SICK Flexi Gateway GETC1 Expansion module - gateway Istruzioni per l'uso

Marca: SICK

Modello: Flexi Gateway GETC1 Expansion module - gateway

Tipo: Istruzioni per l'uso

O P E R A T I N G I N S T R U C T I O N S

Flexi Gateway GETC1

Expansion module - gateway

Described product

lexi Gateway GETC1

Manufacturer

SICK AG

Erwin-Sick-Str. 1

79183 Waldkirch

Germany

Legal information

his work is protected by copyright. Any rights derived from the copyright shall be

reserved for SICK AG. Reproduction of this document or parts of this document is

only permissible within the limits of the legal determination of Copyright Law. Any modi‐

fication, abridgment or translation of this document is prohibited without the express

written permission of SICK AG.

The trademarks stated in this document are the property of their respective owner.

Original document

his document is an original document of SICK AG.

EtherCAT®

EtherCat® is a registered trademark and patented technology licensed by Beckhoff

Automation GmbH, Germany.

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Contents

1 About this document........................................................................ 5

1.1 Purpose of this document........................................................................ 5

1.2 Scope......................................................................................................... 5

1.3 Target groups and structure of these operating instructions................ 5

1.4 Further information................................................................................... 6

1.5 Symbols and document conventions...................................................... 6

2 Safety information............................................................................ 8

2.1 General safety notes................................................................................ 8

2.2 Intended use............................................................................................. 8

2.3 Improper use............................................................................................. 8

2.4 Requirements for the qualification of personnel.................................... 8

3 Product description........................................................................... 10

3.1 Configuration of the safety controller...................................................... 10

3.2 Overview of the module............................................................................ 11

3.3 Configuration and function...................................................................... 11

3.4 Status indicators....................................................................................... 12

4 Project planning................................................................................ 13

4.1 Design........................................................................................................ 13

4.2 Integration into the controller network.................................................... 13

4.2.1 Integration via the fieldbus interface..................................... 13

5 Mounting............................................................................................. 15

5.1 Safety......................................................................................................... 15

5.2 Mounting procedure................................................................................. 15

5.3 Module exchange...................................................................................... 15

6 Electrical installation........................................................................ 16

6.1 Safety......................................................................................................... 16

6.2 Device connection.................................................................................... 16

7 Configuration..................................................................................... 17

7.1 Offline, online and security configuration............................................... 17

7.2 Configuring the network interfaces......................................................... 18

7.2.1 Configuring the higher-level controller.................................... 18

7.2.2 Enabling emergency messages.............................................. 18

7.2.3 Addressing................................................................................ 19

7.2.4 Configuring the output data (routing to CPU)......................... 19

7.2.5 Configuring the input data (routing to network)..................... 20

8 Commissioning.................................................................................. 22

8.1 Check during commissioning and modifications.................................... 22

CONTENTS

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9 Operation............................................................................................ 23

9.1 Operation of the display........................................................................... 23

9.2 Display menu............................................................................................ 23

9.3 Regular thorough check........................................................................... 23

10 Maintenance...................................................................................... 24

10.1 Regular thorough check........................................................................... 24

11 Troubleshooting................................................................................. 25

11.1 Status indicators....................................................................................... 25

11.2 Possible faults........................................................................................... 27

12 Decommissioning............................................................................. 28

12.1 Disposal..................................................................................................... 28

13 Technical data.................................................................................... 29

13.1 Data sheet................................................................................................. 29

13.2 Data exchange in the network................................................................. 30

13.2.1 EtherCAT® – standard objects............................................... 30

13.2.2 EtherCAT® – manufacturer-specific objects.......................... 31

13.3 Dimensional drawings.............................................................................. 36

14 Ordering information........................................................................ 37

14.1 Scope of delivery....................................................................................... 37

14.2 Ordering information for main module.................................................... 37

14.3 Ordering information for expansion module........................................... 37

14.4 Ordering information for accessories...................................................... 37

15 Annex.................................................................................................. 39

15.1 Compliance with EU directives................................................................. 39

16 List of figures..................................................................................... 40

17 List of tables....................................................................................... 41

CONTENTS

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1 About this document

1.1 Purpose of this document

These operating instructions contain the information required during the life cycle of the

afety controller.

Operating instructions of the safety controller must be made available to all people who

work with the device.

1.2 Scope

These operating instructions apply to the Flexi Compact safety controller.

his document is included with the following SICK part numbers (this document in all

available language versions):

•

8024566

Furthermore, the following documents contain information about the safety controller:

able 1: Available documents

Document Title Part number

Operating instructions FLX3-XTDI1 expansion module

or safety controllers

8024571

Operating instructions FLX3-XTDO1 expansion mod‐

ule for safety controllers

8024570

Operating instructions FLX0-GPNT1 expansion mod‐

ule f

or safety controllers

8024567

Operating instructions FLX0-GETC1 expansion mod‐

ule for safety controllers

8024566

Operating instructions Flexi Loop Safe Series Con‐

nection Hardware

8015834

Operating instructions Flexi Loop in the Safety

esigner Software

8018174

Competence brochure Guide for Safe Machinery 8008007

1.3 Target groups and structure of these operating instructions

These operating instructions are intended for the following target groups: project devel‐

oper

s (planners, developers, designers), installers, electricians, safety experts (such as

CE authorized representatives, compliance officers, people who test and approve the

application), operators, and maintenance personnel.

These operating instructions are organized by the life phases of the device: project

planning, mounting, electrical installation, commissioning, operation and maintenance.

The table below shows the target groups and how – for many applications – these are

typically divided up between the manufacturer and the entity operating the machine in

which the device is to be integrated:

ABOUT THIS DOCUMENT 1

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Area of responsibility Target group Specific chapters of these operating instruc‐

ions

Manufacturer Project developers

(planners, developers,

designers)

Project planning, page 13

Technical data, page 29

Installers Mounting, pa

ge 15

Electricians Electrical installation, page 16

Safety experts Project planning, pa

ge 13

Commissioning, page 22

Technical data, page 29

Operating entity Operators Troubleshooting, pa

ge 25

Maintenance staff Troubleshooting, page 25

Ordering information, page 37

Chapters not listed here are intended for all target groups. All target groups must follow all of the safety

and warning instructions in all chapters of the operating instructions!

In other applications, the operating organization is also the manufacturer of the equip‐

ment w

ith the corresponding allocation of the target groups.

1.4 Further information

www.sick.com

he following information is available via the Internet:

•

This document in other languages

•

Data sheets and application examples

•

CAD files and dimensional drawings

•

Certificates (such as the EU declaration of conformity)

•

Guide for Safe Machinery. Six steps to a safe machine

•

Safety Designer (software for configuring safety solutions made by SICK AG)

1.5 Symbols and document conventions

The following symbols and conventions are used in this document:

Safety notes and other notes

DANGER

Indicates a situation presenting imminent danger, which will lead to death or serious

injuries if not prevented.

WARNING

Indic

ates a situation presenting possible danger, which may lead to death or serious

injuries if not prevented.

CAUTION

Indic

ates a situation presenting possible danger, which may lead to moderate or minor

injuries if not prevented.

NOTICE

Indic

ates a situation presenting possible danger, which may lead to property damage if

not prevented.

1 ABOUT THIS DOCUMENT

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NOTE

Indic

ates useful tips and recommendations.

Instructions to action

he arrow denotes instructions to action.

1. The sequence of instructions for action is numbered.

2. Follow the order in which the numbered instructions are given.

✓

The check mark denotes the result of an instruction.

ABOUT THIS DOCUMENT 1

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2 Safety information

2.1 General safety notes

This chapter contains general safety information about the safety controller.

urther safety information is provided in the respective chapters to cover the specific

situations in which the product may be used.

DANGER

If t

he device is not integrated in the way intended by the manufacturer, the protective

function of the device can be impaired. The dangerous state may be ended too late.

Plan the integration of the safety component in accordance with the machine

requirements, see "Project planning", page 13.

2.2 Intended use

The Flexi Compact safety controller is a freely configurable control for safety applica‐

ions. Sensors and switching elements (e.g. light curtains, laser scanners, switches,

sensors, encoders, emergency stop pushbuttons) are connected to the safety controller

and are linked logically. The corresponding actuators of the machines or systems can

be switched off safely via the switching outputs of the safety controller.

Incorrect use, improper modification or manipulation of the module will invalidate any

warranty from SICK; in addition, any responsibility and liability of SICK AG for damage

and secondary damage caused by this is excluded.

The safety controller system is only suitable for use in industrial environments.

2.3 Improper use

Among others, the safety controller is not suitable for the following applications:

•

Out

doors

•

Underwater

•

In explosion-hazardous areas

•

In residential areas

2.4 Requirements for the qualification of personnel

The protective device must be configured, installed, connected, commissioned, and

ser

viced by qualified safety personnel only.

Project planning

For project planning, a person is considered competent when he/she has expertise and

experience in the selection and use of protective devices on machines and is familiar

with the relevant technical rules and national work safety regulations.

Mechanical mounting, electrical installation, and commissioning

or the task, a person is considered qualified when he/she has the expertise and

experience in the relevant field and is sufficiently familiar with the application of the

protective device on the machine to be able to assess whether it is in an operationally

safe state.

2 S

AFETY INFORMATION

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Operation and maintenance

or operation and maintenance, a person is considered competent when he/she has

the expertise and experience in the relevant field and is sufficiently familiar with the

application of the protective device on the machine and has been instructed by the

machine operator in its operation.

SAFETY INFORMATION 2

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3 Product description

3.1 Configuration of the safety controller

Configuration of the safety controller

A s

afety controller comprises the following components:

•

A main module

•

Up to 12 optional expansion modules (excluding maximum 1 gateway)

PWR

FLEXIcompact

I11

I10

I12

I15

I17

I16

I18

I19

I20

I14

PWR

I13

Figure 1: Example maximum configuration

Main module

Expansion module - gateway

IO expansion module

Complementary information

•

The gateway and IO expansion modules can be arranged arbitrarily.

3 PRODUCT DESCRIPTION

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3.2 Overview of the module

Figure 2: Gateway expansion module

Release element of the module

Display

RJ45 female connector: EtherCAT® input

RJ45 female connector: EtherCAT® output

Backplane bus

3.3 Configuration and function

Prerequisites

•

he module can only be operated with a main module.

Configuration

Table 2: Interfaces of the module

Description Quantity

RJ45 female connector 2

Function

he module enables a safety controller to send data to a network for control and

diagnostic purposes, and to receive data from the network.

The module offers the following functions:

•

Integration into an EtherCAT® network as a slave

An EtherCAT® master (e.g., higher-level controller or computer) and/or another Ether‐

CAT® slave device can be connected at the RJ45 female connector.

Complementary information

•

oltage is supplied to the module via the backplane bus. Communication with the

main module of the safety controller also occurs via the backplane bus.

PRODUCT DESCRIPTION 3

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3.4 Status indicators

Status indicators

Figure 3: Status indicators

Status indicator

able 3: Status indicator

Labeling Color Function

PWR Green/Red Device status

RUN Green EtherCAT® operational status

ERR Red EtherCAT® error

IN, OUT Green/yellow/white Network activity for Ethernet

J45 female connector 1 and

female connector 2

Further topics

•

"Oper

ation", page 23

•

"Troubleshooting", page 25

3 P

RODUCT DESCRIPTION

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4 Project planning

4.1 Design

Mounting

•

vironment meets the requirements of IP54 or higher, e.g., IP54 control cabinet.

•

Mounting on a 35 mm × 7.5 mm mounting rail in accordance with IEC 60715.

•

The mounting rail is connected to the functional earth.

•

Mounting rail is mounted on a mounting plate.

•

Mounting plate is connected to functional earth.

•

Mounting in a vertical orientation (on a horizontal mounting rail).

•

Take suitable ESD protection measures.

Air circulation

To ensure sufficient air circulation and cooling, sufficient distance must be kept in the

control cabinet above and below the module.

Provide an adequate clearance in front of the module (front side) for the connected

cables.

≥ 30≥ 30

≥ 25

Figure 4: Clearances for adequate air circulation

equired distance:

•

Above and below the module: ≥ 30 mm

•

In front of the module: ≥ 25 mm

4.2 Integration into the controller network

4.2.1 Integration via the fieldbus interface

Prerequisites

•

he EtherCAT® slave information (ESI file) is installed in the hardware catalog of

the higher-level controller.

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Parameters to be configured

arameter:

•

Unique station alias

You can configure the parameters via the following interfaces:

•

Safety Designer

•

Configuration software for the relevant fieldbus network

Complementary information

ou can find the required device description file and the device symbol for integration

into a higher-level controller in the following locations:

•

On the Internet on the gateway product page at www.sick.com

•

In the configuration software program directory on the computer

4 P

ROJECT PLANNING

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5 Mounting

5.1 Safety

WARNING

lectrical voltage

There is a risk of injury from electrocution while connecting the devices.

Disconnect the power for the entire plant/machine.

WARNING

Unintended start of the plant/machine

The plant/machine could inadvertently start while you are connecting the devices.

Disconnect the power for the entire plant/machine.

5.2 Mounting procedure

For information on the mounting process, please see the operating instructions:

•

“F

lexi Compact” (SICK part number 8024573)

5.3 Module exchange

Approach

Disconnect the module and the connected components from all voltage sources.

2. Dismantle the defective module.

3. Mount the new module.

MOUNTING 5

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6 Electrical installation

6.1 Safety

WARNING

lectrical voltage

There is a risk of injury from electrocution while connecting the devices.

Disconnect the power for the entire plant/machine.

WARNING

Unintended start of the plant/machine

The plant/machine could inadvertently start while you are connecting the devices.

Disconnect the power for the entire plant/machine.

6.2 Device connection

Prerequisites

etwork cable requirement:

•

Type: 100Base-TX

•

Cables with RJ45 connections

•

Twisted pair Ethernet cable, maximum length 100 m in accordance with

EN 50173

•

Use of wire pairs 1/2 and 3/6

•

Shielded cables

•

Cat 5 STP or higher

Pin assignment

Figure 5: Connections

RJ45 female Ethernet connector

6 ELE

CTRICAL INSTALLATION

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7 Configuration

7.1 Offline, online and security configuration

Overview

All c

onfiguration parameters are assigned to a configuration group. The configuration

groups differ, for example, when transmitting and saving the configuration.

The following configuration groups are available

•

Offline configuration

•

Online configuration

•

Security configuration

Offline configuration

All of

fline configuration parameters are written to the safety controller using the Transfer

to device function. The offline configuration includes, for example, all parameters of the

hardware configuration.

These parameters can only be configured in the configuration software.

To configure the parameters, no connection to the safety controller must exist. Only

establish a connection to the safety controller when you want to transfer the configura‐

tion.

The application is stopped while the configuration is transferred to the safety controller.

The offline configuration is stored in the SmartPlug. A (defective) module can be

replaced with a compatible module without having to reconfigure the device. The offline

configuration must be compatible with the physical safety controller.

Within the offlline configuration, a distinction is made between the following configura‐

tion data.

Configuration data:

•

Safety configuration

Configuration data that affect the safety function of a device, e.g., configuration of

afety capable inputs, safety outputs, logic, …

•

tandard configuration

Configuration data that affect the non-safety function of a device, e.g., configura‐

ion of test outputs, configuration of non-safe modules.

•

on-functional configuration

Configuration data that have no effect on the functioning of the device, e.g. tag

name

s, comments in the logic, project information of the user

Online configuration

Each of the online configuration parameters have their own transfer option and can

be individually written to the safety controller. The online configuration includes, for

example, the parameters relating to the network settings.

These parameters can be configured in the configuration software or via a module with

a display.

To configure the parameters using the configuration software, a connection to the

safety controller must exist.

The application does not need to be stopped while the configuration is transferred to

the safety controller.

The online configuration is saved in and read back from the SmartPlug using the mod‐

ule position and the module type. If the module position is maintained, a (defective)

module can be replaced with a compatible module without having to reconfigure the

CONFIGURATION 7

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device. If the module position is changed, the saved parameters will not work. If, for

xample, the module position of a gateway is changed, the connection parameters

need to be reconfigured before a connection to the safety controller can be established.

The old module positions are corrected when writing an offline configuration.

If online configuration parameters are configured without a SmartPlug inserted, these

settings will only apply temporarily until the safety controller is restarted or a SmartPlug

is inserted.

Security configuration

he security configuration includes the following parameters:

•

Passwords for user groups

These parameters can only be configured in the configuration software.

The application does not need to be stopped while the configuration is transferred to

the safety controller.

The security configuration is saved in the SmartPlug. A (defective) module can be

replaced with a compatible module without having to reconfigure the device.

Further topics

•

"Smar

tPlug"

•

"Display menu", page 23

7.2 Configuring the network interfaces

7.2.1 Configuring the higher-level controller

Approach

Load the device description file into the configuration software of the higher-level

controller. Follow the instructions in the online help or in the user manual of the

higher-level controller to do so.

2. Add the gateway in the EtherCAT® network.

3. Select and configure the process data objects (PDOs). Only one input PDO and one

output PDO can be active at any one time.

4. If necessary, assign a station alias.

Complementary information

You can find the device description file and device symbol on the gateway product page

at www.sick.com.

The selected PDOs of the higher-level controller must match the selected PDOs in the

configuration software.

7.2.2 Enabling emergency messages

Approach

In the main navigation pane, click Configuration.

2. In the navigation pane under GETC, select the EtherCAT emergency messages menu

item.

3. Activate the All active option.

✓

The emergency messages are transmitted to the higher-level control system.

7 C

ONFIGURATION

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7.2.3 Addressing

7.2.3.1 Setting a station alias

Overview

ation alias is a 16-bit address than you can use to address the device in the higher-

level control system.

Approach

1. In the main navigation pane, click Configuration.

2. In the navigation tree of the required module, select the Addressing menu item.

3. Enter the station alias in the Setting for station alias field.

7.2.3.2 Reading and transmitting values

Overview

If t

he values in the project and the values in the device differ, you can read the values

from the device and apply them to the project or transfer the values from the project to

the device.

Approach

1. In the main navigation pane, click Configuration.

2. In the navigation tree of the required module, select the Addressing menu item.

3. Perform the required action:

Click on Read from device. The values are read from the device and adopted in

the project.

Click on Transmit to device. The values are read from the device and adopted in

the project.

7.2.4 Configuring the output data (routing to CPU)

Overview

he gateway can receive up to 100 bytes of output data from a higher-level control

system. The actual data volume and contents depends on how the output data are

configured in the higher-level control system.

The configuration of the output data includes the following points:

•

Specifying the routing

•

Enter the tag names for the data received from the network

Approach

In the main navigation pane, click Configuration.

2. In the navigation tree of the required module, select Routing to CPU.

3. In the PDO used from file drop-down menu, select the data volume configured in the

higher-level control system.

✓

A red guide line shows the end of the configured data volume.

4. Select a routing template and drag it onto a single byte or several bytes of the

output data block.

✓

The bits, bytes or data formats are available as inputs in the logic editor.

✓

Each bit, byte or data format inherits a default tag name from the routing.

5. If required, edit the default tag name in the Settings tab.

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Complementary information

able 4: Colors of the bytes and bits of a record

Color Meaning

Light blue The byte or the bit is empty.

Blue The byte or the bit is occupied. The relevant module, input or

out

put is configured in the hardware configuration of the safety

controller.

Gray The byte or the bit is occupied. The relevant module, input or

output is not yet configured in the hardware configuration of the

safety controller.

You can monitor the status of the communication with the network. A status bit for the

eceipt of data from the network is provided for this. If the gateway detects a fault in the

communication, it sets the contents of the output records and the associated status bit

to Null.

7.2.5 Configuring the input data (routing to network)

Overview

he gateway can send up to 100 bytes of input data to a higher-level control system.

The input data can comprise the statuses of the inputs and outputs, the logic results, or

diagnostic data.

Approach

In the main navigation pane, click Configuration.

2. In the navigation tree of the required module, select Routing to Network.

3. In the PDO used from file drop-down menu, select the data volume configured in the

higher-level control system.

✓

A red guide line shows the end of the configured data volume.

4. Select the required input data and drag it onto a single byte or several bytes of the

input data block.

The following input data are available:

Routing templates contain templates for the routing of data from the logic

editor.

Inputs contain the input values of the modules.

Outputs contain the output values of the modules as well as the logic results

from the logic editor.

Diagnostics contains the checksums and status information of the modules.

✓

The bits, bytes or data formats are available as individual outputs in the logic

editor.

✓

Each bit, byte or data format inherits a default tag name from the routing.

5. If required, edit the default tag name in the Settings tab.

Complementary information

able 5: Colors of the bytes and bits of a record

Color Meaning

Light blue The byte or the bit is empty.

Blue The byte or the bit is occupied. The relevant module, input or

out

put is configured in the hardware configuration of the safety

controller.

Gray The byte or the bit is occupied. The relevant module, input or

output is not yet configured in the hardware configuration of the

safety controller.

7 CONFIGURATION

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Modello: Flexi Gateway GETC1 Expansion module - gateway

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