About the Book

Document Scope

The present document describes the integration of a Safety Logic Controller (SLC) with connected safety-related TM5/TM7 I/O devices into a Logic/Motion Controller environment in EcoStruxure Machine Expert and Machine Expert - Safety.

Topics covered include:

  • Setup of the bus architecture

  • Configuration of the devices

  • Configuration of the standard and safety-related parameters of the devices

  • Setup and creation of a safety-related project

  • Commissioning, operation, and maintenance of the application

  • System diagnostics

  • Interchange of data between the Logic/Motion Controller and the Safety Logic Controller (SLC)

The present document is a general guideline which focuses on the integration of Embedded Safety into the Logic/Motion Controller application. For detailed information on device-specific characteristics and procedures, refer to the respective user guides.

Validity Note

This document has been updated for the release of EcoStruxureTM Machine Expert V2.1.

For product compliance and environmental information (RoHS, REACH, PEP, EOLI, etc.), go to www.se.com/ww/en/work/support/green-premium/.

The characteristics that are described in the present document, as well as those described in the documents included in the Related Documents section below, can be found online. To access the information online, go to the Schneider Electric home page www.se.com/ww/en/download/.

The characteristics that are described in the present document should be the same as those characteristics that appear online. In line with our policy of constant improvement, we may revise content over time to improve clarity and accuracy. If you see a difference between the document and online information, use the online information as your reference.

Related Documents

Document title

Reference

Modicon M262 Logic/Motion Controller - Hardware Guide

EIO0000003659 (ENG)

EIO0000003660 (FRE)

EIO0000003661 (GER)

EIO0000003662 (ITA)

EIO0000003663 (SPA)

EIO0000003664 (CHS)

EIO0000003665 (POR)

EIO0000003666 (TUR)

Safety Logic Controller TM5CSLCx00FS - Hardware Guide

EIO0000000889 (ENG)

EIO0000000891 (GER)

EIO0000000892 (ITA)

EcoStruxure Machine Expert Programming Guide

EIO0000002854 (ENG)

EIO0000002855 (FRE)

EIO0000002856 (GER)

EIO0000002857 (ITA)

EIO0000002858 (SPA)

EIO0000002859 (CHS)

M262 Logic/Motion Controller - Programming Guide

EIO0000003651 (ENG)

EIO0000003652 (FRE)

EIO0000003653 (GER)

EIO0000003654 (ITA)

EIO0000003655 (SPA)

EIO0000003656 (CHS)

EIO0000003657 (POR)

EIO0000003658 (TUR)

TM5 Sercos III Interface - Hardware Guide

EIO0000003221 (ENG)

EIO0000003222 (FRE)

EIO0000003223 (GER)

EIO0000003225 (ITA)

EIO0000003224 (SPA)

EIO0000003226 (CHS)

EcoStruxure Machine Expert - Safety - User Guide

EIO0000002147 (ENG)

EIO0000002338 (GER)

EIO0000004294 (ITA)

Safety Modules - Reference Guide

EIO0000002265 (ENG)

EIO0000002266 (GER)

EIO0000004295 (ITA)

SafeLogger for EcoStruxure Machine Expert - Safety

EIO0000002596 (ENG)

EIO0000002597 (GER)

EIO0000004361 (ITA)

Product Related Information

 DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION OR ARC FLASH
  • Disconnect all power from all equipment including connected devices prior to removing any covers or doors, or installing or removing any accessories, hardware, cables, or wires except under the specific conditions specified in the appropriate hardware guide for this equipment.
  • Always use a properly rated voltage sensing device to confirm the power is off where and when indicated.
  • Replace and secure all covers, accessories, hardware, cables, and wires and confirm that a proper ground connection exists before applying power to the unit.
  • Use only the specified voltage when operating this equipment and any associated products.
Failure to follow these instructions will result in death or serious injury.

For the Safety Logic Controllers:

 DANGER
potential for EXPLOSION
  • Only use this equipment in non-hazardous locations, or in locations that comply with Class I, Division 2, Groups A, B, C and D.
  • Do not substitute components which would impair compliance to Class I, Division 2.
  • Do not connect or disconnect equipment unless power has been removed or the location is known to be non-hazardous.
  • Do not use the USB port(s), if so equipped, unless the location is known to be non-hazardous.
Failure to follow these instructions will result in death or serious injury.

For the Logic/Motion Controllers:

This equipment has been designed to operate outside of any hazardous location. Only install this equipment in zones known to be free of a hazardous atmosphere.

 DANGER
POTENTIAL FOR EXPLOSION
Install and use this equipment in non-hazardous locations only.
Failure to follow these instructions will result in death or serious injury.
 WARNING
INSUFFICIENT AND/OR INEFFECTIVE SAFETY-RELATED FUNCTIONS
  • Perform a risk assessment as per ISO 12100 and/or other equivalent assessment and appropriately consider all applicable regulations and standards that apply to your machine/process before using equipment described in the present document..
  • In your risk assessment, verify that the equipment described in the present document meets all requirements regarding the Safety Integrity Level (SIL), the Performance Level (PL), and any other safety-related requirements and capabilities applicable to your machine/process.
  • In your risk assessment, consider all pertinent manuals and documentation of all products used in your machine/process.
  • Verify that modifications to parameter values, settings, wiring, and any other type of modification to your machine/process, do not compromise or reduce the Safety Integrity Level (SIL), Performance Level (PL) and/or any other safety-related requirements and capabilities applicable to your machine/process.
  • After modifications of any type whatsoever, commission or recommission the machine/process in compliance with all regulations, standards, and process definitions applicable to your machine/process.
  • During commissioning or recommissioning of the machine/process, verify the correct operation and effectiveness of all safety-related functions and non-safety-related functions by performing comprehensive tests for all operating states, for the defined safe state of your machine/process, and for all potential error situations.
  • Do not include any wiring information, programming or configuration logic, parameter values, or any other type of settings described in the present document in your machine/process without thoroughly testing your entire application.
  • Ensure that your overall machine/process in which the Safety Chain Solution is used is properly certified and/or approved according to all standards, regulations, and directives applicable at the installation site of the machine/process.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
 WARNING
LOSS OF CONTROL
  • The designer of any control scheme must consider the potential failure modes of control paths and, for certain critical control functions, provide a means to achieve a safe state during and after a path failure. Examples of critical control functions are emergency stop and overtravel stop, power outage and restart.
  • Separate or redundant control paths must be provided for critical control functions.
  • System control paths may include communication links. Consideration must be given to the implications of unanticipated transmission delays or failures of the link.
  • Observe all accident prevention regulations and local safety guidelines.1
  • Each implementation of this equipment must be individually and thoroughly tested for proper operation before being placed into service.
Failure to follow these instructions can result in death, serious injury, or equipment damage.

1 For additional information, refer to NEMA ICS 1.1 (latest edition), "Safety Guidelines for the Application, Installation, and Maintenance of Solid State Control" and to NEMA ICS 7.1 (latest edition), "Safety Standards for Construction and Guide for Selection, Installation and Operation of Adjustable-Speed Drive Systems" or their equivalent governing your particular location.

Before you attempt to provide a solution (machine or process) for a specific application using the POUs found in the library, you must consider, conduct and complete best practices. These practices include, but are not limited to, risk analysis, functional safety, component compatibility, testing and system validation as they relate to this library.

 WARNING
IMPROPER USE OF PROGRAM ORGANIZATION UNITS
  • Perform a safety-related analysis for the application and the devices installed.
  • Ensure that the Program Organization Units (POUs) are compatible with the devices in the system and have no unintended effects on the proper functioning of the system.
  • Use appropriate parameters, especially limit values, and observe machine wear and stop behavior.
  • Verify that the sensors and actuators are compatible with the selected POUs.
  • Thoroughly test all functions during verification and commissioning in all operation modes.
  • Provide independent methods for critical control functions (emergency stop, conditions for limit values being exceeded, etc.) according to a safety-related analysis, respective rules, and regulations.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
 WARNING
UNINTENDED EQUIPMENT OPERATION
  • Only use software approved by Schneider Electric for use with this equipment.
  • Update your application program every time you change the physical hardware configuration.
Failure to follow these instructions can result in death, serious injury, or equipment damage.

Care must be taken and provisions made for use of this library for machine control to avoid inadvertent consequences of commanded machine operation, state changes, or alteration of data memory or machine operating elements.

 WARNING
UNINTENDED EQUIPMENT OPERATION
  • Place operator devices of the control system near the machine or in a place where you have full view of the machine.
  • Protect operator commands against unauthorized access.
  • If remote control is a necessary design aspect of the application, ensure that there is a local, competent, and qualified observer present when operating from a remote location.
  • Configure and install the Run/Stop input, if so equipped, or, other external means within the application, so that local control over the starting or stopping of the device can be maintained regardless of the remote commands sent to it.
Failure to follow these instructions can result in death, serious injury, or equipment damage.

Terminology Derived from Standards

The technical terms, terminology, symbols and the corresponding descriptions in this manual, or that appear in or on the products themselves, are generally derived from the terms or definitions of international standards.

In the area of functional safety systems, drives and general automation, this may include, but is not limited to, terms such as safety, safety function, safe state, fault, fault reset, malfunction, failure, error, error message, dangerous, etc.

Among others, these standards include:

Standard

Description

IEC 61131-2:2007

Programmable controllers, part 2: Equipment requirements and tests.

ISO 13849-1:2015

Safety of machinery: Safety related parts of control systems.

General principles for design.

EN 61496-1:2013

Safety of machinery: Electro-sensitive protective equipment.

Part 1: General requirements and tests.

ISO 12100:2010

Safety of machinery - General principles for design - Risk assessment and risk reduction

EN 60204-1:2006

Safety of machinery - Electrical equipment of machines - Part 1: General requirements

ISO 14119:2013

Safety of machinery - Interlocking devices associated with guards - Principles for design and selection

ISO 13850:2015

Safety of machinery - Emergency stop - Principles for design

IEC 62061:2015

Safety of machinery - Functional safety of safety-related electrical, electronic, and electronic programmable control systems

IEC 61508-1:2010

Functional safety of electrical/electronic/programmable electronic safety-related systems: General requirements.

IEC 61508-2:2010

Functional safety of electrical/electronic/programmable electronic safety-related systems: Requirements for electrical/electronic/programmable electronic safety-related systems.

IEC 61508-3:2010

Functional safety of electrical/electronic/programmable electronic safety-related systems: Software requirements.

IEC 61784-3:2016

Industrial communication networks - Profiles - Part 3: Functional safety fieldbuses - General rules and profile definitions.

2006/42/EC

Machinery Directive

2014/30/EU

Electromagnetic Compatibility Directive

2014/35/EU

Low Voltage Directive

In addition, terms used in the present document may tangentially be used as they are derived from other standards such as:

Standard

Description

IEC 60034 series

Rotating electrical machines

IEC 61800 series

Adjustable speed electrical power drive systems

IEC 61158 series

Digital data communications for measurement and control – Fieldbus for use in industrial control systems

Finally, the term zone of operation may be used in conjunction with the description of specific hazards, and is defined as it is for a hazard zone or danger zone in the Machinery Directive (2006/42/EC) and ISO 12100:2010.

NOTE: The aforementioned standards may or may not apply to the specific products cited in the present documentation. For more information concerning the individual standards applicable to the products described herein, see the characteristics tables for those product references.