integrity Level
PLC
Programmable Logic Controller
1.5

About this manual
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Symbols/icons and writing style/spelling standard used
840010507
NOTICE
These are notes that provide you with information regarding particularities of a device or a
software function.
ATTENTION
Warning!
A warning lets you know about specific or potential hazards. It is intended to protect you
from accidents and help prevent damage to devices and systems.
•
Please read and follow the warnings carefully!
Failure to do so may negatively impact the safety functions and cause a hazardous state
to occur.
Menus and commands
The names of software menus, submenus, options, and commands, selection fields, and
windows are written in
bold font
. Example: Click on
Edit
in the
File
menu.
1.6

Safety
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Safety
888325899
This section is intended to support your safety and the safety of the system users.
 Please read this section carefully before you work with a samosPRO system.
Qualified persons
888327435
The modular samosPRO safety control may only be installed, commissioned, and maintained
by qualified persons.
Qualified persons are those who
• have suitable technical training
and
• have been trained by the machine operator in the operation and applicable safety guide-
lines
and
• have access to the samosPRO operating instructions and have read said instructions and
have duly noted these
and
• have access to the operating instructions for the safety devices connected to the safety
control (e.g. safety light curtain) and have read them and duly noted them.
Areas of application of the device
888328971
The modular samosPRO safety control is an adjustable control for safety applications. It is
usable
• as per EN 61508 up to SIL 3
• as per EN 61131-6 up to SIL 3
• as per EN 62061 up to SIL CL 3
• as per EN ISO 13849-1:2015 to performance level e / category 4
• as per EN 81-1
• as per EN 50156-1
– The safety function must be tested at least once annually
– A consistent redundant structure must be implemented
– If relay expansion modules are used, the correct switching of the relays must be moni-
tored using feedback contacts (EDM)
– The requirements of EN 50156-1, Section 10.5.6, must be considered
The level of safety actually achieved depends on the external wiring, the implementation of the
wiring, the parameterization, the selection of the command encoder, and their arrangement on
the machine.
Opto-electronic and tactile safety sensors (e.g. light curtains, laser scanners, safety switches,
sensors, emergency stop switches) are connected and logically linked at the modular safety
control. The corresponding actuators on the machine or systems can be securely switched off
via the switch outputs of the safety control.
2
2.1
2.2

Safety
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12
Proper use
888330507
The modular samosPRO safety control may only be operated under the following conditions:
• You are operating the control within the specified operating limits for voltage, temperature,
etc. (see the following for further information:
Technical data [ch. 12, p. 81] )
• You are operating the control within the specified areas of application. (Further informati-
on:
Areas of application of the device [ch. 2.2, p. 11] )
The control may only be operated by qualified personnel and may only be used on a machine
on which it has been installed and commissioned for the first time by a qualified person in ac-
cordance with this manual.
In the event of any other use or any changes to the device – including within the scope of in-
stallation – this shall nullify any warranty claim with respect to Wieland Electric GmbH.
• The external power supply of the devices must able to bridge a short-term power outage
of 20 ms in accordance with EN 60204. Suitable PELV- and SELV-capable power packs
can be obtained as accessories from Wieland Electric.
• The modules for the samosPRO system correspond to class A, group 1, in accordance with
EN 55011. Group 1 includes all ISM devices in which intentionally generated and/or wired
HF power, which is required for the internal function of the device itself, occurs.
• If you wish to use the samosPRO system for domestic purposes, you need to take additio-
nal steps to prevent the emission of radio frequency interference in limit class B according
to EN 55011. Here are some steps you might take:
– The use of interference suppressor filters in the supply circuit
– Installation in grounded switch cabinets or boxes
UL/CSA applications:
• Use lines that are suitable for a temperature range of 60 to 75°C.
• Tighten the screw terminals with a torque of 5-7 lbs/in.
• Only use in a pollution degree 2 environment.
• The modules must be supplied by a voltage source with protective isolation, which is pro-
tected by a fuse in accordance with UL 248 with a nominal power of 100 V, wherein V cor-
responds to the direct current power supply with a maximum value of 42.4 V DC, which
means that the requirements of UL 508 for the current and voltage limits are met.
• The maximum permissible total current for the SP-SDIO modules with outputs Q1 to Q4 is
Itotal = 3.2 A.
NOTICE
The safety functions are not evaluated by UL. The approval corresponds to UL508, general
applications.
2.3

Safety
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General safety information and protective measures
888331531
ATTENTION
Note the safety information and protective measures!
Note the following points in order to ensure proper use of the samosPRO safety control.
• Please follow the standards and guidelines valid in your country when installing and using
the samosPRO safety control.
• The national/international legal regulations apply to the installation and use of the safety
control as well as for the commissioning and repeated technical testing, particularly the
following:
– Machinery Directive 2006/42/EC
– EMC Directive 2014/30/EU
– Work Equipment Directive 2009/104/EC
– Low-Voltage Directive 2014/35/EU
– The accident prevention regulations/safety rules
– RoHS (Restriction of Hazardous Substances) Directive 2011/65/EU
• Manufacturers and operators of a machine on which a samosPRO safety control is being
used are responsible for coordinating with the proper authorities with regard to applicable
safety guidelines/rules and complying with these.
• The notices, particularly the test notices, must be observed without fail.
Further information:
Requirements for electric installation [ch. 7.1, p. 66]
The tests must be conducted by qualified persons or by those who are personally authori-
zed and commissioned to do so and must always be fully documented at all times by a
third-party.
• This manual must be provided to the operator of the machine on which the samosPRO sa-
fety control is being used. The machine operator must be trained by qualified persons and
is required to read this manual.
2.4

Safety
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Environmentally friendly behavior
888332555
The modular samosPRO safety control and the corresponding modules are designed such that
they stress the environment as little as possible. They use only a minimum of power and re-
sources.
 Make sure that you also carry out work while always considering the environment.
Disposal
888334091
The disposal of unusable or irreparable devices should always be done in accordance with the
respectively valid country-specific waste-elimination guidelines (e.g. European Waste Code 16
02 14).
NOTICE
We will be happy to help you in disposing of these devices.
Simply contact us.
Sorting of materials
888335627
ATTENTION
Important information
• The sorting of materials may only be carried out by qualified persons!
• Care must be used when disassembling the devices. There is a risk of injuries during this
process.
Before you can route the devices to the environmentally-friendly recycling process, it is neces-
sary to sort the various materials of the samosPRO devices.
 Separate the housing from the rest of the components (particularly from the PC board).
 Place the separated components into the corresponding recycling containers (see the
following table).
Table 2: Overview of disposal according to components
Components
Disposal
Product
Housing
PC boards, cables, connectors, and
electric connecting pieces
Plastic recycling
Electronics recycling
Packaging
Cardboard, paper Paper/cardboard recycling
2.5
2.5.1
2.5.2

Product description
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Product description
888337163
This section will provide you with information on the properties of the samosPRO system and
describes the setup and function.
System properties
888338699
Illustration 1: Modular samosPRO safety control
The samosPRO system is characterized by the following system properties:
• Modular setup:
1 controller module and up to 12 input/output expansion modules, each of which has an
overall width of 22.5 mm
• 16 to 116 inputs and 4 to 56 outputs
• They can be programmed using the samosPLAN 6 software
• Can use up to 300 standard and application-specific logical blocks
• Standard logical blocks: AND, OR, NOT, XNOR, XOR
• Application-specific logical blocks: Emergency stop, two-hand, muting, operating mode
selection switch, reset, restart
• Can be integrated into different networks using gateways (e.g. ProfibusDP, CANopen,
Modbus/TCP, etc.)
The samosPLAN 6 programming software is available for configuring the control tasks. It can
be
downloaded [ch. 1.3, p. 8] on our website on the Internet.
3
3.1

Product description
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16
System setup
888341643
A samosPRO system consists of the following modules and/or components:
• 1 Controller module
• 1 Program removable storage
• samosPLAN 6 programming software
• Up to 2 gateway modules
• Up to 12 additional SP-SDIO, SP-SDI and SP-DIO input/output modules
• In addition, SP-XX expansion modules can be used. This may be, for example, the
SNS4084K standstill monitor or the relay output expansions.
These modules are shown in the report from samosPLAN 6 but cannot be logically connec-
ted to the modules of the samosPRO system.
Further information: Software manual, chapter "Special case: SP-XX expansion module"
Examples
Illustration 2: Example of a minimum samosPRO system setup with a SP-COP2 controller module
Illustration 3: Example 2 - Maximum setup of a samosPRO system
3.2

Product description
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17
Table 3: Overview of modules (without program removable storage)
Type
Description
Inputs
Out-
puts
Logical
blocks
Max. occur-
rence
SP-COP1
Controller module
20
4
300
1×
SP-COP2-EN
Controller module
16-20
1)
4-8
1)
300 1x
SP-COP2-ENI
Controller module
16-20
1)
4-8
1)
SP-SDIO
Input/output expansion
8
4
–
12x
SP-SDI
Input expansion
8
–
–
SA-OR-S1
Relay output expansion
–
4
–
4×
2)
SA-OR-S2
Relay output expansion
–
2
–
8×
2)
SP-DIO
Input/output expansion
8
1)
8
1)
–
12×
SP-PROFIBUS-DP
PROFIBUS DP gateway
–
–
–
2×
SP-CANopen
CANopen gateway
–
–
–
SP-EN-ETC
EtherCAT Gateway
–
–
–
1) 4 inputs or 4 outputs can be configured as an option
2)
Maximum 16 safe relay outputs

Product description
Wieland Electric GmbH | BA000966 | 08/2017 [8151]
18
Version, compatibility, and features
840060811
There are various module versions and function packages for the samosPRO product family
that enable various functions. This section will give you an overview as to which module versi-
on, which function package, and/or which version of the samosPLAN 6 you will need to be able
to use a certain function or a certain device.
Table 4: Module and software versions required
Available with module version and higher
Feature/
functionality
SP-COP1-x
SP-COP2-EN-x
SP-COP2-ENI-x
samosPLAN
6
Safe I/O
(SP-SDIO, SP-SDI)
A-01 A-01 A-01 V1.0
Modbus TCP
---
---
A-01
V1.0
PROFINET IO
---
---
B-01.xx
V1.0
Non-secure I/O
(SP-DIO)
C-01.xx C-01.xx C-01.xx V1.0
EtherCAT
(SP-EN-ETC)
C-01.xx C-01.xx C-01.xx V1.0
EtherNet/IP
---
---
D-01.xx
V1.0
Press features
1)
D-01.xx
D-01.xx
D-01.xx
V1.0
Standstill monitor
1)
D-03.xx
D-03.xx
D-03.xx
V1.0
1)
only available with module variants -P (example: SP-COP2-EN-P-x)
Info
• You can find the module version on the type plate of the modules.
• You will find the samosPLAN 6 software version in the main menu.
• The latest software version is available in the Internet at the following address
http://www.wielandinc.com/.
• Newer modules are backwards-compatible, which means that each module can be re-
placed with a module having a higher module version.
• You can find the date of manufacture for a device on the type plate in the
S/N
field in the
format <Product no.>yywwnnnnn (yy = year, ww = calendar week).
3.3

Product description
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19
Controller module SP-COP1
888347531
Description
888349067
The SP-COP1 controller module is a central processing unit for the entire system in which all of
the signals are monitored and logically processed according to the configuration stored in the
SP-COP-CARD1 program removable storage. The module has safe inputs and outputs as well
as test signal outputs. The system outputs are switched as a result of the processing. The in-
ternal safety bus in this case serves as a data interface.
Module versions
In addition to the basic version, there is the SP-COP1-P compact module.
It has additional functions for:
• Press control
• Motion detection (standstill monitor)
Display elements, interfaces, and terminal description
888350603
Illustration 4: SP-COP1 display elements
Table 5: 4 LED displays
LED
Meaning
PWR/EC Display of the supply voltage state
Display of an error through various
Flashing codes [ch. 10.3.1, p.
73]
MS
Display of the Module state [ch. 10.3.1, p. 73]
CV Display of the verification state of the
Control project [ch. 10.3.1,
p. 73]
Input LED I1 to I20
State display of the Inputs [ch. 10.3.1, p. 73]
Output LED Q1 to Q4
State display of the Outputs [ch. 10.3.1, p. 73]
3.4
3.4.1
3.4.2

Product description
Wieland Electric GmbH | BA000966 | 08/2017 [8151]
20
Table 6: SP-COP1 pin assignment
Pin
assignment
A1
24 V supply voltage for all modules, except for supply of outputs
A2 GND of supply voltage
I1 - I20
Safe, digital inputs
Q1 - Q4 Safe, digital outputs
B1
24 V supply voltage of outputs Q1 - Q4
T1 - T4 Test signal outputs