Application manual 06/2003 Edition

simotion
SIMOTION Safety Integrated
Safety Unit TM 121C

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine
 Preface, Table of Contents

General information on 1
SIMOTION
parameterization software

Safety Unit TM 121C Operating modes 2

Safety components 3
Application manual for presses
Operating elements 4

Procedural functions of 5
mechanical presses

Procedural functions of hydraulic 6

presses

Procedural functions of press 7

brakes

General functions 8

Operating and fault messages 9

Documentation 10

6AU1900-0DM20-0XA0

06.2003 Edition

Downloaded from www.Manualslib.com manuals search engine

 Safety instructions
This manual contains instructions that should be observed to ensure your personal safety and to protect the equipment
from damage. The instructions are highlighted in the manual by a warning triangle and are marked as follows according to
the level of danger:

! Danger
This warning indicates an imminently hazardous situation which, if appropriate precautions are not
taken, will result in death, serious injury or considerable property damage.

! Warning
This warning indicates an imminently hazardous situation which, if appropriate precautions are not
taken, may result in death, serious injury or considerable property damage.

! Caution
indicates an imminently hazardous situation which, if appropriate precautions are not taken, may
result in minor injury or property damage.

Caution
indicates an imminently hazardous situation which, if appropriate precautions are not taken, may
result in property damage.

Attention
highlights an important item of information about the product or its use, or indicates a section of the
instructions that deserves careful attention.

Qualified personnel
The equipment may be commissioned and operated by qualified personnel only. For the purposes of the safety
instructions in this instruction manual, a Qualified Person is one who is authorized to commission, ground and label
devices, systems and circuits in accordance with accepted safety standards.

Intended use
Please observe the following information:

! Warning
The device may only be used in applications as provided for in the catalog and in the technical
description, and only in connection with power supply units that have either been recommended or
approved by Siemens.

Successful and safe operation of this equipment is dependent on proper transport, storage, erection
and installation, as well as careful operation and maintenance.

Trademarks
SIMATIC®, SIMOTION®, SINUMERIK® and SITOP® are registered trademarks of Siemens AG.
Other designations in this document may be trademarks whose use by third parties for their own purposes may infringe on
the rights of the trademark holder.

Copyright Siemens AG 2003 All Rights Reserved Liability exclusion

Passing this document on to third parties, reproducing this document or We have checked the contents of this Manual to ensure that they match the
using or relating its contents is not permitted without express authority. hardware and software described herein. However, because deviations
Offenders will be liable for damages. All rights, including rights created cannot be completely ruled out, we cannot guarantee complete conformance.
by patent grant or registration of a utility model or design, are reserved. The information contained in this document is checked regularly and any
necessary corrections are included in subsequent editions. We are thankful
for any recommendations or suggestions.
Siemens AG
Automation & Drives
Motion Control Systems
P.O. Box 3180, D-91050 Erlangen © Siemens AG 2003
Germany We reserve the right to make technical changes.

Siemens AG Safety Unit TM 121C

Downloaded from www.Manualslib.com manuals search engine

 Preface

General information
In the interest of clarity, the information in this Manual does not purport to cover all
details or variations in equipment, nor to provide for every possible contingency to
be met in connection with installation, operation or maintenance.

The contents of this Manual shall neither become a part of nor modify any prior or
existing agreement, commitment or legal relationship. The sales contract contains
the entire obligation entered into by Siemens. The warranty contained in the
contract between the parties is the sole warranty of Siemens. Any statements
contained herein do not create new warranties nor modify the existing warranty.

Purpose of this manual

This handbook is a supplement to the equipment manual of the SIMOTION Safety
Unit TM 121C with the order number 6AU1900-0CM20-0XA0.

This handbook provides:

• explanatory functional descriptions of mechanical presses, hydraulic presses
and press brakes.
• assistance in the use of the parameterization masks.

For whom is this manual intended?

• Project planners
• Electricians and fitters
• Service and operating personnel

Contact persons
If you should encounter problems or questions when working with the manual,
please consult the service center listed on the feedback form at the end of the
manual.

Assistance in finding information

To help you get oriented, please turn to the table of contents.

© Siemens AG 2003 All Rights Reserved

SIMOTION Safety Unit (AP) - Edition 06.2003 v

Downloaded from www.Manualslib.com manuals search engine

 Notes

© Siemens AG 2003 All Rights Reserved

vi SIMOTION Safety Unit (AP) - Edition 06.2003

Downloaded from www.Manualslib.com manuals search engine

 Content

1 General information on parameterization software .................... 1-9

2 Operating modes ............................................................................ 2-11

2.1 Selecting the operating mode ....................................................... 2-11
2.2 Operating modes and press cycles .............................................. 2-12
2.2.1 Setup (operating mode 1).......................................................... 2-13
2.2.2 Single stroke (operating mode 2) .............................................. 2-14
2.2.3 Continuous stroke (operating mode 3) ...................................... 2-15
2.2.4 Changeover (operating mode 4) ............................................... 2-16
2.2.5 Automatic continuous stroke (operating mode 5)...................... 2-17
2.2.6 Single-stroke ESPE (operating mode 6) ................................... 2-19

3 Safety components......................................................................... 3-21

3.1 Parameterization of safety components ....................................... 3-22
3.2 Example of safety component wiring ............................................ 3-24

4 Control elements............................................................................. 4-27

4.1 Two-hand control .......................................................................... 4-27
4.1.1 Determining the safety distance ................................................ 4-29
4.2 Foot switch.................................................................................... 4-30
4.3 Acknowledge button for group acknowledgement........................ 4-31
4.4 Electro-sensitive protective equipment (ESPE)............................ 4-32
4.4.1 Determining the safety distance with ESPE .............................. 4-33
4.5 Control function with light curtain.................................................. 4-34
4.5.1 Mode selector ............................................................................ 4-34
4.5.2 Modes for clock operation ......................................................... 4-34
4.5.3 Starting the press in clock mode ............................................... 4-34
4.5.4 Restart inhibit of light curtain in clock mode .............................. 4-35
4.5.5 Restart inhibit of light curtain in safety mode............................. 4-36
4.6 EMERGENCY OFF output signal ................................................. 4-37

5 Procedural functions of mechanical presses .............................. 5-39

5.1 Cam evaluation ............................................................................. 5-39
5.2 Speed monitor............................................................................... 5-42
5.3 Control of press safety valves....................................................... 5-43
5.4 Valve monitoring ........................................................................... 5-45

6 Procedural functions of hydraulic presses.................................. 6-47

6.1 Control of valves for hydraulic presses......................................... 6-47
6.2 Valve monitoring ........................................................................... 6-48

© Siemens AG 2003 All Rights Reserved

SIMOTION Safety Unit (AP) - Ausgabe 06.2003 vii

Downloaded from www.Manualslib.com manuals search engine

 Inhalt

7 Procedural functions of press brakes .......................................... 7-51

7.1 Selecting the operating mode ....................................................... 7-51
7.2 Protective features........................................................................ 7-51
7.3 Control elements........................................................................... 7-51
7.4 Generating enables ...................................................................... 7-52
7.4.1 Information on control signals.................................................... 7-52
7.5 Folding function............................................................................. 7-54
7.5.1 Access protection ...................................................................... 7-54
7.5.2 Watchdog timer ......................................................................... 7-55
7.5.3 Dynamic valve monitoring ......................................................... 7-56
7.5.4 Valve control .............................................................................. 7-57
7.6 Information on functionality ........................................................ 7-59
7.6.1 Conditions for fast downward movements ................................ 7-59
7.6.2 Tilt monitor ................................................................................. 7-59
7.6.3 "Moving" and "distance" access protection ............................... 7-60
7.7 Application examples and procedural functions ........................... 7-61
7.7.1 Single operator control with foot switch..................................... 7-61
7.7.2 Multiple operator control with foot switch .................................. 7-62

8 General functions ........................................................................... 8-63

8.1 Single operator/multi-operator control .......................................... 8-63
8.2 Single operator control via 2 foot switches and
operating error monitor .............................................................. 8-64
8.3 Output assignment (0.5 A)............................................................ 8-65

9 Operating and fault messages ...................................................... 9-67

10 Documentation.............................................................................. 10-71
10.1 Documentation of inputs (notes)................................................. 10-71
10.2 Documentation of outputs (notes)............................................... 10-72
10.3 Documentation of system data ................................................... 10-72

© Siemens AG 2003 All Rights Reserved

viii SIMOTION Safety Unit (AP) - Ausgabe 06.2003

Downloaded from www.Manualslib.com manuals search engine

 1 General information on parameterization
1
software

The parameterization masks are arranged in such a way that it is immediately

apparent to the user whether one-channel or two-channel signals are required to
achieve the necessary safety level.

• For one-channel signals, the left side of the mask contains a terminal block
field in which block X3 or X4 can be selected. The required pin assignment can
also be entered.

• For two-channel signals, terminals X3/X4 are automatically preassigned. The

only data that can be entered is the pin assignment. The pin assignment is
identical for blocks X3 and X4!

The entered value is saved by pressing the Accept button. A green dot appears to
the left if the entry has been saved properly and completely.

© Siemens AG 2003 All Rights Reserved

SIMOTION Safety Unit (AP) - Edition 06.2003 1-9

Downloaded from www.Manualslib.com manuals search engine

 General information on parameterization software

Notes

© Siemens AG 2003 All Rights Reserved

1-10 SIMOTION Safety Unit (AP) - Edition 06.2003

Downloaded from www.Manualslib.com manuals search engine

 2 Operating modes
2
2.1 Selecting the operating mode
Definition
Up to 6 operating modes can be parameterized.
A "1 of 6" selection indicates the presence of a short circuit and a faulty multiple
selection of operating modes. The use of test voltages, i.e. the selection of clocking
via the internal sensor supply, is therefore not required for the mode selector.

Parameterization
The assignment of the connection terminals to the operating mode is shown in
Figure 2-1, left section.

Figure 2-1 Operating modes

© Siemens AG 2003 All Rights Reserved

SIMOTION Safety Unit (AP) - Edition 06.2003 2-11

Downloaded from www.Manualslib.com manuals search engine

 Operating modes

Example of wiring

L+

1
1 2 3 4 5 6
-S

2
3
4
5
6
7

X3.3 X4.3 X3.4 X4.4 ...

Figure 2-2 Mode selector

2.2 Operating modes and press cycles

The 6 operating modes presented below can be selected in the parameterization
mask in the right section of Figure 2-1.

Please note the following rules:

• Each selected operating mode is associated with an enable mask, e.g. for start
and stop conditions, an external start and additional safety devices.
• The entries that are adjustable for a particular operating mode are indicated by
a white field. They have been assigned default parameters and are indicated
by a black dot.
• If conditions are being pre-assigned at additional terminals (start enables,
external start, etc.), an additional window for selecting the terminals
automatically appears in the mask.
• Irrelevant entries are grayed out and cannot be activated.
• An operating mode type can also have several parameterizations if, for
example, the number of safety devices varies.
• The Setup operating mode (operating mode 1) is predefined and cannot be
modified.

© Siemens AG 2003 All Rights Reserved

2-12 SIMOTION Safety Unit (AP) - Edition 06.2003

Downloaded from www.Manualslib.com manuals search engine

 Operating modes

2.2.1 Setup (operating mode 1)

Definition
The press will only move while the two-hand buttons are being pressed. This is
also the case when the ram is moving upward. The press automatically comes to a
standstill at the end of each stroke (TDC). The operating elements must be
deactivated before a new start can be initiated.

A triple-action stop during a single stroke is not required with this control unit since
the Setup operating mode reaches the same level of safety as, for example, the
single stroke mode.

Parameterization

Figure 2-3 Enabling of operating mode 1

Note on "Safe motion" parameterization

When parameterizing "Selected safety device can be disabled via terminal", other
suitable safety measures must be effective for the specific machine when this
parameter is activated.

© Siemens AG 2003 All Rights Reserved

SIMOTION Safety Unit (AP) - Edition 06.2003 2-13

Downloaded from www.Manualslib.com manuals search engine

 Operating modes

2.2.2 Single stroke (operating mode 2)

Definition
Pressure must be maintained on the two-hand buttons for activating the ram until
the hazardous closing movement is completed (just prior to the BDC). The press
then automatically moves back to the TDC and comes to a standstill. The press
can also be activated using a foot switch. In this case, however, suitable safety
measures (safety gate, light curtain) must be implemented that either make it
impossible to reach into the hazardous area with the hands during a closing
movement or that cause the machine to come to a standstill in the event of such an
action.
The same applies if the "Transfer through input terminal" parameter is selected for
the "Transfer of START command".

Parameterization

Figure 2-4 Enabling of operating mode 2

© Siemens AG 2003 All Rights Reserved

2-14 SIMOTION Safety Unit (AP) - Edition 06.2003

Downloaded from www.Manualslib.com manuals search engine

 Operating modes

2.2.3 Continuous stroke (operating mode 3)

Definition
This operating mode requires the implementation of suitable safety measures and
an automated feed and removal of parts. After a start pulse, the press continues
running until it is brought to a standstill by a stop signal.

Depending on the selections made in the enable mask, the press either stops in
the TDC or comes to an immediate standstill.

Parameterization

Figure 2-5 Enabling of operating mode 3

© Siemens AG 2003 All Rights Reserved

SIMOTION Safety Unit (AP) - Edition 06.2003 2-15

Downloaded from www.Manualslib.com manuals search engine

 Operating modes

2.2.4 Changeover (operating mode 4)

Definition
This is not a production mode type. The production mode is deactivated in this
operating mode. In order to carry out an automatic changeover, e.g. to a new
production part, a standard control unit can be used to access the clutch and brake
(e.g. to adjust the stroke height).

Note
In this operating mode, the machine manufacturer must ensure that it is not
possible to initiate a hazardous stroke when the press is controlled by a standard
control unit. Safety measures may have to implemented to safeguard the
machine.

Parameterization

Figure 2-6 Enabling of operating mode 4

© Siemens AG 2003 All Rights Reserved

2-16 SIMOTION Safety Unit (AP) - Edition 06.2003

Downloaded from www.Manualslib.com manuals search engine

 Operating modes

Figure 2-7 Valve control of mechanical press (mechanical operation)

Figure 2-8 Valve control of hydraulic press (hydraulic operation)

2.2.5 Automatic continuous stroke (operating mode 5)

Definition
This operating mode differs from the continuous mode in that two steps are
required to enable the machine for the first time:

• First, the automatic continuous stroke mode is enabled using the two-hand
control.
• Then the machine can be started by an external enable signal via the terminal.

Note
• If at the time of the two-hand activation there is an external enable signal, the
machine starts immediately.
• In this mode, the two-hand control acts as a command device only (not a
safety device). The operator must be protected by additional safety
equipment, e.g. ESPE!

© Siemens AG 2003 All Rights Reserved

SIMOTION Safety Unit (AP) - Edition 06.2003 2-17

Downloaded from www.Manualslib.com manuals search engine

 Operating modes

Operating instructions
• The machine stops at the next BDC when the external enable signal ceases. It
can be restarted with this signal alone within the next 30 s.

• Two switching steps (see "Definition") are always required when a restart does
not take place within the next 30 s or when a safety device or a continuous
stroke stop (BDC or immediate stop) was activated.

Parameterization

Figure 2-9 Enabling of operating mode 5

© Siemens AG 2003 All Rights Reserved

2-18 SIMOTION Safety Unit (AP) - Edition 06.2003

Downloaded from www.Manualslib.com manuals search engine

 Operating modes

2.2.6 Single-stroke ESPE (operating mode 6)

Using a light curtain to control the press is described in the Control Elements
chapter.

Parameterization

Figure 2-10 Enabling of operating mode 6

© Siemens AG 2003 All Rights Reserved

SIMOTION Safety Unit (AP) - Edition 06.2003 2-19

Downloaded from www.Manualslib.com manuals search engine

 Operating modes

Notes

© Siemens AG 2003 All Rights Reserved

2-20 SIMOTION Safety Unit (AP) - Edition 06.2003

Downloaded from www.Manualslib.com manuals search engine

 3 Safety components
3
The contacts can be wired directly in the control unit. Additional contactors or
relays are not required. The following cyclical monitoring procedures are performed
in the program:

• Short circuit monitor between the two mutually isolated signal circuits.
• Discrepancy check of whether both switch-off circuits carry out a signal
change when the button is activated. The change between the two signals is
also monitored over time. The only elements that do not adhere to the preset
discrepancy time are the safety gate components.

The following components are available and can be combined as required:

• EMERGENCY OFF with restart inhibit (4x)

• EMERGENCY OFF without acknowledge (4x)
• Engaging lock (without acknowledge) (2x)
• Safety guard with restart inhibit (4x)
• Safety guard without acknowledge (4x)
• Safety gate with manual acknowledge (3x)
• Safety gate without manual acknowledge (3x)

Light curtains that are only used in the safety mode can be connected to the
existing safety guard components. For a description of their mode of operation, see
the Operating Elements chapter.

The parameterization of light curtains that are switched in safety and clock mode is
presented in the Operating Elements chapter.

Comments
• The EMERGENCY OFF that is activated in the parameterization is always
active for the entire control unit. It can, however, be deactivated for individual
operating modes (e.g. useful when creating different EMERGENCY OFF
circuits).
• The same applies to the engaging lock and the safety gate and safety guard
components. In this case, the safety devices can be specifically deselected in
the operating modes in which they are to be inactive.

Note
Without the implementation of additional safety measures, safety gates and
safety guards without a restart inhibit are not suitable for hazardous areas that
can be walked through.

© Siemens AG 2003 All Rights Reserved

SIMOTION Safety Unit (AP) - Edition 06.2003 3-21

Downloaded from www.Manualslib.com manuals search engine

 Safety components

3.1 Parameterization of safety components

Figure 3-1 EMERGENCY OFF safety functions

Figure 3-2 Safety guard safety functions

© Siemens AG 2003 All Rights Reserved

3-22 SIMOTION Safety Unit (AP) - Edition 06.2003

Downloaded from www.Manualslib.com manuals search engine

 Safety components

Comment
If the EMERGENCY OFF or the "Safety guard with restart inhibit" is selected, a
flashing fault lamp or, optionally, a separate alarm lamp (parameterizable)
indicates that the system is ready for acknowledgement.

Figure 3-3 Safety gate safety functions

Note on safety gate with manual acknowledgement

Both contacts must be activated to open the safety gate. If only one contact is
activated and reclosed, an alarm is output with a continuous light. In this case,
both contacts will then have to be opened and reclosed.

The continuous light goes out after both contacts have been properly opened.
When the contacts are closed, a flashing signal indicates that the safety gate is
ready for acknowledgement. After the acknowledge button has been activated,
the machine is again ready to be started.

For safety gates without acknowledgement, there is no display if only one contact
is opened and reclosed due to an operation error. The problem is eliminated by
completely opening and reclosing the gate.

Figure 3-4 Engaging lock safety functions

© Siemens AG 2003 All Rights Reserved

SIMOTION Safety Unit (AP) - Edition 06.2003 3-23

Downloaded from www.Manualslib.com manuals search engine

 Safety components

3.2 Example of safety component wiring

Clock voltage
X2.5 L+
X2.1 L+

X3.5 X4.5

Figure 3-5 Example of EMERGENCY OFF wiring

© Siemens AG 2003 All Rights Reserved

3-24 SIMOTION Safety Unit (AP) - Edition 06.2003

Downloaded from www.Manualslib.com manuals search engine

 Safety components

Clock voltage
X2.6 L+
X2.2 L+

X3.6 X4.6

Figure 3-6 Example of safety guard wiring

© Siemens AG 2003 All Rights Reserved

SIMOTION Safety Unit (AP) - Edition 06.2003 3-25

Downloaded from www.Manualslib.com manuals search engine

 Safety components

Notes

© Siemens AG 2003 All Rights Reserved

3-26 SIMOTION Safety Unit (AP) - Edition 06.2003

Downloaded from www.Manualslib.com manuals search engine

 4 Control elements
4
4.1 Two-hand control
Definition
It must be ensured that the operator is not located within the hazardous area during
the press cycle. To guarantee this, the operator must press both engagement
buttons within 500 ms of each other to initiate a press stroke. These engagement
commands are edge controlled so that even if only one engagement button is
released briefly, the engagement command is disabled.

The period of 500 ms during which the system is ready to switch on begins as
soon as the button is activated and is reset when both buttons are in the neutral
position and one button is reactivated. The two-hand engagement command is only
generated if the two-hand activation has been simultaneous and if both
engagement buttons are activated.

Operating instructions
• A maximum of 3 two-hand consoles can be connected.
• Each console has its own two-hand function.
• It is possible to use consoles that can be plugged in. Plug-in monitoring takes
place via the NC and NO contacts of the two-hand buttons. This eliminates the
need for an additional contact for plug-in monitoring.
• A keyswitch is needed to activate and deactivate a console. The console that is
plugged in must match the preselected console.
• If you wish to switch off the two-hand console, the input must be parameterized
for a console switch-off and you must also specify whether the switch-off takes
place via an NC or NO contact. Console deactivation is implemented via a high
level at the activation and deactivation input (fail safe).
• The operating modes in which the two-hand buttons are to be disabled are
selected on the right side of the parameterization mask.

© Siemens AG 2003 All Rights Reserved

SIMOTION Safety Unit (AP) - Edition 06.2003 4-27

Downloaded from www.Manualslib.com manuals search engine

 Control elements

Parameterization

Figure 4-1 Two-hand control

Example of wiring

Clock voltage
X2.5 L+

X2.6 L+

X2.1 L+

X2.2 L+

X3.1 X3.2 X4.1 X4.2

Figure 4-2 Two-hand control

© Siemens AG 2003 All Rights Reserved

4-28 SIMOTION Safety Unit (AP) - Edition 06.2003

Downloaded from www.Manualslib.com manuals search engine

 Control elements

4.1.1 Determining the safety distance

The reaction times of the control unit and the machine must be considered when
determining the safety distance. The reaction time and the resulting safety distance
can be calculated using the following equation:

S = (T2 + T3) * vg

S: Safety distance
T2: Reaction time of control unit
T3: Reaction time of machine
vg: Activation time (1.6 m/s according to EN 999)

Example:

T2 Control unit according to Safety Unit data sheet

connection of the lag meter for determining

the reaction time of the machine (empirical
T3 Machine measurement)

use the poorest of 10

measurement values!

© Siemens AG 2003 All Rights Reserved

SIMOTION Safety Unit (AP) - Edition 06.2003 4-29

Downloaded from www.Manualslib.com manuals search engine

 Control elements

4.2 Foot switch

This has the same function as the two-hand control with the exception that it has
only one NC and one NO contact.

A maximum of 3 foot switches can be connected.

Parameterization

Figure 4-3 Operation of the foot switch

© Siemens AG 2003 All Rights Reserved

4-30 SIMOTION Safety Unit (AP) - Edition 06.2003

Downloaded from www.Manualslib.com manuals search engine

 Control elements

Example of wiring

Clock voltage
X2.5 L+
X2.1 L+

X3.7 X4.7

Figure 4-4 Foot switch

4.3 Acknowledge button for group acknowledgement

Definition
This button is used to reset signals requiring acknowledgement, such as error
messages and safety guard acknowledgement messages.

Parameterization

Figure 4-5 Operation of the acknowledge button

© Siemens AG 2003 All Rights Reserved

SIMOTION Safety Unit (AP) - Edition 06.2003 4-31

Downloaded from www.Manualslib.com manuals search engine

 Control elements

4.4 Electro-sensitive protective equipment (ESPE)

Definition
These primarily include safety light curtains or light barriers that monitor access to
the hazardous areas of the press. These light curtains are intrinsically safe, i.e. in
the event of a malfunction they go into a safe state and they have certified their
suitability for presses by means of type examinations (confirmed by test
certificates).

Operating instructions
The light curtain provides two "light path unobstructed“ channels.
• In some light curtains with semiconductor outputs, the short circuit test for
both channels is already integrated. In this case, the short circuit monitor of
the control unit should be switched off!
• When using light curtains with relay outputs, the short circuit monitor of the
control unit must be active!

It is the task of the press safety control unit to correctly interpret the output signal of
the light curtain and to generate from it the subsequent operation and control of the
press safety valve. Light curtains can be operated in:
• safety mode, as a substitute for a permanently-closed safety gate (see the
Safety Components chapter)
• control mode. In this mode, the operator can reach into the protective zone
when the press is at a standstill in the TDC position in order to remove parts or
add material. After the operator leaves the protected area, the press
automatically resumes operation. Reaching into the machine while the ram is
descending causes the press to come to an immediate standstill. In the control
mode, there is both a single-stroke mode and a two-stroke mode. Which
mode is selected depends on whether a separate step is required when
material is fed to the machine during which the operator leaves the protective
zone.

The following light curtains have been tested with the control unit:
- Type 3RG78..., by Siemens in safety or clock mode (clock mode as of July 03)
- TypeC4000 advanced, by Sick in safety or clock mode
Others upon request

© Siemens AG 2003 All Rights Reserved

4-32 SIMOTION Safety Unit (AP) - Edition 06.2003

Downloaded from www.Manualslib.com manuals search engine

 Control elements

4.4.1 Determining the safety distance with ESPE

The reaction times of the ESPE, the control unit and the machine must be
considered when determining the safety distance. The reaction time and the
resulting safety distance can be calculated using the following equation:

S = (T1 + T2 + T3) * vg + k

S: Safety distance
T1: Reaction time of the ESPE
T2: Reaction time of control unit
T3: Reaction time of machine
vg: Activation time (1.6 m/s or 2.0 m/s according to EN 999)
k: Addition for resolving power of the ESPE
k = 8 * (p-14); p: Resolving power of the ESPE

Example:

T1 ESPE according to manufacturer data sheet

T2 Control unit according to Safety Unit data sheet

connection of lag meter for determining

the reaction time of the machine (empirical
T3 Machine measurement)
use the poorest of 10
measurement values!

© Siemens AG 2003 All Rights Reserved

SIMOTION Safety Unit (AP) - Edition 06.2003 4-33

Downloaded from www.Manualslib.com manuals search engine

 Control elements

4.5 Control function with light curtain

4.5.1 Mode selector
The mode selector (single stroke and two-stroke) is connected to simple digital
inputs. A short circuit between these signals is identified by means of the "1 of 2"
selection. An intermediate position is not required.

Comment
The light curtain receives its voltage supply from the Safety Unit through output
X2.x. Therefore, the light curtain is without voltage when the mode selector is set
to "Off".

Note
If the light curtain is not active, the power supply for the light curtain must be
switched off so that the unlit LED will indicate to the operator that the light curtain
is not operational.

4.5.2 Modes for clock operation

Definition
There are two modes for clock operation – the standard mode and the Sweden
mode. The only difference between the two modes is in the manner in which they
start after a restart inhibit.

Standard mode
In the standard mode, an interruption of the light field is initially required before
starting the machine or before starting it after a restart inhibit. After that, the first
start of the press must be initiated by the command device. The two-hand switch is
provided for this purpose.

Sweden mode
In the Sweden mode, a command device acknowledgement is required before
starting the machine or before starting it after a restart inhibit. The press is then
started by interrupting the light field (interrupting it twice in the case of the two-
stroke mode).

4.5.3 Starting the press in clock mode

In clock mode, the press is started after one or two interruptions of the light field.
The following conditions apply for these interruptions:

• The prerequisites for the first start must be met.

• The interruption must last longer than 100 ms.
• The interruption must take place at the top dead center.
• The previous interruption may not lie farther back than 30 s.

© Siemens AG 2003 All Rights Reserved

4-34 SIMOTION Safety Unit (AP) - Edition 06.2003

Downloaded from www.Manualslib.com manuals search engine

 Control elements

4.5.4 Restart inhibit of light curtain in clock mode

The restart inhibit is indicated by a flashing fault lamp and is activated in the
following cases:

• Start of the Safety Unit after a power off or stop (keyswitch position).
• In the event that the operating mode is changed on the selection switch of the
light curtain. In the clock mode, if there is an interruption during a hazardous
movement.
• In the clock mode, in the event that there is no intervention for more than 30 s.

The restart inhibit is acknowledged by the command device. Either a separate

button or a two-hand control can be used as a command device.

Parameterization

Figure 4-6 Operating the light curtain

© Siemens AG 2003 All Rights Reserved

SIMOTION Safety Unit (AP) - Edition 06.2003 4-35

Downloaded from www.Manualslib.com manuals search engine

 Control elements

Example of wiring

L+
M
PE

Output of Safety Unit

X2.x (L+)

7
1

OSSD1

OSSD2
4
3

4
Warning!
Clocking may not be connected
to the control unit side.

X3.8 X4.8
Light path Restart
unobstructed lockout acknowledge
(if required)

Figure 4-7 Light curtain

4.5.5 Restart inhibit of light curtain in safety mode

The restart inhibit is activated in the event of an intervention during a hazardous
movement. This is indicated by the flashing of the fault lamp.

It is reset by means of the acknowledge button for group acknowledgement.

© Siemens AG 2003 All Rights Reserved

4-36 SIMOTION Safety Unit (AP) - Edition 06.2003

Downloaded from www.Manualslib.com manuals search engine

 Control elements

4.6 EMERGENCY OFF output signal

This function is used for the external processing of the control unit EMERGENCY
OFF signal. The control command to a contactor combination must correspond to
the feedback within a certain adjustable time period.

Attention
This function is not activated until after the feedback input has been
parameterized.

Parameterization

Figure 4-8 Mechanical operation – EMERGENCY OFF output signal

See also Figure 5-6.

Note
• The discrepancy time between the activation of the outputs and the signaling
of the feedback input depends on the response times of the contactors in
use. Typical values lie between 50 ms and 200 ms. Therefore, this maximum
value should not be exceed in the parameterization.
• The Safety Unit ensures there will be an output signal in Category 4. Systems
connected downstream must be designed in the category they require.
• After the Safety Unit restarts, the output signal for output activation must be
acknowledged if the output signal has been parameterized for that mode.
• If the output signal has not been parameterized in a certain mode, it is reset
when that mode is activated. If the output signal is activated using a mode
selector, it is not activated until after acknowledgement.
• The acknowledgement request is output via the corresponding message.

© Siemens AG 2003 All Rights Reserved

SIMOTION Safety Unit (AP) - Edition 06.2003 4-37

Downloaded from www.Manualslib.com manuals search engine

 Control elements

Example of wiring

EMERGENCY OFF
acknowledge
-S

Contactor relay
feedback
X3.11
61 62 61 62

-K10B
-K10A

EMERGENCY OFF contacts,

e.g. for load voltage
L+

33 34 33 34

23 24 23 24

13 14 13 14
-K10A

-K10B
X6.8

(M)

A1 A2
-K10B
X6.7

(P)
A2 A1
-K10A

Figure 4-9 EMERGENCY OFF output signal

© Siemens AG 2003 All Rights Reserved

4-38 SIMOTION Safety Unit (AP) - Edition 06.2003

Downloaded from www.Manualslib.com manuals search engine

 5 Procedural functions of mechanical
5
presses

5.1 Cam evaluation

Definition
The system monitors the safety cams for operating and switching off the press to
ensure that they are operating correctly.

According to the current regulations, it is not sufficient to generate cam signals with
electronic components alone (proximity switches or shaft angle encoders).
Therefore, on mechanical presses, a mechanical limit switch must be used to query
the ramp up cam as late as possible in the TDC. The ramp up cam activates the
end of the hazardous closing movement and the press switch-off. In addition, the
over run cam, which also plays a part in monitoring the TDC switch-off and
monitors the overtravel distance of the clutch/brake combination, must be
mechanical in design.

Since presses capable of higher speed ranges are becoming more common, an
additional electronically designed dynamic cam that calculates the speed-
dependent brake engagement point can be looped into the TDC switch-off.

Example of a cam setting

BDC Switch-off time TDC

170° to 180° up to 340°

Run-up cam
(mechanical)

Dynamic cam
(electronic)

up to 320° 10°

Overtravel cam
(mechanic)
Figure 5-1 Example of a cam setting

© Siemens AG 2003 All Rights Reserved

SIMOTION Safety Unit (AP) - Edition 06.2003 5-39

Downloaded from www.Manualslib.com manuals search engine

 Procedural functions of mechanical presses

In the case of fixed stroke speeds without dynamic cams, the TDC switch-off
occurs on the leading edge of the over run cam.

For the TDC stop at variable stroke speeds, a separate electronic cam switchgear
is provided that calculates the brake engagement point from the stroke speed. This
dynamic cam switches in the range of 320° to 340°, for example, and takes over
the TDC switch-off on a falling edge.

Parameterization

Figure 5-2 Mechanical operation – Cam monitoring system

© Siemens AG 2003 All Rights Reserved

5-40 SIMOTION Safety Unit (AP) - Edition 06.2003

Downloaded from www.Manualslib.com manuals search engine

 Procedural functions of mechanical presses

Example of wiring

Clock voltage

L+
L+

Electronic cam switchgear,

PLC or initiator

X3.9 X3.10

Run-up cam Overtravel cam Dynamic TDC

switch-off

Figure 5-3 Cam evaluation

© Siemens AG 2003 All Rights Reserved

SIMOTION Safety Unit (AP) - Edition 06.2003 5-41

Downloaded from www.Manualslib.com manuals search engine

 Procedural functions of mechanical presses

5.2 Speed monitor

Definition
The safety cams are mounted on a shaft in the mechanical cam switchgear. During
rotation, the speed monitor at the end of this shaft generates pulses that are
monitored. Should the pulses cease, e.g. in the case of a shaft break or faulty
timing belt, the press comes to an immediate standstill.

The "Speed monitor“ function can only be deselected if the safety cams are
mounted directly on the main drive shaft.

Operating principle of the monitor

A proximity switch at the cam controller (30 pulses per stroke) is used to monitor a
shaft break using an adjustable time interval. If the monitor does not detect at least
one pulse during this interval, the press is brought to a standstill.

Functional description of the monitor

An encoder that outputs 30 pulses per rotation is integrated in each cam
switchgear. These pulses are used to check whether the shaft or the cam
switchgear is defective. The encoder must be connected to the hardware counter
of the Safety Unit, terminal X9.

The cam switchgear expects to receive pulses when the press ram is moved. The
monitor checks whether at least one pulse is counted during the adjustable time
periods. If not, an error is output that causes the machine to be brought to an
immediate standstill.

The time intervals must be set to the working speed of the machine and must be
kept as small as possible for the slowest machine speed. The overtravel angle may
not exceed 90°.

Parameterization

Figure 5-4 Mechanical operation – Speed monitor

© Siemens AG 2003 All Rights Reserved

5-42 SIMOTION Safety Unit (AP) - Edition 06.2003

Downloaded from www.Manualslib.com manuals search engine

 Procedural functions of mechanical presses

Example of wiring

L+
M

+
-B -
1

X9.2 X9.7

Figure 5-5 Speed monitor

5.3 Control of press safety valves

This function is used to control two press safety valves (clutch and brake). Both
valves are controlled simultaneously, each via two channels (P/M-switching) with
24 V/2 A.

Figure 5-6 Extras - Output pin assignment (mech.)

© Siemens AG 2003 All Rights Reserved

SIMOTION Safety Unit (AP) - Edition 06.2003 5-43

Downloaded from www.Manualslib.com manuals search engine

 Procedural functions of mechanical presses

Example of wiring

press safety valve (if present)

X4.11

Position feedback of
1
+
- -BY02

X4.10
+

1
-
L+
M

-BY01
X6.4

PSV2
X6.3

1 2

-Y02
X6.2

PSV1
X6.1

1 2
-Y01

Figure 5-7 Press safety valves

© Siemens AG 2003 All Rights Reserved

5-44 SIMOTION Safety Unit (AP) - Edition 06.2003

Downloaded from www.Manualslib.com manuals search engine

 Procedural functions of mechanical presses

5.4 Valve monitoring

If, for mechanical safety reasons, the clutch/brake-combination is equipped with
limit switches that display the switching position of the valves, these are read in via
the feedback inputs in the control unit and compared to the activation of the outputs
(watchdog timer).

Note
If an electrical valve monitor is not in use, monitoring must be accomplished by
means of other measures with a comparable degree of safety (hydraulic or
electric).

Parameterization

Figure 5-8 Mechanical operation – Watchdog timer

© Siemens AG 2003 All Rights Reserved

SIMOTION Safety Unit (AP) - Edition 06.2003 5-45

Downloaded from www.Manualslib.com manuals search engine

 Procedural functions of mechanical presses

Notes

© Siemens AG 2003 All Rights Reserved

5-46 SIMOTION Safety Unit (AP) - Edition 06.2003

Downloaded from www.Manualslib.com manuals search engine

 6 Procedural functions of hydraulic presses
6
6.1 Control of valves for hydraulic presses
Definition
This function controls the following elements:
• Directional valves for both the upward and downward movement
• Safety valves
Operating instructions
• This function can be used to activate 3 different valves (or double valves).
• Each valve is controlled via two channels (P/M-switching) with 24 V/2 A.
• Single channel inputs are the reversing point in the TDC and BDC.
• In the case of an automatic takeover, the "Safety point" and "Pressure value"
signals must be queried on the input side.
• In "Setup" mode, activation of the two-hand switch or the foot switch causes
the press to move to BDC (inching). An upward movement is brought about by
activating the "UP button".

Note on the wiring of the "Takeover point"

The "Safety point" and "Pressure value" signals are evaluated at the takeover
point. To detect a short circuit between these two signals, one of them must be
supplied via the encoder clock (e. g. by using a mechanical switch).
Parameterization

Figure 6-1 Extras - Output pin assignment (hydr.)

© Siemens AG 2003 All Rights Reserved

SIMOTION Safety Unit (AP) - Edition 06.2003 6-47

Downloaded from www.Manualslib.com manuals search engine

 Procedural functions of hydraulic presses

Figure 6-2 Hydraulic operation – End-of-stroke signals

6.2 Valve monitoring

Parameterization

Figure 6-3 Hydraulic operation – Watchdog timer

Note
If an electrical valve monitor is not in use, monitoring must be accomplished by
means of other measures with a comparable degree of safety (hydraulic or
electric).

© Siemens AG 2003 All Rights Reserved

6-48 SIMOTION Safety Unit (AP) - Edition 06.2003

Downloaded from www.Manualslib.com manuals search engine

 Procedural functions of hydraulic presses

Example of wiring

X4.12
1
+
-

Position feedback of press

safety valve (if present)
-BY03

X4.11
1
+
- -BY02

X4.10
+

1
-
L+
M

-BY01
X6.6

PSV3
X6.5

1 2

-Y02
X6.4

PSV2
X6.3

1 2
-Y02
X6.2

PSV1
X6.1

1 2
-Y01

Figure 6-4 Valve monitoring

© Siemens AG 2003 All Rights Reserved

SIMOTION Safety Unit (AP) - Edition 06.2003 6-49

Downloaded from www.Manualslib.com manuals search engine

 Procedural functions of hydraulic presses

Notes

© Siemens AG 2003 All Rights Reserved

6-50 SIMOTION Safety Unit (AP) - Edition 06.2003

Downloaded from www.Manualslib.com manuals search engine

 7 Procedural functions of press brakes
7
7.1 Selecting the operating mode
• Up to 6 operating modes can be parameterized.
• For press brakes, operating modes 1-6 are equivalent and have no special
functions.
• The only exception is operating mode 1, which is intended for fault
acknowledgement.

7.2 Protective features

The protective features (EMERGENCY OFF, EMERGENCY OFF output signal,
safety guard, safety gate, engaging lock) do not require special handling for the
folding functionality.

7.3 Control elements

The control elements (two-hand control, foot switch, acknowledge button for group
acknowledgement) do not require special handling for the folding functionality.

© Siemens AG 2003 All Rights Reserved

SIMOTION Safety Unit (AP) - Edition 06.2003 7-51

Downloaded from www.Manualslib.com manuals search engine

 Procedural functions of press brakes

7.4 Generating enables

An "Enable signals for operating mode (1-6)" mask is assigned to each operating
mode. The operating modes are handled identically.
Parameterization

Figure 7-1 Enabling for operating modes

7.4.1 Information on control signals

• Start condition
The "Start condition" signal is an enable signal for the downward movement. It
must be available prior to every start of a downward movement (HIGH level),
but can change its state during the movement.

This function can be disabled when no additional start condition is required

(default).

© Siemens AG 2003 All Rights Reserved

7-52 SIMOTION Safety Unit (AP) - Edition 06.2003

Downloaded from www.Manualslib.com manuals search engine

 Procedural functions of press brakes

• Request "DOWN"
The "DOWN" request signal is the start command from the higher level control
to the Safety Unit for initiating the downward movement. There must be an
enable signal from the Safety Unit for the downward movement. The "DOWN"
request signal must be active for the duration of the downward movement. The
press is stopped on a falling edge (operational stop).

If the request for the downward movement will not be read in by a higher level
control, this function can be disabled (default).

• Request "UP"
The "UP" request signal is the start command from the higher level control to
the Safety Unit for initiating the upward movement (see Figure 7-7 Valve
control, Part 3). The signal must be active for the duration of the upward
movement. The press is stopped on a falling edge.If valves will not be
controlled by the Safety Unit during the upward movement, this function can be
disabled (default). The upward movement is not a safety-oriented function and
can be implemented by a higher level control. In Chapter 7.5.4, the valve
(valve pair) that is to be controlled during the upward movement can be
assigned.

• Request "fast downwards speed"

The "Fast downwards speed" request signal is the command from the higher
lever control to the Safety Unit for activation of the fast downward movement.
The signal must be active for the duration of the fast downward movement. In
the case of a LOW level, the downward movement is always slow.

If the enable for the fast downward movement is to be generated internally, this
function can be disabled (default).

Note
Information on enabling the fast downward movement are found in Chapter 7.6.1
"Conditions for fast downward movements".

• "MUTE point"
The "MUTE point" initiates the press movement. The MUTE point signal is
LOW active. It must provide a HIGH level for the duration of the fast downward
movement. In the case of a LOW level, the downward movement is always
slow. If the MUTE point is approached with a fast downward movement, the
system changes to a slow movement.

If the "Two-hand foot-operation" function (see Chapter "Conditions for fast

downward movement") is to be implemented, the MUTE point must be
parameterized. The rapid downward movement with 2-hand operation is
interrupted at the MUTE point.

The "MUTE point" function can be deactivated (default).

• Jog mode – for "multi-operator control"

In jog mode, a control element (hand or foot) can remain activated with multi-
operator control. A jog function can be implemented with the second control
element. This function is primarily used during press motion. If the job mode is
activated during the fast downward movement, the system automatically

© Siemens AG 2003 All Rights Reserved

SIMOTION Safety Unit (AP) - Edition 06.2003 7-53

Downloaded from www.Manualslib.com manuals search engine

 Procedural functions of press brakes

changes to the slow downward movement.

This function can be deactivated (default).

• External safety device 1 (2)

This signal can be used to query 2 one-channel safety devices. A LOW level at
one of the inputs de-energizes the valves. This can be used, for example, to
implement a "Tilt monitor" (Chapter 7.6.2).

7.5 Folding function

Functions specific to die bending presses are parameterized in the "Folding
function" menu. These functions include:

• Access protection (moving safety devices, distance protection)

• Valve monitor (watchdog or dynamic)
• Emergency off output signal
• Valve control

7.5.1 Access protection

Figure 7-2 Access protection

Two safety devices can be parameterized for access protection (light curtain or
laser safety device). Each access protection can be activated as required for the
mode. If the access protection is deactivated in a specific operating mode, it must
be switched off. Preferably this will be implemented via the ESPE supply (0.5 A
output). One dual-channel input is used per access protection. The fast downward
movement for foot operation is only possible when the access protection is active
(for exceptions, see Chapter 7.6.1). If access protection 1 and access protection 2
are active in a particular operating mode, they are ANDed. A falling edge on an
active access protection de-energizes the valves. The access protection is not
evaluated beyond the mute point (function required for light curtain).

© Siemens AG 2003 All Rights Reserved

7-54 SIMOTION Safety Unit (AP) - Edition 06.2003

Downloaded from www.Manualslib.com manuals search engine

 Procedural functions of press brakes

7.5.2 Watchdog timer

Figure 7-3 Watchdog timer

The run time of three valves can be monitored.

The valve run time can be variably parameterized from 20 to 2000 ms. The
feedback input can be defined as an NO or NC contact.

© Siemens AG 2003 All Rights Reserved

SIMOTION Safety Unit (AP) - Edition 06.2003 7-55

Downloaded from www.Manualslib.com manuals search engine

 Procedural functions of press brakes

7.5.3 Dynamic valve monitoring

Figure 7-4 Dynamic valve monitoring

Three valves can be monitored dynamically.

Switching is monitored every time the corresponding valve is activated.
The feedback input can be defined as an NO or NC contact.
To be able to control the valve, the read back input must be at LOW level before
the valve is activated.
During switching, at least one leading edge must be received at the read back input
(for NO contact.

Note
The valve can be activated on short start pulses from the command devices, but
it does not switch through due to valve run times. Since in this case there would
also be no feedback at the read back input, this would result in a valve switching
fault. For this reason, a response delay can be parameterized for the valve. The
response delay for the valve monitor can be variably set to between 20 and
2000 ms.

© Siemens AG 2003 All Rights Reserved

7-56 SIMOTION Safety Unit (AP) - Edition 06.2003

Downloaded from www.Manualslib.com manuals search engine

 Procedural functions of press brakes

7.5.4 Valve control

Figure 7-5 Valve control, part 1

The valve control can be implemented in accordance with performance

requirements.
A maximum of 3 valve pairs can be controlled. For the switching variant on the left,
the maximum possible output current is doubled (with equal loading of both the P
and M switches).

Figure 7-6 Valve control, part 2

One of two valve control variants can be selected:

• Variant 1
Here the press safety valve and valve 1 (or valve pair 1) are controlled for the
slow downward movement. All 3 valves (or valve pairs) are controlled for the
fast downward movement.

• Variant 2
Here the press safety valve and valve 1 (or valve pair 1) are controlled for the
slow downward movement. The press safety valve and valve 2 (or valve pair 2)
are controlled for the fast downward movement.

For this variant, it can optionally be specified whether valve 1 (slow movement)
is to remain controlled after activation. The control is reset as soon as a safety
device "responds", the "fast" request is set, the upward movement is initiated
or the operating mode is changed.

© Siemens AG 2003 All Rights Reserved

SIMOTION Safety Unit (AP) - Edition 06.2003 7-57

Downloaded from www.Manualslib.com manuals search engine

 Procedural functions of press brakes

Figure 7-7 Valve control, part 3

For the "UP" request, you can specify which valve (valve pair) is to be controlled
during the upward movement.

Figure 7-8 Valve control, part 4

The "operational stop" function provides for "gentler" braking when a stop request
is made via the command devices or on a falling edge of the "DOWN" signal
request.
When a stop command is initiated either by a command device or on the falling
edge of the "DOWN" signal request, a shutdown delay (0 – 5000 ms) can be
parameterized. The stop command immediately switches off the "Enable DOWN"
output. Using this signal, the flow, e.g. through the control valve, can be reduced by
the higher level control and the machine speed can be slowed. A parameterized
delay time is available for the implementation of this process.

The corresponding valve (valve 1/valve 2) can be set to be de-energized

immediately by switching the "fast downwards speed" request signal.

• Switching the "fast downwards speed" request signal level from "0" to
"1"
Valve 1 (valve pair 1) is de-energized immediately.

• Switching the "fast downwards speed" request signal level from "1" to
"0"
Valve 2 (valve pair 2) is de-energized immediately.

© Siemens AG 2003 All Rights Reserved

7-58 SIMOTION Safety Unit (AP) - Edition 06.2003

Downloaded from www.Manualslib.com manuals search engine

 Procedural functions of press brakes

7.6 Information on functionality

7.6.1 Conditions for fast downward movements
• Foot control
To be able to initiate a rapid downward movement by foot control, the access
protection that is activated in the respective operating mode must supply the
enable (HIGH level). If access protection has not been parameterized in the
respective operating mode, a fast downward movement cannot be initiated by
foot control.
• Two-hand control (two-hand/foot control)
According to the EN 12622 standard, two-hand control is only permissible in
the Setup mode.
If the fast downward movement is to be initiated by two-hand control up to the
MUTE point during operation, access protection is not required. A MUTE point
must be parameterized for this function. Switching of the valve is initiated at the
MUTE point (slow speed). A stop can now be initiated via the "DOWN" request
signal and control can be switched to foot control (foot mode ).

7.6.2 Tilt monitor

Figure 7-9 Tilt monitor

Two one-channel proximity switches can be connected under the "Generate

enable" menu item using the two external safety devices. This function is fail-safe
(HIGH level for enable).
The proximity switches must be installed on the machine according to the desired
maximum tilt.

© Siemens AG 2003 All Rights Reserved

SIMOTION Safety Unit (AP) - Edition 06.2003 7-59

Downloaded from www.Manualslib.com manuals search engine

 Procedural functions of press brakes

7.6.3 "Moving" and "distance" access protection

In the following figure, two safety devices can be parameterized for access
protection for an operating mode. If both are parameterized in the same operating
mode, the enable is ANDed. A falling edge at one of the safety devices always
brings about a stop. To enable the fast downward movement, the safety devices
parameterized in the respective operating mode must provide a HIGH level signal.

Application example:
Activation of distance protection (zone protection) from the MUTE point onward.

Figure 7-10 Distance protection

In this example, the downward movement was started in mode 2 (e. g. foot).
The "DOWN" request signal of the higher level control is reset at the MUTE point
(or any point). This brings about a machine stop. The system can then switch to
operating mode 3. Access protection 2 is now active. In this case, a MUTE point
cannot be parameterized in operating mode 3 since access protection would
otherwise be deactivated beginning with the MUTE point.

© Siemens AG 2003 All Rights Reserved

7-60 SIMOTION Safety Unit (AP) - Edition 06.2003

Downloaded from www.Manualslib.com manuals search engine

 Procedural functions of press brakes

7.7 Application examples and procedural functions

The application examples apply to a handshake with a higher level process control.

7.7.1 Single operator control with foot switch

Inputs: UPPER POINT MUTE POINT END

STROKE
EMERGENCY OFF
switch

Access protection E1

Access protection E2

Operating mode 2

Foot NO (1)

Foot NC (1)

'DOWN' request

'Fast
downwards movement'
request

Outputs:

'DOWN' enable

Valve 1 (slow)

Press safety valve

Valve 2 (fast)

Emergency off output

signal

Figure 7-11 Example for foot switch

For this example, it is assumed that a foot switch and an access protection (dual-
channel E1/E2) have been parameterized for mode 2. The valves are controlled via
variant 2.

© Siemens AG 2003 All Rights Reserved

SIMOTION Safety Unit (AP) - Edition 06.2003 7-61

Downloaded from www.Manualslib.com manuals search engine

 Procedural functions of press brakes

7.7.2 Multiple operator control with foot switch

Inputs: UPPER POINT MUTE POINT END

STROKE
EMERGENCY OFF switch

Access protection E1

Access protection E2

Operating mode 4

Foot NO (1)

Foot NC (1)

Foot NO (2)

Foot NC (2)

'DOWN' request

'Fast
downwards movement'
request

Outputs:

'DOWN' enable

Valve 1 (slow)

Press safety valve

Valve 2 (fast)

Emergency off output signal

Figure 7-12 Example for multiple operators with foot switch

For this example, it is assumed that two foot switches and an access protection
(dual-channel E1/E2) have been parameterized for mode 4. The valves are
controlled via variant 2.

© Siemens AG 2003 All Rights Reserved

7-62 SIMOTION Safety Unit (AP) - Edition 06.2003

Downloaded from www.Manualslib.com manuals search engine

 8 General functions
8
8.1 Single operator/multi-operator control

Figure 8-1 Implementation of single operator/multi-operator control

In the above configuration, operating mode 2 is set for single operator/multi-

operator control. Foot switch 2 can be selected using an NO contact (it can be
deactivated). The deactivation input should be switched by the selector switch for
single operator/multi-operator control.

© Siemens AG 2003 All Rights Reserved

SIMOTION Safety Unit (AP) - Edition 06.2003 8-63

Downloaded from www.Manualslib.com manuals search engine

 General functions

• Multi-operator control
Multi-operator control (2-foot) is activated when operating mode 2 is selected
and foot switch 2 is not deactivated. In this case, if foot switch 2 is not
connected, a corresponding message is output and the valves cannot be
controlled (contact monitor).

• Single operator control

Single operator control (foot) is activated when operating mode 2 is selected
and control element 2 is deactivated. In this case, if foot switch 2 is not
connected, a corresponding message is output and the valves cannot be
controlled (connection monitor).

Note
• The connection monitor checks whether, for single operator control, all other
control elements (deactivated control elements) have been removed.
• For multi-operator control, all activated control elements must be connected
(contact monitor).
• If the monitoring function responds, messages are output to notify the user.

8.2 Single operator control via 2 foot switches and operating

error monitor

To implement single operator control via 2 separate foot switches, each foot switch
must be parameterized in a separate operating mode (e.g. foot switch 1 in
operating mode 2 and foot switch 2 in operating mode 3).

A complete stroke can be performed in operating mode 2 (foot switch 1).

Subsequently, the operating mode can be changed and a complete stroke can be
performed in operating mode 3 (foot switch 2). If operating mode 2 is active and
foot switch 2 was activated, a suitable message is output and the machine is
prevented from starting.

The system stops if a control element that was not selected is activated during a
press movement.

© Siemens AG 2003 All Rights Reserved

8-64 SIMOTION Safety Unit (AP) - Edition 06.2003

Downloaded from www.Manualslib.com manuals search engine

 General functions

8.3 Output assignment (0.5 A)

Figure 8-2 Output assignment (0.5 A)

The assignment of the 0.5 A outputs can be parameterized for terminals X2.3,
X2.4, X2.7 and X2.8.

Output X2.8 is used to parameterize whether the acknowledge message for the
safety gates is to be signalized on the fault indicator lamp.

The following functions can be assigned to outputs X2.3, X2.4 and X2.7:

• ESPE/access protection - supply

This function is used to control ESPE operation. If no ESPEs have been
parameterized for a particular operating mode, the ESPE is switched off as
soon as the corresponding operating mode is selected.

• (Acknowledge) signal, protective door

The acknowledge request for the safety gates can also be signalized on a
separate output.

• Enable "DOWN" (for edging presses)

This function signalizes to a higher level control that all conditions for the
downward movement have been met. The "DOWN" enable is set when no
active safety devices have been violated and the active control elements have
been actuated. Even if a shutdown delay has been parameterized for the
valves, this output is set to LOW level as soon as the active control elements
are no longer being actuated (see Chapter "Valve control").

• Active operator element actuated

This function signalizes that the control elements that are active in the
respective operating modes have been actuated.

• Safety devices closed (+acknowledge)

This function signalizes that all safety devices that are active in the respective
operating mode are closed, or are closed and acknowledged.

© Siemens AG 2003 All Rights Reserved

SIMOTION Safety Unit (AP) - Edition 06.2003 8-65

Downloaded from www.Manualslib.com manuals search engine

 General functions

• "Moving downwards" (for hydraulic operation!)

This function signalizes that the downward movement of the hydraulic press is
being performed. This means that the press safety valves and the valves for
the downward movement are being controlled.

• "Moving upwards" (for hydraulic operation!)

This function signalizes that the upward movement of the hydraulic press is
being performed. This means that the press safety valves and the valves for
the upward movement are being controlled.

© Siemens AG 2003 All Rights Reserved

8-66 SIMOTION Safety Unit (AP) - Edition 06.2003

Downloaded from www.Manualslib.com manuals search engine

 9 Operating and fault messages
9
Table 9-1 System errors
Display Error description Corrective
measure
F001 Error in internal CPU RAM See 1)
F002 RAM error See 1)
F003 EPROM error See 1)
F004 Data error in dual port RAM See 1)
F005 Data error in memory card or memory card empty See 1)
F006 Dissimilar FW versions See 1)
F007 Internal synchronization error See 1)
F008 Watchdog has responded See 1)
F009 Undervoltage error in 5V supply See 1)
F010 ODIS signal error See 1)
F011 PLD error See 1)
F012 Subsystem ID error See 1)
F013 Error from plug-in monitor for memory card See 1)
F014 Keyswitch error See 1)
F015 CPU error See 1)
F016 System data error See 1)
F017 Program execution error See 1)
F018 Application error See 1)
F019 Serial interface error See 1)
F020 Error, input X4.1 See 2)
F021 Error, input X4.2 See 2)
F022 Error, input X4.3 See 2)
F023 Error, input X4.4 See 2)
F024 Error, input X4.5 See 2)
F025 Error, input X4.6 See 2)
F026 Error, input X4.7 See 2)
F027 Error, input X4.8 See 2)
F028 Error, input X4.9 See 2)
F029 Error, input X4.10 See 2)
F030 Error, input X4.11 See 2)
F031 Error, input X4.12 See 2)
F032 Error, input X4.13 See 2)
F033 Error, input X4.14 See 2)
F034 Error, input X4.15 See 2)
F035 Error, input X4.16 See 2)
F036 – F039 Not assigned -
F040 Error, input X3.1 See 2)
F041 Error, input X3.2 See 2)

© Siemens AG 2003 All Rights Reserved

SIMOTION Safety Unit (AP) - Edition 06.2003 9-67

Downloaded from www.Manualslib.com manuals search engine

 Operating and fault messages

Display Error description Corrective

measure
F042 Error, input X3.3 See 2)
F043 Error, input X3.4 See 2)
F044 Error, input X3.5 See 2)
F045 Error, input X3.6 See 2)
F046 Error, input X3.7 See 2)
F047 Error, input X3.8 See 2)
F048 Error, input X3.9 See 2)
F049 Error, input X3.10 See 2)
F050 Error, input X3.11 See 2)
F051 Error, input X3.12 See 2)
F052 Error, input X3.13 See 2)
F053 Error, input X3.14 See 2)
F054 Error, input X3.15 See 2)
F055 Error, input X3.16 See 2)
F056 – F059 Not assigned -
F060 Error, output X6.1 See 3)
F061 Error, output X6.3 See 3)
F062 Error, output X6.5 See 3)
F063 Error, output X6.7 See 3)
F064 Error, output X2.1 See 3)
F065 Error, output X2.2 See 3)
F066 Error, output X2.3 See 3)
F067 Error, output X2.4 See 3)
F068 – F069 Not assigned -
F070 Error, output X6.2 See 3)
F071 Error, output X6.4 See 3)
F072 Error, output X6.6 See 3)
F073 Error, output X6.8 See 3)
F074 Error, output X2.5 See 3)
F075 Error, output X2.6 See 3)
F076 Error, output X2.7 See 3)
F077 Error, output X2.8 See 3)

Corrective measures for system errors:

1) Restart the device (INIT). Replace the device if the error reoccurs.
2) Check the wiring and correct if necessary. Specifically check the
parameterization of the sensor supply (external/internal). A more precise
statement on the source of the error can only be made after evaluation of the
error entries in the diagnosis buffer.
3) Check the wiring and correct if necessary. A more precise statement on the
source of the error can only be made after evaluation of the error entries in the
diagnosis buffer.

© Siemens AG 2003 All Rights Reserved

9-68 SIMOTION Safety Unit (AP) - Edition 06.2003

Downloaded from www.Manualslib.com manuals search engine

 Operating and fault messages

Table 9-2 Error messages requiring acknowledgement

Display Error description
F101 Over run cam static "1"
F102 Over run cam failed
F103 Over run cam static "0"
F104 Overtravel distance to long
F105 Ramp up cam failed
F106 Operating mode change not in TDC
F107 Short circuit at mode selector switch
F108 Speed monitor
F109 Runtime error, channel 1 (valve 1)
F110 Runtime error, channel 2 (valve 2)
F111 Runtime error, channel 3 (valve 3)
F112 Runtime error, channel 4 (EMERGENCY OFF output signal)
F113 Light curtain mode selection (1 cycle/2 cycle)
F114 Short circuit or "0" at light curtain mode selector switch
F115 Setting - dynamic cam
F122 Discrepancy error, transfer point
F123 Error in dynamic valve control, channel 1
F124 Error in dynamic valve control, channel 2
F125 Error in dynamic valve control, channel 3
F316 Restart inhibit, EMERGENCY OFF is set
F317 Restart inhibit, safety guard is set
F318 Restart inhibit, light curtain is set
F319 Restart inhibit, EMERGENCY OFF output signal
F320 *) Safety gate closed – not ready for acknowledge (blocked)
F321 *) Safety gate closed – ready for acknowledge
This error can only be acknowledged in the Setup operating mode
*)
If the safety gate display is parameterized for the fault lamp.

© Siemens AG 2003 All Rights Reserved

SIMOTION Safety Unit (AP) - Edition 06.2003 9-69

Downloaded from www.Manualslib.com manuals search engine

 Operating and fault messages

Table 9-3 Self-acknowledging error messages

Display Error description
F201 Discrepancy error, EMERGENCY_OFF 1
F202 Discrepancy error, EMERGENCY_OFF 2
F203 Discrepancy error, EMERGENCY_OFF 3
F204 Discrepancy error, EMERGENCY_OFF 4
F205 Discrepancy error, EMERGENCY_OFF 5
F206 Discrepancy error, EMERGENCY_OFF 6
F207 Discrepancy error, EMERGENCY_OFF 7
F208 Discrepancy error, EMERGENCY_OFF 8
F209 Discrepancy error, safety guard 1
F210 Discrepancy error, safety guard 2
F211 Discrepancy error, safety guard 3
F212 Discrepancy error, safety guard 4
F213 Discrepancy error, safety guard 5
F214 Discrepancy error, safety guard 6
F215 Discrepancy error, safety guard 7
F216 Discrepancy error, safety guard 8
F217 Contact error, two-hand 1
F218 Contact error, two-hand 2
F219 Contact error, two-hand 3
F220-F222 Not assigned
F223 Discrepancy error, restart inhibit 1
F224 Discrepancy error, restart inhibit 2
F225 Discrepancy error, light curtain
F226 Contact error, foot switch 1
F227 Contact error, foot switch 2
F228 Contact error, foot switch 3
F229 Discrepancy error, access protection 1
F230 Discrepancy error, access protection 2
F231 Plug-in control, two-hand 1
F232 Plug-in control, two-hand 2
F233 Plug-in control, two-hand 3
F234 Plug-in control, foot 1
F235 Plug-in control, foot 2
F236 Plug-in control, foot 3
F237 Operating error (two-hand 1 was actuated but is not active)
F238 Operating error (two-hand 2 was actuated but is not active)
F239 Operating error (two-hand 3 was actuated but is not active)
F240 Operating error (foot switch 1 was actuated but is not active)
F241 Operating error (foot switch 2 was actuated but is not active)
F242 Operating error (foot switch 3 was actuated but is not active)

© Siemens AG 2003 All Rights Reserved

9-70 SIMOTION Safety Unit (AP) - Edition 06.2003

Downloaded from www.Manualslib.com manuals search engine

 10 Documentation
10
10.1 Documentation of inputs (notes)

X3
Pin Description Cable Notes
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
X4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

© Siemens AG 2003 All Rights Reserved

SIMOTION Safety Unit (AP) - Edition 06.2003 10-71

Downloaded from www.Manualslib.com manuals search engine

 Documentation

10.2 Documentation of outputs (notes)

• Outputs 2 A

X6
Pin Description Cable Notes
1
2
3
4
5
6
7 Emergency stop P
8 Emergency stop N

• Outputs 0.5 A

X2
Pin Description Cable Notes
1 Output P Cycle 1
2 Output P Cycle 2
3
4
5 Output P Cycle 3
6 Output P Cycle 4
7
8 Error message

10.3 Documentation of system data

The CRC checksum should be entered on the label on the back of the memory
card and on the label located on the housing next to the memory card.

A complete function text must be performed after changes are made to the
parameterization, whether after the equipment is exchanged or
after the memory card is replaced (see Chapter 2.2 Device manual).

© Siemens AG 2003 All Rights Reserved

10-72 SIMOTION Safety Unit (AP) - Edition 06.2003

Downloaded from www.Manualslib.com manuals search engine

 To
SIEMENS AG
A&D MC BMS
P.O. Box 3180
D-91050 Erlangen

Tel. +49 (180) 50 50 222

Fax +49 (9131) 98 2176
E-Mail: [email protected]

Return address:
Your name: ___________________________________
Your position: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
Your company: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
Street: ___________________________________
City: ___________________________________
Telephone: ___________________________________

Please put a cross next to your industry sector:

❐ Automotive industry ❐ Pharmaceutical industry

❐ Chemical industry ❐ Plastics processing
❐ Electrical industry ❐ Paper industry
❐ Food industry ❐ Textile industry
❐ Control technology ❐ Transportation
❐ Mechanical engineering ❐ Other _ _ _ _ _ _ _ _ _ _ _ _ _
❐ Petrochemical industry ❐

© Siemens AG 2003 All Rights Reserved



SIMOTION Safety Unit (AP) - Edtion 06.2003 73

Downloaded from www.Manualslib.com manuals search engine

 Comments/suggestions
Your comments and suggestions assist us in improving the quality and usability of our
documentation. Please fill in this questionnaire at the next opportunity and send it back to Siemens.

Title of manual: Safety Unit TM 121C Application manual for presses

Order no. of manual: 6AU1900-0DM20-0XA0

Please enter your personal assessment on a scale from 1 = good to 5 = poor.

1. Does the contents meet your requirements? □

2. Is the required information easy to locate? □
3. Are the texts easy to understand? □
4. Does the degree of technical detail meet your requirements? □
5. How do you rate the quality of the figures and tables? □

If you have encountered any specific problems, please describe them below:
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________

© Siemens AG 2003 All Rights Reserved

74 SIMOTION Safety Unit (AP) - Edition 06.2003

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine
 Siemens AG
Automation and Drives
Motion Control Systems
P.O. Box 3180, D – 91050 Erlangen © Siemens AG 2003
Subject to change without prior notice.
Federal Republic of Germany
Order no.: 6AU1900-0DM20-0XA0

www.ad.siemens.de Printed in the Federal Republic of Germany

Downloaded from www.Manualslib.com manuals search engine