Melsec Qs Safety Plc Cc-link Safety

7/31/2019 Melsec Qs Safety Plc Cc-link Safety

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MITSUBISHI ELECTRIC AUTOMATION, INC. REVISION B, AUGUST 2007. CONFIDENTIAL DOCUMENT: FOR MEAU AND AUTHORIZED DISTRIBUTOR USE ONLY

The MELSEC QS Safety PLC

& CC-LinkSafety Network


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Overview

What this presentation covers

Background on safety

Product features & benefits

Market/sales strategy

Conclusions


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Part 1: Background on Safety


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Before we begin

Typically, before any type of safety system isimplemented

a Risk Assessment must be performed

This identifies the hazards

Their type, frequency, severity and what can be doneto avoid them

Once this is complete, the level of protection requiredcan be determined

Two standards exist to define the required protection

level IEC 61508

EN 954


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Safety standards

The QS & CC-LinkSafety are

certified to IEC 61508 SIL 3

EN 954 Category 4

These are the acceptedindustry certification levels for

safety control systems QS certification was awarded

by TUV

Advantage

A customer can be assured

that the QS will meet therequired level of safetyperformance


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Background on IEC 61508

IEC 61508 guarantees the level of system reliability (FunctionalSafety)

Assured by certified design methods

Defined by Safety Integrity Levels (SIL 1-4)

Measure of likelihood that system will do what its supposed to when

you need it to In simple terms, like MTBF

SIL 3 essentially predicts an undetected failure will happen aboutonce in 1,100 years!

BUT:Doesnt guarantee system is safe in operation; still requiresthe controller to be programmed competently and assessed as

such Advantage

QS is certified to SIL 3; puts it on a level playing field withcompetition


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Background on EN 954

Relates to the design of machinery

Defines five levels (B, 1-4)

Specifies that the system should not lose its safetycapability because of a fault

System should also be able to detect faults Accumulation of faults should also not cause a loss of

safety capability

Advantage Design ofCC-LinkSafety I/O complies with Category

4 Some safety devices may only be Category 3 (or

lower)



Part 2: Overview of the MELSEC QS



QS Overview

A safety PLC based on the Q Series Automation Platform

A standalone platform

Links to Q Series via NET/H

Handles I/O (safety and non-safety) via CC-LinkSafety

A new version of CC-Link

Uses GX Developer as normal Advantages

Existing MELSEC customers already have high familiarity

No new programming techniques to learn

Logic & networks are handled same way as regular Q Series

QS can be easily integrated with installed Q Series base Benefits

Selection makes sense to existing users

Low risk decision; proven technology



QS Overview

Key components

QS001 Safety CPU

QS034B-E Safety Base Rack

QS061P-A1 Safety Power Supply

QS0J61BT12 CC-LinkSafetyMaster

QS0J65BTB2-12DT CC-LinkSafety I/O blocks

These are all separate products to theexisting Q Series line-up

All are marked as a safety product by adistinctive yellow stripe across the topof the unit

Standard NET/H modules can also beused with the QS

Advantages Few new part numbers to learn

Safety systems easilydistinguished in a panel

Yellow stripe



Why use a QS instead of safety relays/safety controllers?

QS has sufficient

scalability to handle thesafety requirements of awhole productionline/large machine

Advantages

Saves cost No safety islands

Simplifies maintenance

Offers more flexibility &diagnostics

Note that Safety PLCmarket is similar to PLCmarket, circa 1975



QS001CPU performance specification

100ns; same as

Q01CPU, slower than

the Q02Hs 34ns

Same as a regular Q

CPU in general

Same as Q01CPU

Note program memory

is larger than program

size, to allow for

storage of comments

and other data

The three files are:

program, commentsand parameters

1024 physical I/O

points can be

addressed



Whats different about the QS CPU?

Dual CPU architecture Uses a 1oo2 (one out of two) votingarchitecture to insure the program hasbeen executed correctly

Two physical processors reside inthe CPU unit

Required for safety certification

Differences would fault the processorand cease system execution

Both CPUs are contained in onephysical case

Additional memory checking & hardwarediagnostics also implemented

Advantage Some competitors use a single CPUarchitecture, execute program twice

Slows system performance



Test & Safety Modes

Two main modes of operation Safety Mode

Test Mode

Safety Mode is used to insure thesystem operates correctly when inactual use

Test Mode permits development &

maintenance before systems areput into action

Advantages Allows maintenance to be

conducted when required

Prevents system abuse when

in operation Benefits Assures system is protected

from tampering



Access control

QS restricts access to three classes ofuser Administrator (highest)

Developer (medium)

User (lowest)

Your class defines your level of accessin both Test & Safety Modes

Up to 128 users can be allowed accessto a project

Access level is defined separately foreach user

Each user has a unique user name &password

Advantages Insures traceability

Accomodates large number ofusers at different levels

Benefits Prevents unauthorized access

Insures proper levels of access aremaintained



Programming the QS Safety PLC

In general, the QS programs thesame way as any other Q Seriessequence CPU

Additional features have beenadded in GX-Developer to supportthe new safety related features

Supported in GX-Developer from

version 8.45X (June 2007) Advantages Uses existing GX Developer

No new software to buy

Minimizes learning curve

Accessible to shop floor

electricians and othermaintenance personnel

Benefit Builds on customers existing

MELSEC expertise



Network communications

Currently QS has the followingconnectivity on networks

CC-LinkSafety

I/O network only

Note QS does not support

local I/Oyet

MELSECNET/H

For linking to Q Series

systems

Permits monitoring

No other networks are currently

supported

Ethernet is planned for 2008



Future plans for CC-LinkSafety

CC-LinkSafety falls under the administrationof the CC-Link Partner Association (CLPA)

Plans are underway to recruit third party

vendors

MELCO also plans to add to their line-up of

CC-LinkSafety products Advantages

Will increase the selection of available

products from multiple vendors

Similar to other open safety network

organizations

Benefits

Avoids customer feeling locked in

Creates freedom of choice



CC-Link& the CLPA

CC-Linkis a high-speed, deterministic, open-technology communication network originally

developed by Mitsubishi Electric

In 2000, Mitsubishi Electric formed the

CC-Link Partner Association (CLPA) to assist

equipment manufacturers to incorporate

CC-Linktechnology into their automation

products and to promote the CC-LinkFamily ofIntegrated Networks on a global basis



CC-Link& the CLPA

As of now, there are more than 4 million

installed CC-Linknodes

More than 850CC-Linkcompatible productshave been developed by hundreds of

manufacturers

CLPA can help Mitsubishi sales by workingwith 3rd party vendors to provide a complete

CC-Linksolution for end users



CC-LinkSafety Network communications

Advantage Safety and standard CC-Linknodes can be combined on the same network

Benefit Provides a more cost effective solution; use regular I/O for non-safety

devices on a safety network


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Key differences between CC-Link& CC-LinkSafety

Item CC-LinkSafety

(CCLS)

CC-Link(V2.0) Comments

Transmission speed Up to 10Mbit/s Up to 10Mbit/s

Bus length Up to 1200m Up to 1200m

Safety cyclic

transmission

Safety Remote I/O

(Safety Input/Output bits)

2048 S-Rx

2048 S-Ry

Not supported CC-Linkdoes not supportSafety I/O

Safety Remote Registers

(Safety Input/Output Words)

128 S-RWw

128 S-RWr

Not supported

Standard (non-safety)

cyclic transmission

Standard Remote I/O(Input/Output bits)

2048 Rx

2048 Ry

8192 Rx

8192 Ry

CC-LinkSafety (CCLS)supports CC-LinkV1specifications for non-safety

communicationStandard Remote Registers(Input/Output Words)

256 RWw256 RWr

2048 RWw2048 RWr

Maximum number of stations 64 (Maximum of 42 SafetySlave stations)

64 CC-Linkdecreases to 42 or

26 depending on station type

Connect to Safety devices? Yes No CC-Linklacks the necessarycertifications to be used as asafety network

Connect to Standard Remote I/O stations? Yes Yes Remote I/O blocks(communicates bit data)

Connect to Standard Remote Device stations? Yes Yes Analog I/O modules(communicates bit and word

data)

Connect to Intelligent Device stations? No Yes Requires transientcommunication; not currentlysupported by CC-LinkSafety

Connect to Local stations? No Yes

Connect to Standby Master station? No Yes


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CC-LinkSafety Transmission Format

Advantage Safety and standard CC-Linknodes can be combined on the same network

Benefit Customers can migrate to CC-LinkSafety using tools and training that they

already have


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Whats different about safety I/O?

As well as being functionallysafe (IEC 61508)

I/O has to support the abilityto keep a system safe (EN 954)

This requires a range of

features not required onconventional I/O

Dual redundant wiring

Test pulses

Timing checks

Also requires its own CPU tomonitor operations

Hence the additional size


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EN 954 revisited

QS is certified to EN 954Category 4

A category 4 circuit is required tobe

Designed so it can withstandthe expected influence

Uses well tried safetyprinciples

Able to prevent a single faultfrom losing the safety function

Able to detect the single faultat or before the next demandon the safety function

If this is not possible, anaccumulation of faults shouldnot lead to a loss of the safetyfunction


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Input/output test pulses

Detection of short circuits

For example, T0 & T1 shorted

Two pulses would besuperimposed on the samechannel: fault detected

Detection of open circuits

T0 or T1 lost

A pulse would be lost: faultdetected

Miswiring

T0 wired to X1

Wrong pulse sensed at a channel:fault detected

Can also detect welded/stuck contacts

Benefit System will detect virtually all faults

that may lead to an unsafecondition


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Output wiring combinations

Outputs are transistor Two wiring options

Source-source

Sink-source Use according to

output device polarity


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GX Developer block parameter setting

Safety remote

station settings

dialog contains all

parameters to setnoise filter,

discrepancy

detection, test

pulses, etc.


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Conclusions

The QS represents Mitsubishiscommitment to safety controls

It offers a high capacity flexible alternativeto discrete safety relays or controllers

CC-Link Safety offers an open, cost

effective, high performance way to networkcritical safety devices

Together, they form a safety solution thatreadily integrates with the rest of theMitsubishi automation solution

Documents

Melsec Qs Safety Plc Cc-link Safety