SICK Safe Stationary Machine Operating instructions

SICK
Brand
SICK
Model
Safe Stationary Machine
Type
Operating instructions
O P E R A T I N G I N S T R U C T I O N S
Safe Stationary Machine
Example application
Described product
S
afe Stationary Machine – Example application
Manufacturer
SICK AG
Erwin-Sick-Str. 1
79183 Waldkirch
Germany
Legal information
T
his work is protected by copyright. Any rights derived from the copyright shall be
reserved for SICK AG. Reproduction of this document or parts of this document is only
permissible within the limits of the legal determination of Copyright Law. Any modifica‐
tion, abridgment or translation of this document is prohibited without the express writ‐
ten permission of SICK AG.
The trademarks stated in this document are the property of their respective owner.
© SICK AG. All rights reserved.
Original document
T
his document is an original document of SICK AG.
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Contents
1 About this document........................................................................ 5
1.1 Purpose of this document........................................................................ 5
1.2 Scope......................................................................................................... 5
1.3 Target groups and structure of these operating instructions................ 5
1.4 Further information................................................................................... 6
1.5 Symbols and document conventions...................................................... 6
2 Safety information............................................................................ 7
2.1 General safety notes................................................................................ 7
2.2 Intended use............................................................................................. 7
2.3 Requirements for the qualification of personnel.................................... 7
3 Product description........................................................................... 9
3.1 Example application................................................................................. 9
3.2 Components.............................................................................................. 9
3.2.1 Project file................................................................................ 9
3.2.2 SISTEMA files........................................................................... 10
3.3 Application description............................................................................. 10
3.4 Structure and function............................................................................. 10
3.4.1 Interlocking............................................................................... 11
3.4.2 Drive monitoring and standstill control.................................. 11
3.4.3 Operating modes..................................................................... 11
3.4.4 Emergency stop....................................................................... 12
3.4.5 Safe state of the machine....................................................... 13
4 Project planning................................................................................ 14
4.1 Manufacturer of the machine.................................................................. 14
4.1.1 Risk assessment..................................................................... 14
4.1.2 Safety functions....................................................................... 14
4.1.3 Implementation of the safety functions................................. 16
4.2 Integrating the equipment into the electrical control............................. 18
4.2.1 Block diagram and circuit diagram......................................... 18
4.2.2 Requirements for components............................................... 19
4.3 Calculation of the performance level...................................................... 22
4.4 Operating entity of the machine.............................................................. 22
5 Configuration..................................................................................... 23
5.1 Overview.................................................................................................... 23
5.2 Hardware configuration of the Flexi Soft safety controller..................... 24
5.3 Logic programming for the MOC.............................................................. 25
5.3.1 Logic programming page 1..................................................... 25
5.3.2 Stationary Machine page of the logic programming............. 26
5.4 Easy Application configuration assistant................................................ 27
5.4.1 Machine parameters............................................................... 27
CONTENTS
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5.4.2 Application parameters........................................................... 29
5.4.3 Summary.................................................................................. 36
5.5 Further configuration options in Expert mode........................................ 36
5.5.1 Speed comparison................................................................... 37
5.5.2 Speed monitoring.................................................................... 40
5.5.3 Safe stop.................................................................................. 41
5.6 Logic programming for the CPU............................................................... 41
5.6.1 Service mode page.................................................................. 41
5.6.2 Automatic mode page.............................................................. 42
5.6.3 Stop signals page..................................................................... 43
5.6.4 From/to FX3-MOC0 page......................................................... 46
5.6.5 Drive control page.................................................................... 48
6 Commissioning.................................................................................. 49
6.1 Thorough check........................................................................................ 49
7 Ordering information........................................................................ 50
7.1 Necessary components for Safe Stationary Machine............................ 50
8 Accessories........................................................................................ 51
8.1 Accessories............................................................................................... 51
9 Annex.................................................................................................. 52
9.1 Checklist for initial commissioning and commissioning........................ 52
9.2 Extending the number of axes................................................................. 55
10 List of figures..................................................................................... 58
11 List of tables....................................................................................... 59
CONTENTS
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1 About this document
1.1 Purpose of this document
These operating instructions contain the information required during the life cycle of
t
he Safe Stationary Machine example application.
These operating instructions must be made available to everyone who works with the
example application.
Read these operating instructions carefully and ensure that you have understood the
contents completely before working with the example application.
1.2 Scope
These operating instructions are valid for the Safe Stationary Machine example applica‐
t
ion.
These operating instructions are included with SICK part number 8020942 (all availa‐
ble language versions of the operating instructions).
NOTICE
T
hese operating instructions do not describe:
•
The Flexi Soft safety controller
•
How to program the Flexi Soft safety controller
•
The necessary sensors and safety switches, and how to implement, mount, and
install them
•
The machine and its drive (which is protected by means of the
Flexi Soft safety controller)
Further information can also be found in the following documents:
T
able 1: Available documents
Document Title Part number
Operating instructions Flexi Soft modular safety con‐
t
roller hardware
8012999
Operating instructions Flexi Soft in the
F
lexi Soft Designer configura‐
tion software
8012998
i10 Lock
Operating instructions
i10 Lock safety locking device 8010025
Operating instructions E100 enabling switch 8010034
Operating instructions ES21 emergency stop push‐
but
ton
8012498
Operating instructions ER12 reset pushbutton 8016415
Operating instructions DFS60S Pro safe encoder 8016866
Mounting instructions DFS60 Core incremental
encoder
8018427
Mounting instructions DBS60 incremental encoder 8017140
Competence brochure Guide for Safe Machinery 8008007
1.3 Target groups and structure of these operating instructions
These operating instructions are intended for the following target groups: project devel‐
oper
s (planners, developers, designers).
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The structure of these operating instructions is based on the life cycle phases of the
S
afe Stationary Machine example application: project planning, configuration, and com‐
missioning.
1.4 Further information
www.sick.com
T
he following information is available via the Internet:
■
This document in other languages
■
Operating instructions and mounting instructions of suitable SICK components for
the Safe Stationary Machine example application
■
Guide for Safe Machinery (“Six steps to a safe machine”)
1.5 Symbols and document conventions
The following symbols and conventions are used in this document:
Safety notes and other notes
DANGER
Indic
ates a situation presenting imminent danger, which will lead to death or serious
injuries if not prevented.
WARNING
Indicates a situation presenting possible danger, which may lead to death or serious
injuries if not prevented.
CAUTION
Indic
ates a situation presenting possible danger, which may lead to moderate or minor
injuries if not prevented.
NOTICE
Indic
ates a situation presenting possible danger, which may lead to property damage if
not prevented.
NOTE
Indic
ates useful tips and recommendations.
Instructions to action
b
T
he arrow denotes instructions to action.
1. The sequence of instructions for action is numbered.
2. Follow the order in which the numbered instructions are given.
✓
The check mark denotes the result of an instruction.
1 A
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2 Safety information
2.1 General safety notes
DANGER
H
azard due to lack of effectiveness of the protective device
In the case of non-compliance, it is possible that the dangerous state of the machine
may not be stopped or not stopped in a timely manner.
b
Please read this document carefully and make sure that you understand the con‐
tent fully before working with the device.
b
Follow all safety notes in this document.
2.2 Intended use
Safe Stationary Machine is an example application.
DANGER
H
azard due to lack of effectiveness of the protective device
Persons and parts of the body to be protected may not be recognized in case of non-
observance.
If you do decide to use the Safe Stationary Machine example application, you must
observe the following points:
•
The example application is an incomplete solution.
•
The example application may only be used in an industrial environment where the
specified standards apply.
•
The example application will only satisfy the requirements of the Machinery Direc‐
tive if additional steps are completed successfully. These include having the entire
system verified by the qualified safety personnel (see "Requirements for the quali‐
fication of personnel", page 7) responsible for implementing the example appli‐
cation in a machine or plant.
The example application may only be used in accordance with the product descrip‐
t
ion (see "Product description", page 9).
Certain requirements must be met before you can use the Safe Stationary Machine
example application:
DANGER
H
azard due to lack of effectiveness of the protective device
In the case of non-compliance, it is possible that the dangerous state of the machine
may not be stopped or not stopped in a timely manner.
b
Carry out a risk assessment (see "Risk assessment", page 14).
b
Select suitable components (see "Requirements for components", page 19).
b
Verify and validate the safety functions (see "Commissioning", page 49).
b
Observe the product or C-type standards (as a basic principle, these take higher
priority than the content of these operating instructions).
2.3 Requirements for the qualification of personnel
The protective device must be configured, installed, connected, commissioned, and
ser
viced by qualified safety personnel only.
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Project planning
F
or project planning, a person is considered competent when he/she has expertise and
experience in the selection and use of protective devices on machines and is familiar
with the relevant technical rules and national work safety regulations.
Mechanical mounting, electrical installation, and commissioning
For the task, a person is considered qualified when he/she has the expertise and expe‐
rience in the relevant field and is sufficiently familiar with the application of the protec‐
tive device on the machine to be able to assess whether it is in an operationally safe
state.
Operation and maintenance
For operation and maintenance, a person is considered competent when he/she has
the expertise and experience in the relevant field and is sufficiently familiar with the
application of the protective device on the machine and has been instructed by the
machine operator in its operation.
2 S
AFETY INFORMATION
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3 Product description
3.1 Example application
Safe Stationary Machine is an example application. It illustrates how you can use the
F
lexi Soft safety controller to implement a safe solution on stationary machines.
In addition to using the various Safe Stationary Machine components, you must also
adapt them as appropriate for the specific machine.
3.2 Components
The Safe Stationary Machine example application consists of the following compo‐
nent
s:
•
SISTEMA file for a safety encoder
Demo_FX3-MOC0_Stationary_Machine_3_DFS60Spro_E148770_V03.ssm
•
SISTEMA file for two non-safe encoders
Demo_FX3-MOC0_Stationary_Machine_3_E117073_V04.ssm
•
Project file for Flexi Soft Designer
Demo_FX3-MOC0_Stationary_Machine_CPU0_E117072_V07.fsp
•
A file that can be imported if a CPU other than the CPU0 is used
Demo_FX3-MOC0_Stationary_Machine_E117072_V07.fsi
3.2.1 Project file
The project file should be opened in Flexi Soft Designer. It contains the following com‐
ponent
s:
•
Hardware configuration
•
Logic programming for the CPU
•
Logic programming for the FX3-MOC0
Hardware configuration
T
he hardware configuration contains the structure of the Flexi Soft system plus hard‐
ware modules and the configuration for the inputs, outputs, and connected elements.
NOTICE
T
he Safe Stationary Machine example application will only work if the elements config‐
ured in the hardware configuration are connected accordingly.
Logic programming for the CPU and Drive Monitor FX3-MOC0
T
he logic programming for the CPU incorporates the programming for the following: two
operating modes, the safe stop signals, and communication with the FX3-MOC0 and
EDM.
Drive Monitor FX3-MOC0 features its own logic programming. This relies on the Station‐
ary Machine Easy Application.
Stationary Machine Easy Application
An Ea
sy Application is a function block that has been specially prepared by SICK ready
for use. It has its own logic page and its own configuration dialog. In addition, it
includes automatic calculations for interdependent configuration parameters and addi‐
tional plausibility checks.
Easy Applications make it easier to configure standard applications.
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3.2.2 SISTEMA files
The SISTEMA software assistant provides assistance when assessing controller safety
w
ithin the context of EN ISO 13849-1.
The two SISTEMA files for either one safety encoder or for two non-safe encoders allow
you to assess what performance level can be achieved.
3.3 Application description
The Safe Stationary Machine example application enables the closed-off hazardous
ar
ea of a machine to be accessed safely. It ensures that the machine is stationary
before access to the closed-off hazardous area becomes possible. Alternatively, access
to the hazardous area can also be enabled if the machine is put into a defined safe
state (e.g. maintenance mode with limited speed).
During a safety-related stop or after the machine is switched on, the machine is pre‐
vented from restarting unexpectedly. The machine can only be restarted once the
access point to the hazardous area has been closed and locked, and the machine has
been reset. An emergency stop function is also integrated.
3.4 Structure and function
NOTICE
T
he Safe Stationary Machine example application requires the protective devices to be
structured in a particular way and to perform specific functions.
The primary safety concept is that people and the machine must be physically sepa‐
r
ated. This means that people are not allowed to enter or reach into the hazardous area
while the machine is in a dangerous state.
The main safety elements consist of physical guards (perimeter safeguards, covers)
and movable guards (doors, flaps).
Figure 1: Example structure and function
3 P
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7
2
1
4
5
6
3
M
M
A
S
1
8
9
ß
Figure 2: Structure required
1
Flexi Soft safety controller
2
Operating mode selector switch for Automatic and Service operating modes
3
Control switches for resetting the protective device and restarting the machine (reset and
r
estart)
4
Control switch for unlocking the safety door or machine cover
5
Enabling switch for Service operating mode
6
Emergency stop pushbutton
7
Safety locking device and safety switch for monitoring and interlocking the safety door or
machine cover
8
Two non-safe encoders or one safety encoder
9
Drive with Drive-Enable, Brake, and Safe Torque Off (STO) functions
ß
Physical guard
3.4.1 Interlocking
The Safe Stationary Machine example application features dual-channel protective
de
vice interlocking:
1 Safety locking device: The monitored locking pin is only able to move if the safety
door or machine cover is closed (prevents pin from being moved into the locking
position unintentionally).
2 Safety switch: If the safety door or machine cover is opened, a safety switch
is actuated.
To open the safety door or machine cover, it is necessary to actuate the control switch
for unlocking the safety door or machine cover.
3.4.2 Drive monitoring and standstill control
Two non-safe encoders or one safety encoder are/is used to monitor the drive. The
s
peed is monitored by Drive Monitor FX3-MOC0.
Drive standstill is controlled by the Flexi Soft safety controller using the FX3-XTIO mod‐
ule. This involves using the Drive-Enable, Brake, and STO drive functions.
3.4.3 Operating modes
The Safe Stationary Machine example application features two operating modes. An
oper
ating mode selector switch is used to switch between the operating modes. Switch‐
ing between the operating modes brings the machine to a controlled stop.
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Automatic operating mode
In A
utomatic operating mode, the safety locking device prevents anyone from entering
the hazardous area while the machine is running. Once the machine has been stopped
and the standstill has been detected by the Flexi Soft safety controller, the safety lock‐
ing device can be unlocked and the safety door can be opened. The safety door is also
monitored by means of a safety switch.
The following sequence starts the machine in Automatic operating mode:
1. Close the safety door.
2. Reset the protective device.
3. Restart the machine.
Service operating mode
Ser
vice operating mode allows the hazardous area to be accessed at any time. How‐
ever, in this mode, the machine is only allowed to run at reduced speed. The safety
functions have to be disabled manually for a limited time. The machine parameters are
monitored. When you switch to Service operating mode, it triggers a controlled machine
stop.
The following sequence starts the machine in Service operating mode:
1. Reset the protective device.
2. Press and hold the enabling switch.
3. Restart the machine.
✓
The machine runs at reduced speed.
As soon as you release the enabling switch, the machine stops.
The following sequence starts the machine again:
1. Press and hold the enabling switch.
2. Restart the machine.
Switching to Automatic operating mode at the end of the service work
S
witching between the operating modes brings the machine to a controlled stop.
The following sequence starts the machine in Automatic operating mode:
1. Close the safety door.
2. Reset the protective device.
3. Restart the machine.
3.4.4 Emergency stop
The emergency stop function puts a stop to the dangerous state of the machine. Differ‐
ent seq
uences must be followed to restart the machine depending on which operating
mode is selected.
In Automatic operating mode:
1. Unlock the emergency stop pushbutton.
2. Reset the protective device.
3. Restart the machine.
In Service operating mode:
1. Unlock the emergency stop pushbutton.
2. Reset the protective device.
3. Press and hold the enabling switch.
4. Restart the machine.
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3.4.5 Safe state of the machine
When the machine is in the safe state, the safety outputs are switched off. The machine
is and r
emains switched off. The machine switches to the safe state in the following cir‐
cumstances:
•
A connection between an encoder and the safety controller has been interrupted.
•
The voltage supply to an encoder or to the safety controller has been interrupted.
•
A fault (discrepancy, short-circuit, etc.) has been detected on the connected safety
switches or on the operating mode selector switch.
•
The external device monitoring has detected a fault.
•
The two connected encoders are unable to provide plausible output signals within
the configured discrepancy time.
•
The safety program of the safety controller requires a safety function to be per‐
formed, e.g.:
°
When the emergency stop pushbutton is pressed
°
When the enabling switch is released in Service operating mode
°
If the speed in Service operating mode is too high
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4 Project planning
4.1 Manufacturer of the machine
DANGER
H
azard due to lack of effectiveness of the protective device
In the case of non-compliance, it is possible that the dangerous state of the machine
may not be stopped or not stopped in a timely manner.
b
Before the Safe Stationary Machine example application can be used, a risk
assessment must be carried out. Check that the machine meets the requirements
for the Safe Stationary Machine example application.
b
Comply with the applicable national regulations derived from the application (e.g.,
work safety regulations, safety rules, or other relevant safety guidelines).
4.1.1 Risk assessment
The manufacturer must check whether the Safe Stationary Machine example is suitable
f
or its specific application case (risk assessment).
In any event, additional work is always necessary before the Safe Stationary Machine
example application can be used, e.g. final configuration of the safety controller.
The manufacturer has the following duties:
•
Carrying out a risk assessment
•
Verifying and validating the safety functions
•
Integrating the individual components in accordance with the appropriate stand‐
ards
NOTICE
In addit
ion to the identified risks, please note that machine-specific C-type standards
may contain special requirements. These must be observed.
NOTICE
F
or the purpose of the Safe Stationary Machine example application and the descrip‐
tion below, it has been assumed that a performance level of PL d is required in accord‐
ance with EN ISO 13849-1.
4.1.2 Safety functions
Identification of hazards
It is e
ssential to take account of all potential hazards that might be posed by a rotating
drive or by movement.
•
Cutting
•
Crushing
•
Shearing
•
Stabbing
•
Drawing-in or trapping
•
Entanglement
•
Impact
•
Impact from broken parts
•
Impact from ejected chips
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Definition of safety functions
T
his section describes how technical measures can be implemented to minimize the
risks associated with the relevant machine.
7
1
4
5
M
M
6
3
8
2
A
S
Figure 3: Safety functions
1
00 – Permanently preventing access
2
01 – Preventing unexpected start-up
3
03 – Disabling safety functions manually and for limited time
4
04 – Temporarily preventing access
5
05 – Monitoring machine parameters
6
06 – Combining or switching safety functions
7
10 – Initiating a stop
8
99 – Emergency stop
Table 2: Definition of safety functions
Safety function Code Description
Permanently preventing
ac
cess
00 Access to a hazardous point is prevented by means of
mechanical covers, barriers, or obstacles (referred to as phys‐
ical guards).
Preventing unexpected
start-up
01 After the “Initiating a stop” function is triggered or the
machine is switched on, deliberate actions are required to put
the machine into operation. These actions include manually
resetting a protective device to prepare for restarting the
machine.
Disabling safety func‐
tions manually and for
a limited time
03 Protective devices sometimes have to be disabled to enable
setup work or process monitoring in Service operating mode.
However, in order for the machine to be operated with the
protection disabled, the enabling switch has to be actuated.
Further risk minimization measures should be implemented.
Temporarily preventing
ac
cess
04 Access to a hazardous point is prevented until the machine is
in a safe state.
Monitoring machine
par
ameters
05 In some applications, it is necessary to monitor various
machine parameters for safety-related limits. If a limit is
exceeded, suitable measures are initiated (e.g., stop, warning
signal).
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Combining or switching
s
afety functions
06 A machine can adopt various states or work in various operat‐
ing modes. Within this context, different safety measures may
be effective or different safety functions may be coupled
together. Measures must be implemented to ensure that the
required level of safety is always achieved. The process of
switching between operating modes, or the selection and
adjustment of different safety measures, is not allowed to
lead to a dangerous state.
Initiating a stop 10 A safety-related stop function places the machine in a safe
state on demand (e.g., if a person approaches). To reduce the
required stopping time, it may be advisable to implement a
stop function which complies with stop category 1 (IEC
60204-1-2-9). Additional safety functions may be necessary
to prevent an unexpected restart.
Emergency stop 99 Emergency stop is a supplementary protective measure; it is
no
t a primary means of reducing risk.
The safety level of this function must be defined
based on the risk assessment for the machine. In particular,
influencing environmental factors (e.g., vibrations, method of
actuation, etc.) must be considered.
4.1.3 Implementation of the safety functions
If the Safe Stationary Machine example application is used, the safety functions descri‐
bed be
low must be implemented:
Access protection with standstill monitoring
It is only possible to enter the hazardous area if the Flexi Soft safety controller has
detected that the machine is at a standstill. The safety locking device keeps the safety
door locked while the machine remains in motion.
Safety functions that must be implemented:
•
SF04: Temporarily preventing access
•
SF99 Emergency stop
Setup mode at limited speed
In c
ertain situations (setup, maintenance), the presence of people in the machine's
hazardous area cannot be avoided. In such situations the risk must be reduced by low‐
ering the speed of the machine and making sure that the machine can only move when
an enabling switch is actuated. The actual command that starts the machine must
come from an additional control switch.
The enabling switch must take the form of a three-position switch. Enabling is only
active in position 2. In positions 1 and 3, the drive receives a stop command from the
safety controller and stops the movement.
Following a valid start sequence, the machine speed is monitored by Drive Monitor FX3-
MOC0. If the monitor detects a speed that is higher than the permissible speed, the
safety controller switches off the drive.
Safety functions that must be implemented:
•
SF03: Disabling safety functions manually and for a limited time
•
SF05: Monitoring machine parameters
•
SF99 Emergency stop
Safe stop
A s
afe stop is used to shut down a drive in a controlled manner while monitoring the
stop.
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This may be triggered by an emergency stop pushbutton, for example, or may occur if
t
he safety controller detects that the speed is too high.
The stop ramp of a drive system is not usually safe. For this reason, the FX3-MOC0
“Safe stop” function block monitors the actual reduction in speed until the drive comes
to a standstill.
The FX3-MOC0 “Safe stop” function block supports two stop states as defined in
IEC 61800-5-2 and IEC 60204-1. The difference between the two relates to the end of
the stop ramp. In the case of the safe stop 1 (SS1) function, the drive system torque is
switched off once the drive has come to a standstill.
NOTE
T
he safe stop 1 function corresponds to a controlled stop in accordance with
IEC 60204-1, stop category 1.
By contrast, the torque remains enabled in the case of the safe stop 2 (SS2) function,
but t
he standstill condition is nevertheless monitored. This enables the drive to act as a
stop control.
NOTE
The safe stop 2 function corresponds to a controlled stop in accordance with
IEC 60204-1, stop category 2.
The stop responses that have to be achieved are:
•
S
afe stop 1 (stop category 1), after the emergency stop pushbutton is pressed
•
Safe stop 2 (stop category 2), if a speed is detected that is higher than the maxi‐
mum speed
•
Safe stop 2 (stop category 2), after the enabling switch is released
•
Safe stop 2 (stop category 2), after switching to a different operating mode
•
Safe stop 2 (stop category 2), if the safety door is opened in Automatic operating
mode but no machine standstill has been detected (e.g., if the locking device is
broken)
Safety functions that must be implemented:
•
SF10: Initiating a stop
•
SF01: Preventing unexpected start-up
Calculation of stopping times
T
he stopping times of the various safety functions depend on the response times of the
sensors, the actuators, and the communication path between the Flexi Soft safety con‐
troller, the actuator, and – where applicable – the process control. For details of how to
calculate stopping times, see the “Calculation of response times” section of the
“Flexi Soft modular safety controller hardware” operating instructions (part no.
8012999).
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Subject to change without notice
4.2 Integrating the equipment into the electrical control
4.2.1 Block diagram and circuit diagram
1
M
4
5
A
S
3
K4 Brake
S4-1/2
ENC1
K4.1 Readback Brake
K2 Drive-Enable
K2.1 Readback Drive-Enable
K3 STO
K3.1 Readback STO
ENC2
S5
S6
S2
S1
S8
K1 Locking on safety door
S7 Safety switch
2
S3 Locking monitoring
Figure 4: Block diagram
1
Safety controller
2
Drive
3
Drive control
4
Operating elements
5
Locking device and interlocking
Flexi Soft XTIO
A2 I7 Q1 Q2 Q3 X2Q4I8
A1 I1 I3 I4 I5 X1I6I2
Flexi Soft XTDI
I5 I6 I8 X5 X6 X8X7I7
I1 I2 I4 X1 X2 X4X3I3
Encoder Box
C3
C1
NC1
NC2
C-
C+
B-
B+
A-
A+
0 V
U
out
ENC2
GND
V
S
Splitter Box
C3
C4
C1
NC1
NC2
C-
C+
B-
B+
A-
A+
0 V
U
out
B-
B+
A-
A+
Sin-
Sin+
Cos-
Cos+
ENC1
GND
V
S
Flexi Soft
CPU0
A1
A2
Flexi Soft
MOC0
S1
Connection cable
(Part no. 2067798)
Connection cable
(Part no. 2067800)
S2 S5
S8
K3.1
K4.1K2.1
S6
S4
-1
S4
-2
S7S3
FE
FE
FE
FE
FE
FE
+24 V DC
0 V DC
FE
E180120/01/2017-05-12
K2
K3
K4
K1
Figure 5: Example circuit diagram
4 P
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Table 3: Switching elements
Element Function Tag name in
F
lexi Soft Designer
Comments
S1 Emergency stop pushbut‐
t
on
S1 E-Stop Dual-channel
S2 Enabling switch S2 Enabling switch Dual-channel
S3 Locking device monitor‐
ing
S3 Locking monitoring Dual-channel
S4-1/2 Operating mode selector
s
witch
S4-1 Automatic mode
S4-2 Service mode
e.g., in the form of a key-
operated (break-before-
make) switch
S5 Reset pushbutton S5 Reset Single-channel
S6 Restart button S6 Start Single-channel
S7 Safety switch S7 Safety switch Dual-channel
S8 Control switch for unlock‐
in
g the door
S8 Open door Single-channel
K1 Unlocking solenoid of
safety locking device
K1 Locking on safety
door
Single-channel
K2 Drive contactor K2 Drive-Enable Single-channel
K3 STO contactor K3 STO Single-channel
K4 Brake contactor K4 Brake Single-channel
K2.1 Drive EDM K2.1 Readback Drive-
Enable
Single-channel
K3.1 STO EDM K3.1 Readback STO Single-channel
K4.1 Brake EDM K4.1 Readback Brake Single-channel
ENC1 Encoder 1 A/B incremental, HTL
24 V
, 2 pairs of outputs
A/B incremental encoder
ENC2 Encoder 2 Sine-cosine, 1 Vss Sine-cosine encoder
4.2.2 Requirements for components
NOTICE
T
he manufacturer that integrates the Safe Stationary Machine example application into
its machine is responsible for the selection and use of the components.
All devices must be operated as per their technical specifications.
The operating instructions for the components must be observed.
Any application that relies on the Safe Stationary Machine Easy example application
can only meet the requirements for category 3, performance level d under
EN ISO 13849-1 if the selected components are sufficient to achieve this category and
PL.
Safety locking device and interlocking
V
arious types of switch can be selected to serve as a safety locking device and inter‐
lock. They must conform to EN ISO 14119 and EN 60204-1.
Emergency stop pushbutton
Various types of switch can be selected to serve as an emergency stop pushbutton.
They must conform to EN ISO 13850 and EN 60204-1.
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Subject to change without notice
Enabling switch
V
arious types of switch can be selected to serve as an enabling switch. These must con‐
form to EN 60947-5-8 and EN 60204-1.
Reset
The reset function and the reset pushbutton must be designed to meet the require‐
ments of IEC 60204-1.
Start
The start function and the restart button must be designed to meet the requirements of
IEC 60204-1.
Operating mode selector switch
The operating mode selector switch must conform to ISO 12100:2010 and
IEC 60204-1.
Control switch for unlocking the door
The control switch for unlocking the door must conform to IEC 60204-1.
Encoders
Various types of encoder or motor feedback system can be selected to serve as encod‐
ers.
Non-safe encoders are not designed and manufactured in accordance with safety
standards. If non-safe encoders are used, they must be implemented in a structure that
meets the requirements for category 3.
The structural design must ensure that an individual mechanical fault is not capable of
impairing the detection capabilities of both encoders.
If category 3 safety encoders are used, category 3 can still be achieved with only one
category 3 safety encoder.
The following requirements apply to encoders in general:
•
Encoders must feature a suitable measurement principle.
Safety encoders are subject to the following additional requirements:
•
The safety encoder must be mounted and implemented in accordance with the
safety encoder instructions.
•
The safety encoder must be operated as per its technical specifications.
•
The use of a safety encoder calls for overdimensioning of the mechanical coupling
and mounting to eliminate the risk of mechanical faults.
Additional requirements for non-safe encoders
DANGER
H
azard due to lack of effectiveness of the protective device
In the case of non-compliance, it is possible that the dangerous state of the machine
may not be stopped or not stopped in a timely manner.
The fact that standard encoders are being used outside of their defined scope of appli‐
cation means that the machine manufacturer has particular responsibilities.
b
Heed and follow the notes/instructions below.
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SICK Safe Stationary Machine Operating instructions

SICK
Brand
SICK
Model
Safe Stationary Machine
Type
Operating instructions
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