HIGH INTEGRITY SAFETY CONTROLLERS TECHNICAL HANDBOOK Handbook.pdf · 2008. 8. 27. · LADDER LOGIC PROGRAMMING Smartgram uses industry stand ard ladder logic to program the Integron

Smartscan Information

INTEGRON HIGH INTEGRITY SAFETY

CONTROLLERS

TECHNICAL HANDBOOK Smartscan Ltd, Pywell Road, CORBY, NN17 5XJ, UK, Tel: +44 (0) 1536 401313, Fax: +44 (0) 1536 268954, Email: [email protected], www.smartscan.com

CD273/ 090807

SSHISC AUG05

INTEGRON

CONTENTS PAGE

INTRODUCTION 1

APPLICATIONS 2

PRODUCT RANGE 3

INTEGRON SPECIFICATIONS 7

ANNUNCIATOR SPECIFICATIONS 10

SOFTWARE INSTALLATION 12

SOFTWARE VALIDATION 13

PROGRAMMING 14

WIRING AND SET UP 32

INSTALLATION SHEETS 33

CD273/090807 HANDBOOK 1

INTEGRON

INTRODUCTION

The Smartscan Integron range of high integrity safety controllers has been developed as an economic and flexible solution for safety system control. Because the Integron uses two independent memory modules, it can be configured to provide dual safe inputs and outputs with full cross monitoring. Suitably programmed, the Integron is compliant with EN9541 category 4.

In addition to providing safety control, the Integron can also be used for nonsafety applications or as a more powerful replacement for the standard range of Smartscan Multi Function Units (MFUs). There are two Integron models to choose from, dependent on the functionality required (see chapter: ‘Specifications’).

Development of the Integron program, which determines the functionality of the module, is carried out using industry standard ladder logic on Windows ® based software. The Smartgram software used to program the Integron allows configuration to suit the application that is required. Usable options, dependant on the model of Integron selected, include timers, speed monitors, counters and relay outputs.

Once the Integron’s program is written, it is then ‘burnt’ onto a ‘Memory Module’ and inserted in the PLC. As the ‘Memory Module’ is a burn once item, the program is secure and cannot be tampered with adding a further dimension to the security of the system.


INTEGRON

APPLICATIONS

The Integron is primarily designed for control of ‘safety zones’ and related ancillary components. This can range from a simple emergency stop controller or two handed controller through to more complex applications where customers need to have the ability to control the interaction between a number of safety zones (in the diagram below).

Other solutions already in development by Smartscan, based on the Integron for control, are:

• Robotic cell entry / exit control • Hydraulic press brake control • Inductive loop control


INTEGRON

PRODUCT RANGE

The product range for the Integron consists of three Integron units, Smartgram software, memory modules and memory module programming units and program validation units. The following is a brief summary of the functionality of each item with further details outlined in chapter ‘Specifications’.

150000 Smartgram software 150001 Programming unit 150002 Validation unit 150102 Validation unit 150201 Integron 22 14 inputs 150202 Integron 52 36 inputs 150220 Annunciator 150100 Memory module (3 pages) 1 set for 150201 150101 Memory module (10 pages) 1 set for 150202

150000 SMARTGRAM SOFTWARE

Windows ® based software used for programming the memory modules for the Integron range. Using industry standard ladder logic, the software is compatible with all three versions of the Integron.

Requirements:

• Microsoft Windows based PC running Windows 98 – XP • Minimum 100 MHz processor • Minimum 64mb RAM • CDROM drive • 3.5” Floppy disc drive • Serial port


INTEGRON

150001 PROGRAMMING UNIT

Required for ‘blowing’ the Smartgram developed program onto the memory modules. The unit is only required by those who develop the Integron programs or need to burn them onto memory modules.

150002 VALIDATION UNIT

Not required for the correct functioning of the Integron but it is a useful method of validating the program in the memory module once written before fitting to the Integron. Consists of a socket for the memory module to be fitted to and a number switches and LEDs. The unit is capable of testing the memory modules by checking the logic. Switches represent the various inputs to the system with the LEDs indicating the output status. Suitable for memory module 150100.

150102 VALIDATION UNIT

As above validation unit but only suitable for memory module 150101.


INTEGRON

150201 INTEGRON 22

Inputs: 7 Dual inputs Outputs: 3

1 Dual safety high current outputs 0.5A Dual safety low current output 60mA

Fault disparity: Checking on outputs Logic rungs: 36 Timers: 8

150202 INTEGRON 52

Inputs: 18 Dual inputs Outputs: 6

2

6 safety high current outputs 0.5A one of which can be split for current monitored mute lamp output and auxiliary. Dual safety electronic outputs 60mA

Fault disparity: User definable anywhere in the logic circuit Logic rungs: 120 Timers: 32 Counters: 4 Speed controllers: 2 Annunciator: 1


INTEGRON

150220 ANNUNCIATOR MODULE

Compatible with Integron 150202 only, this module takes the annunciator output (up to 16 signals) and activates a relevant relay on the annunciator module. The relay outputs can then be used for external signalling for display lamps for example. Each relay generates 0.5 amp output.

Each 150202 Integron can drive one annunciator module. Only one Integron can be connected to an annunciator.

150100 MEMORY MODULE

Memory modules (1 set comprises two chips) for use with 150201.

150101 MEMORY MODULE

Memory modules (1 set comprises two chips) for use with 150202.


INTEGRON

INTEGRON SPECIFICATIONS

ELECTRONIC AND ENVIROMENTAL SPECIFICATION

150201 INTEGRON 22

Power requirement L+ L 2228 V DC ripple <10% diode protected Current consumption 150mA Input rating Electronic sink 1mA Output rating Electronic sink 100mA Operating temperature 0°C to +50°C Enclosure IP40 Response time 5ms Classification EN954 category 4 Power status indicators Red = OK Input indicators Yellow = On Output indicators Green = On

150202 INTEGRON 52

Power requirement L+ L 2228 V DC ripple <10% diode protected Current consumption 150mA Input rating Electronic sink 1mA Output rating Electronic sink 100mA, relay sink 500mA Operating temperature 0°C to +50°C Enclosure IP40 Response time 5ms Classification EN954 category 4 Power status indicators Red = OK Input indicators Yellow = On Output indicators Green = On


INTEGRON

DIMENSIONS AND MOUNTING SPECIFICATION

INTEGRON 22 150201

INTEGRON 52 150202

• 35mm DIN rail mounting


INTEGRON

ELECTRONIC CONNECTION SPECIFICATIONS

INTEGRON 22 150201

• Where A1 and B1 are connected to 2228 V DC

INTEGRON 52 150202

• Where A1 and B1 are connected to 2228 V DC

• Where any one of A26, B26, A27 or B27 can be connected to the annunciator module 150220


INTEGRON

ANNUNCIATOR SPECIFICATIONS

ELECTRONIC AND ENVIROMENTAL SPECIFICATION

Power requirement L+ L 2228 V DC ripple <10% diode protected Current consumption 150mA all lights on plus load current Input rating Electronic sink 1mA Output rating 1A Operating temperature 0°C to +50°C Enclosure IP40 Response time 1S Classification CE Power status indicators Red = OK Input indicators Yellow = Data Output indicators Green = On

DIMENSIONS AND MOUNTING SPECIFICATION

• 35mm DIN rail mounting


INTEGRON

ELECTRONIC CONNECTION SPECIFICATIONS

• The data input must be output OT7 or OT8 from HISC 150202 • Outputs can drive any device of less than one amp (total module

current = 5A) • Outputs are single channel and not intended to control safety related

functions


INTEGRON

SOFTWARE INSTALLATION

To use the HISC range, you will need to have a PC of the following specification and the following items:

• Microsoft Windows based PC running Windows 98 – XP • Minimum 100 MHz processor • Minimum 64mb RAM • CDROM drive • 3.5” Floppy disc drive • Serial port • HISC • Set of relevant memory modules • 150001 Programming module or similar • 150002 or 150102 Validation unit (optional) • 150000 Smartgram software

To install the required software on your PC, you will need to do the following:

• Insert CDROM in CD reader • Run and install program ‘Mp56200 full’. This installs MPLab, the

software required to ‘blow’ hex files onto the memory module using Programming unit 150001.

• Run ‘setup’ from the CDROM. This will create a folder on the computer drive called ‘Smartgram’ and copy over the required data for the program.

• Remove the CDROM from the reader.

Installation is now complete.


INTEGRON

SOFTWARE VALIDATION

To ensure traceability of written programs and allow the originator to be identified, a validation sequence has been developed for Smartgram. Once the software has been installed, a registered user identity will be provided which will always be embedded into the memory modules when ‘burnt’ and can be retrieved if required.

To get a validation number you will need to contact Smartscan (Email: [email protected]) and provide your company details. Once these have been provided a unique serial number and validation key will be allocated which needs to be entered into the Smartgram software.

To do this, open the Smartgram program (see next chapter); click the options menu from the main menu:

Enter the serial number and validation key in the spaces provided:

Click apply to complete the validation process. Press exit to return to the main screen.


INTEGRON

PROGRAMMING

To open and run Smartgram, double click the icon found in C:\Smartgram on your hard disc:

Smartgram will then open in a new window.

MENU NAVIGATION

Depending on the position that Smartgram was closed in, the screen may still show the last project worked on. At this stage, do not worry about the contents as these can be cleared before starting a new project.

The main menu bar positioned along the top of the screen allows navigation to key areas of the program:

• ‘Clear’ clears the current page from memory (not the entire project) • ‘Load’ loads an existing hex file from the a: drive • ‘Compile’ compiles the hex file for the project • ‘Timers’ opens the page used for defining the timers in the software • ‘Print’ prints the project to a printer • ‘Save’ saves the compiled hex file to the a: drive • ‘Options’ sets the printer margins, processor and validation key • ‘Help’ appears as you pass your mouse over a particular area • ‘Quit’ closes the program

Note: ‘Caps Lock’ must be on when programming Smartgram software.

Status Window


INTEGRON

OPTIONS MENU

Firstly open options and set the processor type you will be working with. For the memory modules 150100 used in Integron 22 150201, select processor 3. For memory module 150101 for Integron 52 150202, select processor 4.

To select the processor type, enter the required number in the box ‘Set processor’ box, click apply then confirm within 2 seconds by pressing ‘y’.

After a few seconds, Smartgram will confirm that the processor has been changed by displaying ‘Done’ in the status window.

Exit the options screen by clicking ‘exit’:

Exiting the options screen brings you back to the main set up and programming screen for each of the processors depending on which you have selected:

For processor (3): 150100 For processor (4): 150101


INTEGRON

The differences between the screens are the number of pages of logic (150100 has three where 150101 has ten) and the inclusion of speed monitoring, annunciator and counters. 150101 also has user definable disparity checking anywhere within the logic circuit, which will be dealt with later.

LADDER LOGIC PROGRAMMING

Smartgram uses industry standard ladder logic to program the Integron range. Using a combination of normally open, normally closed, connectors and links, a diagram can be quickly and simply built.

To add a contact into the ladder logic, select a contact type from the contact string menu by clicking on it then click again in the area where the contact is required on the ladder logic diagram (see over the page).

The logic contact will then be applied accordingly.

‘Links’ can be applied by clicking in the upper ‘rung’ of the two rungs to be connected.

Each logicinput contact must be named as an input, a relay or as a defined output. The following example over the page shows a fully developed logic page:


INTEGRON

DEFINING CONTACTS

Each logic contact needs identifying to determine its nature and function. The contacts available vary dependant on the processor. Those available are highlighted on each menu when the required processor is selected.

Note that the Integron has two processors (A&B) which have some different output functions (See later).

For processor (3): 150100

Physical inputs IN1IN7 Physical outputs OT1OT4 Timers TM1TM8 Internal relay RE1RE10 Pulse on falling edge PT1PT4 Output disparity fault FL1

For processor (4): 150101

Physical inputs IN1IN18 Physical outputs OT1OT8 Timers TM1TM32 Internal relay RE1RE48 ON relay OFF relay REONREOF Pulse on falling edge PT1PT16 Disparity Fault FL1 Transferred signals XR1XR16

To identify a contact, click in the light grey area beneath the contact and type the identifier as required into the box.


INTEGRON

PHYSICAL INPUTS AND OUTPUTS

Defined in Smartgram by the identifier INXX (for inputs) and OTXX (for outputs, it is necessary to relate the number of the input and output to the input connection hard wired on the Integron. The following diagrams relate the INXX and OTXX identifiers to the physical connections on the relevant Integron.

The Integron is dual monitoring. In safety applications where safety outputs are required, the logic must be the same for each processor. Where differences are required in each processor for outputs where non safety is required, the processors logic may vary.

As an example, in the case of Integron 52, there is one nonsafety output (OT1 – see later tables) which can be used for mute monitoring and auxiliary out so the logic may be different in each processor.

INTEGRON 52

IN / OT Terminals Notes IN1 A2/B2 IN2 A3/B3 IN3 A4/B4 IN4 A5/B5 IN5 A6/B6 IN6 A7/B7 IN7 A8/B8 OT1 A9/B9 0.5A output OT2 A10/B10 0.5A output OT3 A11/B11 0.5A output OT4 A12/B12 60mA output


INTEGRON

INTEGRON 52

IN / OT Terminals Notes IN1 A2/B2 IN2 A3/B3 IN3 A4/B4 IN4 A5/B5 IN5 A6/B6 IN6 A7/B7 IN7 A8/B8 IN8 A9/B9 IN9 A10/B10 IN10 A11/B11 IN11 A12/B12 IN12 A13/B13 IN13 A14/B14 IN14 A15/B15 IN15 A16/B16 IN16 A17/B17 IN17 A18/B18 IN18 A19/B19 IN19 Internal contact. 1 OT1 A20/B20

0.5A output

A20 = Mute lamp non safety output on processor A. B20 = Auxiliary nonsafety output on processor B.

OT2 A21/B21 0.5A output OT3 A22/B22 0.5A output OT4 A23/B23 0.5A output OT5 A24/B24 0.5A output OT6 A25/B25 0.5A output OT7 A26/B26 60mA output OT8 A27/B27 60mA output TIMERS

1 IN19 is not a physical contact but is produced inside the Integron. It is the feedback signal from the mute monitoring function and will be on if the mute output is on and current is being taken by the lamp. IN19 = on when OT1 is on and current draw >5ma.


INTEGRON

When calling a timer contact, this must be identified by TMXX depending on the number of the timer used. The timer must be defined and identified in Smartgram if called as a contact. To define a timer, select the ‘Timers’ option from the main menu:

When selected, for processor type 4 (150101), the menu on the right is displayed:

To set up a timer, just type in the time required.

The left two columns define timers TM1TM16 and can be set from 025.5 seconds. The right two columns define timers TM17TM32 and can be set from 042.5 minutes.

When selected, for processor type 3 (150100), the menu on the right is displayed:

Timers are divided into tenth second and ten second increment timers which can be adjusted until the required time is defined. To change the mix of timers, toggle the ‘spinners’ until the required mix is shown.

Click ‘CALC’ to display the mix and the times. Adjust as required. Note: The number displayed in the ‘spinners’ box is not related to the number of tenth or ten second timers but is an internal register for the program.

The timer outputs are ‘Delay On’ timers and operate when the timer completes. The timer is reset when the preceding contact is opened before the timer completes or the contact is reopened. For example (below) TM1 becomes active on IN1 after a preset time and remains active until IN1 is opened again.


INTEGRON

INTERNAL RELAYS

Internal relays can be viewed as subroutines for use within the Integron. For example the three inputs defined below can be viewed as internal relay RE1 and called later as part of the Smartgram logic program.

• Processor 3 (150100) RE1RE10 • Processor 4 (150101) RE1RE48

The last 3 internal relays in the Integron 22 have lights connected to them in the form of LEDs on the Integron. They can be used for diagnostic purposes and are located on top.

RE46 Red LED RE47 Yellow LED RE48 Green LED

ON RELAY / OFF RELAY (REON / REOF)

The REON and REOF commands in Smartgram are used when a contact is to be defined as always on or always off when related to a normally open contact.

The command is specific to processor 4 (150101)

• REON Relay is always closed • REOF Relay is always open


INTEGRON

PULSE ON FALLING EDGE

Pulse on falling edge is available as an output and is useful for such things as safety switches. Identified as PTXX these can then be called within the logic.

• Processor 3 (150100) PT1PT4 • Processor 4 (150101) PT1PT16

OUTPUT DISPARITY FAULT

This function is specific to processor 3 (150100) and relates to fault checking on the outputs only. If for example OT1 on processor A and B show different values and ‘Output Disparity Fault’ checking is enabled then fault is turned on (‘FL1’ is enabled).

To enable ‘Output Disparity Fault’ you must first create a logic string as per below to turn FL1 on when a fault occurs (as below).

It is advisable to use a timer to verify that the disparity is real and not for example a time delay on button presses or similar. This can be simply achieved by developing a small logic circuit as follows over the page:


INTEGRON

Here FL1 becomes active on detection of disparity. FL1 activates timer (TM1) after a preset amount of time and if TM1 remains active (closed) then this will, in this case, stop output to OT1.

If FL1 is only active momentarily (for less time than TM1 is preset), then TM1 will not activate. If TM1 activates then it will open normally closed contact and deactivate OT1. The circuit below is selflatching as TM1 is feeding back into the circuit and the system will need to be reset to repower OT1.

DISPARITY FAULT AND TRANSFERRED SIGNALS

Similar in concept to disparity ‘Output Disparity Fault’ this is specific to processor 4 (150101) although it can be used to check for disparity anywhere in the logic circuit not just outputs. It therefore allows for much more flexibility in the logic program.

‘Transferred Signals’ creates internal relays identified by XR relays (XR1 to XR16). As there is a lot of capacity in the processor 4, you could decide to use part of one processor for non safety circuits in the same HISC and the XR relays allow signals to be transferred between processors A to B where programs are not identical.

Upto sixteen signals can be transferred and eight signals can be used for disparity checking.

To call the ‘Disparity Check and Transferred Signal’ functions, click the Disparity and RX button on the menu for processor 4.


INTEGRON

This will display the following:

To identify the relays required, these can be inputs, outputs or internal relays, enter these into the main boxes under the contacts.

These will then be available as XR relays for transferring data between processors where programs are not identical.

For contacts where fault disparity checking is required, enter a tick in the relevant check boxes and these will then be monitored for disparity checks.

When a disparity is discovered, FL1 is turned on.

To enable disparity checking in processor 4, it is required that something be used to enable checking. In the ‘disparity enable’ box type in the name of a relay contact that is to be used to turn disparity checking on and off. In the case below, REON has been used so disparity checking is always on. It could just as easily be an internal contact or an input or output.

Timer functions may still be required to check as discussed in the previous section.


INTEGRON

SPEED MONITORING

Speed monitoring can be accomplished using the Integron 52 only. This is set up in the Smartgram software and is useful for such applications as establishing a speed window for muting a light curtain. There are two speed monitors available within the Integron.

The speed is measured by counting the number of pulses received during one second and when this level is exceeded the relevant output goes on. The maximum pulse rate is 100 Hz (100 pulses per second) and the minimum is 2 Hz (2 pulses per second).

There are 2 set points available for each speed monitor. To use speed monitoring, select ‘speed monitor’ from the options menu for processor 4 (150101).

The following menu is displayed. Identify the input to be used for speed monitoring (in this case IN9). Then input the trigger levels in ‘Level 1’ and ‘Level 2’.

In this case, internal relays have been used to determine actions within Smartgram main logic.


INTEGRON

COUNTERS

There are four counters available for use in the Integron 52 only (processor 4). This is set up in the Smartgram software. The counter may be used to count pulses from an input and when the set point is reached the counter stops and turns the output on. Reset reinitialises the counter.

• Define the input to be used that will be providing the pulses using INXX and entering this in the box ‘Input Pulses’.

• Enter the relevant INXX relating to the input to be used for the reset. • Enter the ‘trigger point’ in Set point • Define the output to be turned on (OTXX) in ‘OUT’

• Maximum count is 65025 • Maximum pulse frequency is 100 Hz

Note: Outputs and resets can be internal relays defined by REXX if external contacts are not required or available.


INTEGRON

ANNUNCIATOR

The annunciator function is available in processor 4 (HISC 150202).

Compatible with the Integron 52, the annunciator module takes the annunciator output (up to 16 signals) and activates a relevant relay. The relay outputs can then be used for external signalling for display lamps for example. Each relay can deliver upto 0.5 amp output.

The module itself takes 16 input signals and converts them into a serial signal of 2 bytes.

Select the annunciator from the main menu to display the following:

Inputs:

Assign the contacts you want to use to the inputs. For example:

These will then be attributed to the relevant annunciator output (see table over the page).

Output from Integron 52:

The output from the Integron must be OT7 or OT8, which are electronic and therefore capable of carrying continuous data.

Define which is to be used in the ‘OUT’ box.

The Annunciator must be enabled before it will work. This can be any contact but for permanent activation, name the contact 'REON' in the ‘ENABLE’ box.


INTEGRON

In the ‘LATCH’ box, REOF will enable continuous update.

Terminal ID Annunciator output A5 1 A6 2 A7 3 A8 4 A9 5 A10 6 A11 7 A12 8 B5 9 B6 10 B7 11 B8 12 B9 13 B10 14 B11 15 B12 16

The Annunciator may be used as an additional output device giving 16 outputs. As the Integron is dual channel with independent processors, it is possible to connect two annunciators to give 32 outputs. To do this the latch must be permanently off, so name the contact 'REOF'


INTEGRON

HEADER

For both processors, it is not essential to the operation of the program, but advisable, that the header sections are completed and contacts named. When the ladder logic is printed out, this will pick up the names given to contacts and include these on the logic diagram.


INTEGRON

COMPILING

Once the program has been written for the Integron, it needs to be compiled. This produces a hex file for ‘burning’ onto a memory module and checks the program for errors. It will not check that the logic is correct but it will ensure all contacts are named and where required, those contacts such as timers have been correctly specified. The following process is followed:

• Checks the names are OK in the coils • Checks the names are OK in the contacts • Checks no limits are exceeded • Creates the file GRAM.ASM for the microchip assembler • Runs the assembler to create GRAM. HEX

To compile a finished program, simply click the ‘compile’ button on the main menu header. Any errors will be highlighted throughout the process and the process will stop at that point with a relevant error message (example below).

Correct the error and recompile.

Once completed the program must be saved. Enter a 3.25” floppy disc into the drive on the computer and click save from the main menu. This saves all the required files in a permanent media.


INTEGRON

PRINTING

Printing of any header page can be simply done by hitting print when in the relevant menu. If you are in the logic diagram page, then the print out will pick up all the correct names for the contacts and reflect them in the printout.

The printouts are useful documentation to explain the theory of operation of a program and how the Integron should be connected. You can only print compiled programs.


INTEGRON

WIRING AND SET UP

When wiring up the Integron it is important to remember that the units are dual channel and hence need wiring as such. Therefore inputs need wiring as follows:

Outputs need wiring thus when connected to relays:

A9

B9

L

L

+24v

+24v

Safety Relays


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Documents

HIGH INTEGRITY SAFETY CONTROLLERS TECHNICAL HANDBOOK Handbook.pdf · 2008. 8. 27. · LADDER LOGIC PROGRAMMING Smartgram uses industry stand ard ladder logic to program the Integron