CONTROLS M SERIES SFETY EXHUST DOUBLE VLVES INTEGRTION GUIDE www.rosscontrols.com
M Series Integration Guide Table of Contents Integration Guide M Safety Exhaust Valve Page General Information Introduction Pulse Testing Exhaust Times and Faulted Flow Rates General Operation Integration Guide for Operation & LED Status M Wiring (Pinouts) M LED Status Lights (Operation) Operation & Monitoring Requirements for M Valves 6 7 Validation Test Procedure for Operation & Monitoring 8 9 Integration Guide (Safe Relay with Standard PLC for Cat, PL d) Rockwell (0R) Schmersal (SRB) Siemens (Sirius SK) Integration Guide (Programmable Safe Relay for Cat, PL e) Pilz (PNOZ) 8 9 Rockwell Guardmaster (0CCR0) 0 Integration Guide (Safe PLC I/O for Cat, PL e) Rockwell rmorblock Guard (7ESxxx) Siemens (ET00PRO) 6 Siemens (Simatic S7) 7 8 Turck (TBPN) 9 Cautions, Warnings and Standard Warranty 08, ROSS CONTROLS. ll Rights Reserved.
Introduction M Series Integration Guide ROSS Controls offers a variety of safety valves for use in various safety functions such as safe exhaust, safe cylinder return, and safe load holding/stop. This document focuses specifically on ROSS Controls M Series valves that are used for safe exhaust functions and utilize solid state pressure sensors to provide feedback to a safety control system for external monitoring. Wiring examples are provided in this document and are shown using specific connections as wired and tested, but there may be other terminals available to use on the various controllers. These are just examples. This integration guide is intended to assist you in integrating the product into your control circuit. However, programs provided in this integration guide are for reference only. These programs have not been certified or tested unless indicated otherwise. While all potential electrical safety control suppliers and solutions cannot be covered, this document provides a template for some suppliers and their devices. Each solution has been designed to meet a specific category and performance level based on ISO 89. Meeting these levels requires other aspects of the system to meet these requirements such as, but not limited to, plumbing, wiring, and monitoring. Pulse Testing In dual channel safety circuits, pulse testing is a method utilized to detect fault conditions that, otherwise, may be undetected. Pulse testing is required in dual channel circuits in order to reach performance level e (PL e). Pulse testing of the solenoids is encouraged and will not affect the performance of the ROSS M valve. However, pulse testing of the feedback sensors is not required. There are two methods of pulse testing outputs. The most common method is to use the native pulse testing instruction embedded by the manufacturer in Safety PLC s and Safety I/O Modules. The other method is to use custom programming code generated by the user. We recommend the use of native pulse testing instructions of the respective manufacturers safety PLC s or I/O modules because these instructions are fixed and cannot be tampered with. These instructions typically have a frequency of 00ms to 600ms and a duration of 0.ms to 0.8ms. Pulse testing the outputs to the solenoids on the M valve at this frequency and duration does not affect the performance of the valve, but does provide a method to monitor for the occurrence of wiring faults in the output portion of the safety circuit controlling the valve solenoids. Exhaust Times and Faulted Flow Rates When designing a safety circuit, the machine stopping time is a critical factor that determines the placement of guarding solutions. One factor in safe distance calculations is the exhaust time of the valve that is responsible for isolating and dumping the pneumatic energy from the machine. The faster your valve exhausts the quicker the machine can stop and the closer your safety devices may be placed to the hazardous area. This can improve overall operating efficiency, and possibly allow the footprint of the machine to be smaller. Even more important than exhaust time is the Faulted exhaust flow rate. Faulted exhaust flow rate is the exhaust rate of the valve in its worst state. Double valves (redundant valve systems used for safety applications) will not exhaust quite as quickly when there is an internal fault condition in the valve such as when one of the redundant valve components is actuated and the other one is not actuated. For this reason, double valves used in safety circuits should always be sized using faulted flow rates as the worst case condition. The chart below shows the M valve s very highflow faulted exhaust flow times at various downstream volumes and operating pressures. Exhaust Time Normal and Faulted Conditions (s) Volume ft (L) 0.07 () 0. (0) 0.7 (0). (0).0 (0) Normal or Faulted to psig ( bar) Operating Pressure 0 psig ( bar) 90 psig (6 bar) psig (0 bar) to 7 psig (0. bar) to psig ( bar) to 7 psig (0. bar) to psig ( bar) to 7 psig (0. bar) N 0.0 0.07 0.09 0. 0.0 0. F 0.07 0.098 0.7 0.8 0.00 0.7 N 0. 0.08 0.7 0.9 0. 0.07 F 0.8 0.0 0. 0.70 0.789.0 N 0.6 0.79 0.97 0.76 0.80 0.97 F 0.6 0..06.68.6.997 N 0.6 0.7...6.899 F 0.608.06.98.68.000.9 N.6.60.7.6.7 7.006 F.60.8 7.98 9.99.07.6 www.rosscontrols.com
M Series Integration Guide Soft Start djustment The function of the optional EEZON (soft start) module is to, on energization, allow outlet pressure to increase at a slower than normal rate until it reaches approximately 60% of inlet pressure, at which point the valve will then open fully to finish filling the system at full flow rate. This feature can be used to lessen the shock of sudden, rapid pressurization of cylinders, and to gradually refill the system. The EEZON module has an adjusting screw that is used to control the rate of pressurization according to number of turns and inlet pressure. The chart on the right can be used to approximate the number of turns (clockwise from full open) it will take in order to adjust the soft start for your system. The necessary setting is dependent upon the number of turns, inlet pressure, and downstream volume to be filled by the valve. M Series Soft Start djustment Flow vs Number of Turns and Inlet Pressure 6000 0 000 80 N Liters/min 000 000 000 0 00 80 SCFM 000 0 0 0 0 6 8 0 Turns (counterclockwise) 0 psig ( bar) 60 psig ( bar) 90 psig (6 bar) psig (8 bar) psig (0 bar) General Operation The ROSS M schematic shows patented cross flow technology and solid state pressure sensors for status feedback. The red box highlights the optional softstart in the unit. Solenoid B Solenoid Pressure Sensors Sensor 08, ROSS CONTROLS. ll Rights Reserved.
M Series Integration Guide M Wiring (Pinouts) The M valve is available with various wiring options for both the solenoid cable and the sensor cable. For example, the following model number is wired internally with the DB wiring option: Model Number: MS0GEXDBG This means the valve in this example is wired with the D solenoid configuration and the B Sensor configuration. Use these diagrams to determine the proper pinouts for your valve. Solenoid M Pinouts Pressure Sensor M Pinouts Sensor Sol Sol Sensor C Sol Sol B D Sol Sol Sensor C Solenoid B B C C C C CC D B DB D C DC M LED Status Lights (Operation) Solenoid Power LED s: These LED s operate independently to indicate power is applied to the solenoids. Green: Power applied. OFF: No power applied. Sensor Power (SEN PWR): This LED indicates whether or not power is applied to the feedback sensors. Green: Power applied. OFF: No power applied. FULT (FLT): Flashing Red: Sensors are in different States. The M unit will automatically fail to a mechanical safe state (no downstream pressure). The monitoring logic should automatically shut off power to both solenoids. it indicates the monitoring logic is not properly detecting this fault. The M unit should be powered down and monitoring logic reviewed and retested before putting into operation again it indicates the unit has an internal malfunction and should be replaced before continuing operation. OFF: Sensors in same state no issue. www.rosscontrols.com
M Series Integration Guide Operation & Monitoring Requirements for M Valves The intent of this document is to provide guidance on how to operate and monitor the M valve for safe operation. test procedure is also provided for verification and validation of the user s external safety control monitoring system. Valve Operation The M valve is a redundant safety exhaust (dump) valve. Its function is that of a /, normally closed, singlesolenoid valve. However, because the valve is redundant it has two operating solenoids that must be operated simultaneously in order to actuate the valve. ctuating the valve will supply pressure from port (supply) to port (outlet) and close port (exhaust). Deactuating the valve will close port (supply) and open port (outlet) to port (exhaust). Deactuation of the valve is accomplished by turning off both solenoids simultaneously. In the event of a valve fault where one of the redundant valve components does not operate synchronously as commanded, the valve will perform its safety function which is to shut off supply and exhaust downstream pressure to atmosphere. Synchronous operation occurs when both sets of valve internals shift within 0 msec of each other. Failure of the valve to shift synchronously leads to a fault in the M valve. This could happen for a variety of reasons, such as: Compromised piston seals Main valve elements experiencing a switching delay due to dirt, debris or resinous oil Insufficient electrical signals to valve solenoids; suitable voltage not available Receipt of signals at solenoids not synchronous Pilot valves experiencing a switching delay due to damaged components, dirt, debris or resinous oil Excessive water buildup in the valve Feedback Monitoring The M valve is equipped with feedback pressure sensors that must be monitored by the user s external safety control & monitoring system to detect any fault condition within the valve. Sensor feedback should always agree with the solenoid actuating signals. Detection of any valve fault should disable the safety control outputs to the valve solenoids and prevent any subsequent attempts to actuate the valve until a safety control system reset is performed. Refer to EN ISO89 for Cat vs Cat monitoring. ctuation Fault Monitoring ctuation fault monitoring should check for valve actuation synchronicity. fter the safety control system outputs provide simultaneous actuation signals to both solenoids, both sensor outputs should switch off within 0 msec of each other. Dependent upon which sensor switches off first, the following faults should be detected.. side fault detection if sensor does not switch off within 0 msec after sensor B switches off, this should be registered as a fault.. B side fault detection if sensor B does not switch off within 0 msec after sensor switches off, this should be registered as a fault. Dectuation Fault Monitoring Dectuation fault monitoring should check for valve deactuation synchronicity. fter the safety control system simultaneously removes the actuation signals from both solenoids, both sensor outputs should switch on within 0 msec of each other. Dependent upon which sensor switches on first, the following faults should be detected.. side fault detection sensor does not switch on within 0 msec after sensor B switches on, this should be registered as a fault.. B side fault detection if sensor B does not switch on within 0 msec after sensor switches on, this should be registered as a fault. 6 08, ROSS CONTROLS. ll Rights Reserved.
Loss of Supply Pressure While ctuated M Series Integration Guide The condition of loss of supply pressure while the valve is actuated must be detected by the safety control monitoring system. Loss of supply pressure while actuated should cause both sensors to switch on due to lack of pressure in both valves outlet port even though the valve is still energized. This fault can be detected when the solenoids are high, and one or both sensors go from low (sensing pressure) to high (not sensing pressure). No Supply Pressure pplied Before ctuation Monitoring of supply pressure may also be utilized if deemed beneficial for the application, but is not required. If you choose to detect this condition it would require the addition of an upstream pressure switch or transducer. The condition of the pressure switch or transducer should be monitored to prevent actuation of the valve when supply pressure is insufficient. Safety System Reset ny detected fault in the valve system should cause the safety control system to deactuate the valve by removing power from both solenoids. reset of the safety control system should only be possible after the valve sensors indicate that the valve is in the deactuated state (both sensors switched on). www.rosscontrols.com 7
M Series Integration Guide Validation Test Procedure for Valve Operation and External Monitoring Logic NOTE: This test procedure should only be performed with an M valve that is known to be functioning properly. If basic valve function is in question, please refer to Section 8 of the Product Operating Instructions for the Valve Test Procedure. Valve Operation. Energize solenoids & B simultaneously. Valve is on, air pressure is supplied downstream from supply port through outlet port, and exhaust port is shut off. Sensors & B are off.. Deenergize solenoids & B simultaneously. Valve is off, supply port is blocked, and downstream air is exhausted from outlet port through exhaust port. Sensors & B are on. ctuation Fault Monitoring (with Fault Latching) These test procedures require fault simulation. It will be necessary to induce faults electrically by disabling one solenoid or the other at different times, which may require special test cabling in order to complete the test procedure. See product data sheet.. Energize only solenoid. This should result in a sensor switching off while sensor B stays on. Your safety control monitoring system should detect this fault in the valve, where sensor switches off and sensor B stays on more than 0 msec after sensor switches off. This fault should trigger the safety outputs to switch off in order to deenergize both solenoids, & B. The fault should be latched in by the safety control system logic until the system is reset. While the fault exists supply port is blocked, and downstream air from outlet port is open to exhaust port. Once the safety control system deenergizes the solenoids, sensors and B should both be on.. Before attempting to reset the safety control system, attempt to energize both solenoids, & B, simultaneously. Supply port should remain blocked and downstream air from outlet port should remain open to exhaust via exhaust port.. Deenergize both solenoids & B. 6. Reset the safety control system. 7. Energize only solenoid B. This should result in sensor staying on while sensor B switches off. Your safety control monitoring system should detect this fault in the valve, where sensor B switches off and sensor stays on more than 0 msec after sensor B switches off. This fault should trigger the safety outputs to switch off in order to deenergize both solenoids & B. The fault should be latched in by the safety control system logic until the system is reset. While the fault exists, supply port is blocked, and downstream air from outlet port is open to exhaust port. Once the safety control system deenergizes the solenoids, sensors and B should both be on. 8. Before attempting to reset the safety control system, attempt to energize both solenoids, & B, simultaneously. Supply port should remain blocked and downstream air from outlet port should remain open to exhaust via exhaust port. 9. Deenergize both solenoids & B. 0. Reset the safety control system. Dectuation Fault Monitoring (with Fault Latching) These test procedures require fault simulation. It will be necessary to induce faults electrically by disabling one solenoid or the other at different times, which may require special test cabling in order to complete the test procedure. See product data sheet.. Energize solenoids & B, simultaneously. This switches the valve on and should result in air pressure being supplied downstream from supply port through outlet port, and exhaust port being shut off. Sensors & B should both switch off.. Deenergize only solenoid. The safety control system should detect the fault in the valve where sensor switches on and sensor B stays off more than 0 msec after sensor switches on. This fault should trigger the safety outputs to switch off in order to deenergize both solenoids and B. The fault should be latched in by the safety control system logic until the system is reset. While the fault exists supply port is blocked and downstream air from outlet port is open to exhaust port. Once the safety control system deenergizes the solenoids, sensors and B should be both on.. Before attempting to reset the safety control system, attempt to energize both solenoids and B simultaneously. Supply port should remain blocked and downstream air from outlet port should remain open to exhaust via exhaust port. 8 08, ROSS CONTROLS. ll Rights Reserved.
Dectuation Fault Monitoring (with Fault Latching) Continued M Series Integration Guide. Deenergize both solenoids & B.. Reset the safety control system. 6. Energize both solenoids, & B simultaneously. This switches the valve on and should result in air pressure being supplied downstream from supply port through outlet port, and exhaust port being shut off. Sensors & B should both switch off. 7. Deenergize only solenoid B. The safety control system should detect the fault in the valve where sensor B switches on and sensor stays off more than 0 msec after sensor B switches on. This fault should trigger the safety outputs to switch off in order to deenergize both solenoids, & B. The fault should be latched in by the safety control system logic until the system is reset. While the fault exists supply port is blocked, and downstream air from outlet port is open to exhaust port. Once the safety control system deenergizes the solenoids, sensors and B should both be on. 8. Before attempting to reset the safety control system, attempt to energize solenoids, & B simultaneously. Supply port should remain blocked and downstream air from outlet port should remain open to exhaust via exhaust port. 9. Deenergize both solenoids & B. 0. Reset the safety control system. Monitoring for Loss of Supply Pressure While ctuated. Energize both solenoids, & B, simultaneously. This switches the valve on and should result in air pressure being supplied downstream from supply port through outlet port, and exhaust port being shut off. Sensors & B should both switch off.. Remove supply air from supply port. Sensors & B should switch on. External monitoring should detect the condition where both solenoids are on, but one or both sensors go from low (sensing pressure) to high (not sensing pressure). This fault should trigger the safety outputs to switch off in order to deenergize both solenoids, & B. The fault should be latched in by the safety control system logic until the system is reset. While the fault exists, supply port is blocked, and downstream air from outlet port is open to exhaust port. Sensors and B should remain on.. Resupply air to supply port. Supply port is blocked and downstream air from outlet port is open to exhaust via port. Sensors & B should both be on. Resupplying air while the fault is latched in the safety control system should not result in air being supplied from supply port to outlet port.. Reset the safety control system. www.rosscontrols.com 9
M Series Integration Guide Integration Guide for pplications Using a Safety Relay with a Standard PLC for External Monitoring (for applications requiring CT, PL d) 0 08, ROSS CONTROLS. ll Rights Reserved.
M Series Integration Guide Integration Guide for Rockwell 0RDS Rockwell 0RDS Part Number: 0RDS Functional Safety Rating: Cat, PL e Uses terminals Customer will have colored wires Can be wired with a PLC for sensors monitoring Examples include with and without pin outs and valve schematic Generic Connection Example (from Rockwell Catalog): The DIS safety relay has two dualchannel inputs and four solidstate outputs. Two of the four solidstate outputs are designed to operate with highcapacitance loads. In addition, the DIS safety relay has SWS input and output. The DIS safety relay can be set for automatic or monitored manual reset by adjusting the switch on the front panel. The configuration switch also sets the ND/OR logic that is applied to the inputs. Con ation Switch d ment Mechanical Stops Screwdriver Slot 0 IMPORTNT djust the switches gently and do not turn past the mechanical stops. Position Reset Function 0 Not pplicable (IN or IN) or L Monitored Manual (IN and IN) or L (IN and IN) and L (IN or IN) or L 6 (IN and IN) or L utomatic/manual 7 (IN or IN) and L 8 (IN and IN) and L Terminal Function V Supply (0%, %) V Common S Pulse Test Output for Channel S Pulse Test Output for Channel S Safety Input for IN Channel S Safety Input for IN Channel S Safety Input for IN Channel S Reset Input S Safety Input for IN Channel Y uxiliary NonSafety Output L Single Wire Safety Output L Single Wire Safety Input, Safety Outputs OSSD, Safety Outputs OSSD for Capacitive Loads www.rosscontrols.com
M Series Integration Guide Integration Guide for Rockwell 0RDS Rockwell 0RDS Wiring Schematic with PLC to Interface to Safety Exhaust Valve With this schematic it is possible to achieve up to Cat, PL d if properly implemented. v 0v S This schematic shows an example of an estop circuit for reference only S S S S S S Safety Relay Out 0 Out Out PLC L L Y S In 0 In In In WHITE BLUE Solenoid B BLCK Solenoid RESET Wire Colors Brown Black White Grey Blue Sol B Sol Pressure Sensors Sensor WHITE BLUE BLCK Sensor BROWN Rockwell 0RDS Program* External monitoring program: a) Sensor error : In <> In after discrepancy time at 0 ms. b) Feedback error : In = In = In0 after installation discrepancy time. c) If error Reset Out & Out. Reset error only after maintenance acknowledge. Reset function. d) IF No feedback error & In. Out0 = pulse of s. c) If error Reset Out & Out. Reset error only after maintenance acknowledge. Reset function. d) IF No feedback error & In. Out0 = pulse of s. *Programs provided in this integration guide are for reference only. These programs have not been certified or tested unless stated otherwise. 08, ROSS CONTROLS. ll Rights Reserved.
M Series Integration Guide Integration Guide for Schmersal SRBE0ST Schmersal SRBE0ST Part Number: SRBE0*ST *= or double inputs Functional Safety Rating: Cat, PL e Uses terminals Customer will have colored wires Can be wired with a PLC for sensor monitoring Examples include with and without pin outs and valve schematic Generic Connection Example for Schmersal SRBE0ST (from Schmersal Catalog): The safety relay has two dualchannel inputs and four solidstate outputs. Two of the four solidstate outputs are designed to operate with highcapacitance loads. In addition, the safety relay has SWS input and output. The safety relay can be set for automatic or monitored manual reset by adjusting the switch on the front panel. The configuration switch also sets the ND/OR logic that is applied to the inputs. Schmersal Wiring Schematic for SRBE0ST with PLC to Interface to Safety Exhaust Valve With this schematic it is possible to achieve up to Category, PL d if properly implemented. v 0v S This schematic shows an example of an estop circuit for reference only X S S S S X7 WHITE BLUE Solenoid B Safety Relay Q Q Y X BLCK Solenoid Out 0 Out Out PLC In 0 In In In RESET Wire Colors Brown Black White Grey Blue Sol B Sol BLUE BROWN Pressure Sensors Sensor WHITE BLCK Sensor Schmersal Program* External monitoring program: a) Sensor error : In <> In after discrepancy time at 0 ms. b) Feedback error : In = In = In0 after installation discrepancy time. c) If error Reset Out set error only after maintenance acknowledge. Reset function. d) IF No feedback error & In. Out0 = pulse of s. * Programs provided in this integration guide are for reference only. These programs have not been certified or tested unless stated otherwise. www.rosscontrols.com
M Series Integration Guide Integration Guide for Siemens SK Siemens SK Part Number: SK Functional Safety Rating: Cat, PL e Uses terminals Customer will have colored wires Can be wired with a PLC for sensor monitoring Examples include with and without pin outs and valve schematic Safety Function Information (from Siemens Catalog): The safety relay has two dualchannel inputs and four solidstate outputs. Two of the four solidstate outputs are designed to operate with highcapacitance loads. In addition, the safety relay has SWS input and output. The safety relay can be set for automatic or monitored manual reset by adjusting the switch on the front panel. The configuration switch also sets the ND/OR logic that is applied to the inputs. safety function describes the reaction of a machine/plant to the occurrence of a specific event (e.g., opening of a protective door.) Execution of the safety function(s) is carried out by a safetyrelated control system. This usually comprises three subsystems, detecting, evaluating and reacting. Detecting (sensors): Used to detect a safety requirement, e.g., emergency stop or a sensor for monitoring a hazardous area (light array, laser scanner etc) is operated. Evaluating (safety relay): Detecting a safety requirement and safely initiating the reaction (e.g., switching off the safety related outputs). Monitoring the correct operation of sensors and actuators. Initiating a reaction upon detection of faults. For the SKI products described in this guide, this concerns evaluation units for safety functions. Reacting (actuators): Switching off the hazard by means of downstream actuators. Detecting (Sensors) Evaluating (Safety Relay) Reacting (ctuators) Generic Siemens Wiring Schematic for SK (from Siemens Catalog) Exhaust Valve 08, ROSS CONTROLS. ll Rights Reserved.
Integration Guide for Siemens SK Siemens Wiring Schematic with Dual Output to Interface to Safety Exhaust Valve Siemens Wiring Schematic with One Safe Output to Interface to Safety Exhaust Valve Q Q Q Q BLCK WHITE BLCK SOL SOL SOL SOL 0v v BLUE 0v v BLUE M Series Integration Guide (options & C) Wire Colors Brown Black White Grey Blue Sol B C Sol B Sol Sol Siemens Wiring Schematic for SKBB0 with PLC to Interface to Safety Exhaust Valve With this schematic it is possible to achieve up to Category, PL d if properly implemented. v 0v S This schematic shows an example of an estop circuit for reference only T T N N NF NK Safety Relay Q Q QM NS Out 0 Out PLC In 0 In In In WHITE BLUE BLCK Reset Solenoid B Solenoid RESET Wire Colors Brown Black White Grey Blue Sol B Sol BLUE BROWN Pressure Sensors Sensor WHITE BLCK Sensor Siemens Program* External monitoring program: a) Sensor error : In <> In after discrepancy time at 0 ms. b) Feedback error : In = In = In0 after installation discrepancy time. c) If error Reset Out set error only after maintenance acknowledge. Reset function d) IF No feedback error & In Out0 = pulse of s * Programs provided in this integration guide are for reference only. These programs have not been certified or tested unless stated otherwise. www.rosscontrols.com
M Series Integration Guide 6 08, ROSS CONTROLS. ll Rights Reserved.
M Series Integration Guide Integration Guide for pplications Using a Safety Relay for External Monitoring (for applications requiring Cat, PL e) www.rosscontrols.com 7
Blockschaltbild diagram PNOZ mm0.p M Series Integration Guide Integration Guide for Pilz PNOZ Pilz PNOZ Part Number: 7700 Pnoz m B0 Functional Safety Rating: Cat, PL e Uses terminals Customer will have colored wires Can be wired with and without test pulses on the sensors Examples include with and without pin outs and valve schematic Block diagram Pin Male Brown White Blue Black Grey Pilz Wiring Schematic (without sensor test pulse) to Interface to Safety Exhaust Valve With this schematic it is possible to achieve up to Category, PL e if properly implemented. 0V V IM6 T0M0 IM7 TM IM8 TM IM9 TM I8 IM0 I9 IM I0 IM I IM SENSOR B BROWN B BLUE Wire Colors Brown Black White Grey Blue B O0 O 0V O V O BLCK I I I I I I6 I I7 B WHITE B BLCK SOL SENSOR B B GREY BLUE Sensor WHITE SOL B Sol B Sol 8 08, ROSS CONTROLS. ll Rights Reserved.
M Series Integration Guide Integration Guide for Pilz PNOZ Pilz Wiring Schematic (with sensor test pulse) to interface to Safety Exhaust Valve With this schematic it is possible to achieve up to Category, PL e if properly implemented. IM6 T0M0 IM7 TM IM8 TM IM9 TM B GREY I8 IM0 I9 IM I0 IM I IM B BROWN SENSOR B BLUE 0V V Wire Colors Brown Black White Grey Blue B O0 O 0V O V O BLCK I I I I I I6 I I7 B WHITE B BLCK SENSOR B SOL BLUE Sensor WHITE SOL B Sol B Sol Pilz Program* Contains pinouts; these can vary based on wiring, i.e., feedback listed as I6 & I7, could be I, I, I6, or I7 * Programs provided in this integration guide are for reference only. These programs have not been certified or tested unless stated otherwise. www.rosscontrols.com 9
M Series Integration Guide Integration Guide for Rockwell 0CCR0 Rockwell 0CCR0 Part Number: 0CCR0BBB Functional Safety Rating: Cat, PL e Software configured safety relay safety I/O with embedded serial port USB programming port plugin slots V DC Generic Connection Example (from Rockwell Catalog): V DC Input Devices with Mechanical Contacts 00 0 0 0 0 0 06 07 08 Input Terminal Block 0 DC COM Input/Output Terminal Block V 0V 6 7 8 9 0 09 V Common Pulse Test Output m Typical Circuit Status The Estop is released and all output devices D...D are OFF. The Feedback Closed indicator is ON. Operational Sequence. Press the Reset button. ll four output devices D...D turn ON and the Feedback Closed indicator turns OFF.. Press the Estop button. ll four output devices D...D turn OFF and the Feedback Closed indicator turns ON. With a short circuit across one of the output device contacts:. Press the Reset button. ll four output devices D...D turn ON and the Feedback Closed indicator remains ON. fter approximately 0 ms, the output devices D...D turn OFF and the Feedback Closed indicator remains ON. Each time the reset button is pressed, the output turns ON momentarily and then turns OFF. The CR0 Safety relay detects the short circuit with the XOR logic in the LL function block. This block allows either the Feedback_OK or Feedback_Fault to turn on the output devices, but not both signals. Rockwell Wiring Schematic (without sensor test pulse) to Interface to Safety Exhaust Valve () Wiring Option 0V V This schematic shows an example of an estop circuit for reference only. SENSOR BROWN BLUE Wire Colors Brown Black White Grey Blue 6 7 8 9 0 BLCK WHITE 00 0 0 0 0 0 09 06 0 07 08 WHITE BLCK SENSOR B SOL SOL B BLUE Sensor Sol B Sol With this schematic it is possible to achieve up to Category, PL e if properly implemented. 0 08, ROSS CONTROLS. ll Rights Reserved.
M Series Integration Guide Integration Guide for Rockwell 0CCR0 Rockwell Wiring Schematic (with sensor test pulse) to Interface to Safety Exhaust Valve (B) Wiring Option This schematic shows an example of an estop circuit for reference only 6 7 8 9 0 BLCK WHITE B GRY B BROWN 00 0 0 0 0 0 09 06 0 07 08 B WHITE B BLCK SOL SENSOR SENSOR B SOL B B BLUE BLUE 0V 0V V Wire Colors Brown Black White Grey Blue B Sensor Sol B Sol With this schematic it is possible to achieve up to Category, PL e if properly implemented. Rockwell Wiring Schematic (without sensor test pulse) to Interface to Safety Exhaust Valve (B) Wiring Option This schematic shows an example of an estop circuit for reference only 6 7 8 9 0 BLCK WHITE 00 0 0 0 0 0 09 06 0 07 08 B WHITE B BLCK SOL SENSOR SENSOR B SOL B B BROWN B BLUE B GRY BLUE V Wire Colors Brown Black White Grey Blue B Sensor Sol B Sol With this schematic it is possible to achieve up to Category, PL e if properly implemented. Rockwell Program* External monitoring program: a) IF I. = I.6 = I. THEN set O.8 = O.9 =. b) Sensor discrepancy error: I. <> I.6 (max. discrepancy time = 0 msec). c) Loss of pressure error: I.7 = I.8 = 0 ND O.8 = O.9= followed by I.7=I.8=O.8=O.9=. d) IF sensor discrepancy error OR loss of pressure error THEN reset O.8 = O.9 =0. Errors must be reset only after maintenance acknowledgement. * Programs provided in this integration guide are for reference only. These programs have not been certified or tested unless stated otherwise. www.rosscontrols.com
M Series Integration Guide 08, ROSS CONTROLS. ll Rights Reserved.
M Series Integration Guide Integration Guide for pplications Using a Safety PLC for External Monitoring and Safe IO (for applications requiring Cat, PL e) www.rosscontrols.com
M Series Integration Guide Integration Guide for Rockwell 7ESIB8XOB8 Rockwell 7ESIB8XOB8 Part Number: 7ESIB9X0B8 Functional Safety Rating: Cat, PL e Uses M Direct M cable Central or IO modules Dual output The Guard I/O modules implement the CPI Safety protocol extensions over EterNET/IP networks and provide various features for a safety system. Use the module to construct a safetycontrol network system that meets the following requirements, up to and including: Safety Integrity Level Claim Limit (SIL CL ), as defined in IEC 608 Category (CT.), Performance Level e (PLe), as defined in ISO89 Rockwell 7ESIB8XOB8 Wiring Schematic (from Rockwell Catalog) to Interface to Safety Exhaust Valve With this schematic it is possible to achieve up to Category, PL e if properly implemented. SENSOR B BROWN B WHITE B BLUE I0/ O0/ Wire Colors Brown Black White Grey Blue B B GRY SENSOR B B BLCK Sensor BLCK SOL BLUE Sol B Sol WHITE SOL B Rockwell Program* External monitoring program: a) IF I.0 = I. = THEN set O.0 = O. = when commanded. b) Sensor discrepancy error: I.0 <> I. (max. discrepancy time = 0 msec). c) Loss of pressure error: I.0 = I. = 0 ND O.0 = O.= followed by I.0=I.=O.0=O.=. d) IF sensor discrepancy error OR loss of pressure error THEN reset O.0 = O.=0. Errors must be reset only after maintenance acknowledgement. * Programs provided in this integration guide are for reference only. These programs have not been certified or tested unless stated otherwise. 08, ROSS CONTROLS. ll Rights Reserved.
M Series Integration Guide Integration Guide for Rockwell 7ES IB8X0BV Rockwell 7ESIB8XOBV Part Number: 7ESIB8X0BV Functional Safety Rating: Cat, PL e Uses M Direct M cable Central or IO modules Safe output The Guard I/O modules implement the CPI Safety protocol extensions over EterNET/IP networks and provide various features for a safety system. Use the module to construct a safetycontrol network system that meets the following requirements, up to and including: Safety Integrity Level Claim Limit (SIL CL ), as defined in IEC 608 Category (CT.), Performance Level e (PLe), as defined in ISO89 B C D E F G H Rockwell 7ESIB8XOBV Wiring Schematic (from Rockwell Catalog) to Interface to Safety Exhaust Valve With this schematic it is possible to achieve up to Category, PL e if properly implemented. SENSOR B BROWN B WHITE B BLUE I0/ O0/ Wire Colors Brown Black White Grey Blue B B GRY SENSOR B B BLCK Sensor D BLCK SOL D WHITE D Sol B Sol SOL B Rockwell Program* External monitoring program: a) IF I.0 = I. = THEN set O.0 = O. = when commanded. b) Sensor discrepancy error: I.0 <> I. (max. discrepancy time = 0 msec). c) Loss of pressure error: I.0 = I. = 0 ND O.0 = O.= followed by I.0=I.=O.0=O.=. d) IF sensor discrepancy error OR loss of pressure error THEN reset O.0 = O.=0. Errors must be reset only after maintenance acknowledgement. * Programs provided in this integration guide are for reference only. These programs have not been certified or tested unless stated otherwise. www.rosscontrols.com
M Series Integration Guide Integration Guide for Siemens ET00PRO Safe Siemens ET00PRO Safe Part Number: ET00PRO Safe Functional Safety Rating: Cat, PL e Uses M Direct M cable Central or IO modules Examples include with and without pin outs and valve schematic Generic Connection Example (from Siemens Catalog): L 8/6 FDI /8 FDI/ FDO L M Vs DI0 DI DI DI Vs DI DI DI6 DI7 S0 S S S L M Sensor contacts are mechanically coupled. Siemens Wiring Schematic for ET00PRO Safe to Interface to Safety Exhaust Valve With this schematic it is possible to achieve up to Category, PL e if properly implemented. SENSOR C GRY C WHITE C BLUE I0/ O0/ Wire Colors Brown Black White Grey Blue C C BROWN SENSOR B C BLCK Sensor C BLCK SOL SOL B C BLUE C Sol B Sol Siemens Program* External monitoring program: a) Sensor error : I.0 <> I.. djust discrepancy time at 0 ms. c) Feedback error : I.0 = I. = Out 0. djust discrepancy time. d) IF feedback or sensor error THEN reset Out 0. Errors must be reset only after maintenance acknowledgement. * Programs provided in this integration guide are for reference only. These programs have not been certified or tested unless stated otherwise. 6 08, ROSS CONTROLS. ll Rights Reserved.
M Series Integration Guide Integration Guide for Siemens Simatic S7 Siemens Simatic S7 Part Number: Simatic S7 Functional Safety Rating: Cat, PL e Uses Terminals Customer will have colored wires Central or IO modules Examples include with and without pin outs and valve schematic Siemens Wiring Schematic Safe Output without Sensor Test Pulse Version C to Interface to Safety Exhaust Valve With this schematic it is possible to achieve up to Category, PL e if properly implemented. 0V V SENSOR BROWN BLUE Wire Colors Brown Black White Grey Blue 0V V (P) (M) Dib.0 Dia.0 WHITE BLCK SENSOR B Sensor C BLCK C BLUE SOL SOL B C Sol B Sol www.rosscontrols.com 7
M Series Integration Guide Integration Guide for Siemens Simatic S7 Siemens Wiring Schematic Safe Output without Sensor Test Pulse Version CC to Interface to Safety Exhaust Valve With this schematic it is possible to achieve up to Category, PL e if properly implemented. 0V V SENSOR C GRY C BLUE Wire Colors Brown Black White Grey Blue C 0V V (P) (M) C BLUE Dib.0 Dia.0 C BLCK C WHITE C BLCK SENSOR B SOL SOL B C BROWN Sensor C Sol B Sol Siemens Wiring Schematic Safe Output with Sensor Test Pulse to Interface to Safety Exhaust Valve With this schematic it is possible to achieve up to Category, PL e if properly implemented. C BROWN 0V V C GRY SENSOR C BLUE Wire Colors Brown Black White Grey Blue 0V V (P) (M) Vs Vs Dib.0 Dia.0 C WHITE C BLCK SENSOR B Sensor C C BLCK C BLUE SOL SOL B C Sol B Sol Siemens Program* External monitoring program a) Sensor error : Dia.0 <> Dib.0. djust discrepancy time at 0 ms. b) Feedback error : Dia.0 = Dib.0 = Out 0. djust discrepancy time. c) IF feedback or sensor error THEN reset Out 0. Errors must be reset only after maintenance acknowledgement. * Programs provided in this integration guide are for reference only. These programs have not been certified or tested unless stated otherwise. 8 08, ROSS CONTROLS. ll Rights Reserved.
M Series Integration Guide Integration Guide for Turck TBPNLFDIOIOL Turck TBPNLFDIOIOL Functional Safety Rating: Cat, PL e Uses M connections Direct M cables Central or IO modules Generic Connection Example (from Siemens Catalog): Turck Wiring Schematic TBPNLFDIOIOL to Interface to Safety Exhaust Valve With this schematic it is possible to achieve up to Category, PL e if properly implemented. SENSOR SENSOR B C GRY C WHITE C BLUE C BROWN C BLCK Sensor Wire Colors Brown Black White Grey Blue C D BLCK SOL SOL B D WHITE D Sol B Sol Turck TBPN Program* External monitoring program: a) Sensor error : I.0 <> I.. djust discrepancy time at 0 ms. b) Feedback error : I.0 = I. = Out. djust discrepancy time. c) IF feedback or sensor error THEN reset Out. Errors must be reset only after maintenance acknowledgement. * Programs provided in this integration guide are for reference only. These programs have not been certified or tested unless stated otherwise. www.rosscontrols.com 9
M Series Integration Guide 0 08, ROSS CONTROLS. ll Rights Reserved.
M Series Integration Guide CUTIONS, WRNINGS and STNDRD WRRNTY PREINSTLLTION or SERVICE. Before servicing a valve or other pneumatic component, be sure that all sources of energy are turned off, the entire pneumatic system is shut off and exhausted, and all power sources are locked out (ref: OSH 90.7, EN 07).. ll ROSS products, including service kits and parts, should be installed and/or serviced only by persons having training and experience with pneumatic equipment. Because any installation can be tampered with or need servicing after installation, persons responsible for the safety of others or the care of equipment must check every installation on a regular basis and perform all necessary maintenance.. ll applicable instructions should be read and complied with before using any fluid power system in order to prevent harm to persons or equipment. In addition, overhauled or serviced valves must be functionally tested prior to installation and use.. Each ROSS product should be used within its specification limits. In addition, use only ROSS parts to repair ROSS products. FILTRTION and LUBRICTION. Dirt, scale, moisture, etc. are present in virtually every air system. lthough some valves are more tolerant of these contaminants than others, best performance will be realized if a filter is installed to clean the air supply, thus preventing contaminants from interfering with the proper performance of the equipment. ROSS recommends a filter with a micron rating for normal applications. 6. ll standard ROSS filters and lubricators with polycarbonate plastic bowls are designed for compressed air applications only. Do not fail to use the metal bowl guard, where provided, to minimize danger from high pressure fragmentation in the event of bowl failure. Do not expose these products to certain fluids, such as alcohol or liquefied petroleum gas, as they can cause bowls to rupture, creating a combustible condition, hazardous leakage, and the potential for human injury or damage to property. Immediately replace a crazed, cracked, or deteriorated bowl. When bowl gets dirty, replace it or wipe it with a clean dry cloth. 7. Only use lubricants which are compatible with materials used in the valves and other components in the system. Normally, compatible lubricants are petroleum based oils with oxidation inhibitors, an aniline point between 80 F (8 C) and 0 F (0 C), and an ISO, or lighter, viscosity. void oils with phosphate type additives which can harm polyurethane components, potentially leading to valve failure which risks human injury, and/or damage to property. VOID INTKE/EXHUST RESTRICTION 8. Do not restrict the air flow in the supply line. To do so could reduce the pressure of the supply air below the minimum requirements for the valve and thereby cause erratic action. 9. Do not restrict a valve s exhaust port as this can adversely affect its operation. Exhaust silencers must be resistant to clogging and must have flow capacities at least as great as the exhaust capacities of the valves. Contamination of the silencer can result in reduced flow and increased back pressure. POWER PRESSES 0. Mechanical power presses and other potentially hazardous machinery using a pneumatically controlled clutch and brake mechanism must use a press control double valve with a monitoring device. double valve without a selfcontained monitoring device should be used only in conjunction with a control system which assures monitoring of the valve. ll double valve installations involving hazardous applications should incorporate a monitoring system which inhibits further operation of the valve and machine in the event of a failure within the valve mechanism. ENERGY ISOLTION/EMERGENCY STOP. Per specifications and regulations, ROSS LOX and LOX with EEZON operation products are defined as energy isolation devices, NOT S EMERGENCY STOP DEVICES. ll products sold by ROSS CONTROLS are warranted for a oneyear period [with the exception of STNDRD WRRNTY all Filters, Regulators and Lubricators ( FRLs ) which are warranted for a period of seven years] from the date of purchase to be free of defects in material and workmanship. ROSS obligation under this warranty is limited to repair or replacement of the product or refund of the purchase price paid solely at the discretion of ROSS and provided such product is returned to ROSS freight prepaid and upon examination by ROSS is found to be defective. This warranty becomes void in the event that product has been subject to misuse, misapplication, improper maintenance, modification or tampering. THE WRRNTY EXPRESSED BOVE IS IN LIEU OF ND EXCLUSIVE OF LL OTHER WRRNTIES ND ROSS EXPRESSLY DISCLIMS LL OTHER WRRNTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO MERCHNTBILITY OR FITNESS FOR PRTICULR PURPOSE. ROSS MKES NO WRRNTY WITH RESPECT TO ITS PRODUCTS MEETING THE PROVISIONS OF NY GOVERNMENTL OCCUPTIONL SFETY ND/OR HELTH LWS OR REGULTIONS. IN NO EVENT IS ROSS LIBLE TO PURCHSER, USER, THEIR EMPLOYEES OR OTHERS FOR INCIDENTL OR CONSEQUENTIL DMGES WHICH MY RESULT FROM BRECH OF THE WRRNTY DESCRIBED BOVE OR THE USE OR MISUSE OF THE PRODUCTS. NO STTEMENT OF NY REPRESENTTIVE OR EMPLOYEE OF ROSS MY EXTEND THE LIBILITY OF ROSS S SET FORTH HEREIN. www.rosscontrols.com
ROSS CONTROLS US Tel: Tech. Svs. 888TEKROSS / Cust. Svs. 800GETROSS www.rosscontrols.com ROSS EUROP GmbH Germany Tel: 96079700 www.rosseuropa.com ROSS SI K.K. Japan Tel: 87787 www.rossasia.co.jp ROSS UK Ltd. UK Tel: 679 www.rossuk.co.uk ROSS SOUTH MERIC Ltda. Brazil Tel: 00 www.rosscontrols.com.br ROSS CONTROLS INDI Pvt. Ltd. India Tel: 96900 email: ross.chennai@rosscontrols.com ROSS CONTROLS (CHIN) Ltd. China Tel: 8669796 www.rosscontrolschina.com ROSS FRNCE S..S. France Tel: 966 www.rossfrance.com ROSS CND Canada Tel: 67677 (6ROSS) www.rosscanada.com (607770 CND INC. N INDEPENDENT REPRESENTTIVE) Printed in the U.S.. Rev. 0/0/8 08 ROSS CONTROLS. ll Rights Reserved. Form MIM Content subject to change.