SMX Programming Manual for the SMX Module - OEM Automatic AB

SMX 

Programming Manual for the 

SMX Module 

Programmng Manual (Vers. HB-37350-820-05F-DE-07.04.2009-SMX-B) 

Programming Manual – SMX Basic Modules 29.10.2009 Page 1 of 183

Table of Contents 

Contents 

TERMS ....................................................................................................................... 7 

PLC .................................................................................................................................................................... 7 

SafePLC ............................................................................................................................................................. 7 

SMX ................................................................................................................................................................... 7 

Function block (functional module) ................................................................................................................... 7 

Function block diagram (function block diagram (FBD) language ) .................................................................... 7 

InPort / OutPort .................................................................................................................................................. 7 

Linkage ............................................................................................................................................................... 7 

Connector ........................................................................................................................................................... 7 

Attribute ............................................................................................................................................................. 7 

Routes ................................................................................................................................................................. 7 

Signal list ............................................................................................................................................................ 7 

Signal cell ........................................................................................................................................................... 7 

PLC input signal list ........................................................................................................................................... 8 

PLC output signal list ......................................................................................................................................... 8 

Instruction list (IL) ............................................................................................................................................. 8 

Compilation ........................................................................................................................................................ 8 

Function block group ......................................................................................................................................... 8 

Function block types .......................................................................................................................................... 8 

Message window ................................................................................................................................................ 8 

Info display ......................................................................................................................................................... 8 

Configuration ..................................................................................................................................................... 8 

MOUSE AND KEYBOARD COMMANDS .................................................................. 9 

Mouse dependent actions ................................................................................................................................... 9 

Keyboard commands .........................................................................................................................................10 

BRIEF DESCRIPTION OF PROCEDURE .................................................................11 

General note ......................................................................................................................................................11 

"Push & Pop" when inserting function blocks ..................................................................................................11 

LOGIC DIAGRAM .....................................................................................................14 

TERMINAL DIAGRAM ..............................................................................................14 

LOGIC DIAGRAM .....................................................................................................16 

PREPARING THE WIRING .......................................................................................18 

MESSAGE WINDOW ................................................................................................19 

PROGRAM CREATION ............................................................................................20 


TRANSFERRING THE PROGRAM ON THE SMX MODULE ...................................21 

Connection settings ..............................................................................................................................................21 

Connection dialog .................................................................................................................................................22 

Validation dialog ..................................................................................................................................................23 

DIAGNOSTIC FUNCTIONS ......................................................................................24 

Procedure for logic diagram diagnose ...............................................................................................................26 

The Scope Monitor ...............................................................................................................................................28 

Procedure when measuring with the scope........................................................................................................29 

Preparing the measurement ...............................................................................................................................30 

"Start" measurement ..........................................................................................................................................30 

"Stopping" a measurement and viewing data ....................................................................................................30 

Measuring schemes ...........................................................................................................................................30 

DIAGRAM MANAGEMENT ......................................................................................33 

Diagram access ..................................................................................................................................................33 

Program information .........................................................................................................................................34 

CONFIGURATION REPORT ....................................................................................35 

PROGRAM DEVELOPMENT AIDS ..........................................................................38 

Info display ...........................................................................................................................................................38 

Signal tracking .....................................................................................................................................................38 

Copying attributes into the message window.....................................................................................................38 

Quick selection .....................................................................................................................................................39 

PREDEFINED FUNCTION BLOCKS ........................................................................40 

Sensor interface .................................................................................................................................................40 

Digital inPorts ...................................................................................................................................................40 

SMX outPorts ....................................................................................................................................................41 

ADDING INPORT BLOCKS ......................................................................................42 

Starting behaviour .............................................................................................................................................43 

Start test .............................................................................................................................................................44 

START-UP TEST ......................................................................................................47 

START AND RESET ELEMENT ...............................................................................48 

ANALOG INTERFACE .............................................................................................52 

Analog inPort Ain1 / Ain2 ................................................................................................................................52 

INSERTING OUTPORT ELEMENTS ........................................................................55 


Relais outPort ....................................................................................................................................................55 

Semi-conductor outPort .....................................................................................................................................56 

HiLo Outport .....................................................................................................................................................57 

EMU Function ...................................................................................................................................................58 

THE LOGIC MODULES ............................................................................................59 

Logic AND ............................................................................................................................................................59 

Logic OR ...............................................................................................................................................................59 

Logic EXKLUSIV OR .........................................................................................................................................60 

Logic NOT ............................................................................................................................................................60 

RS Flip Flop ..........................................................................................................................................................61 

Timer .....................................................................................................................................................................62 

Permanently logic "1" module ............................................................................................................................63 

Result of the EMU module ..................................................................................................................................63 

CONNECTING POINT INPORT ................................................................................64 

CONNECTING POINT OUTPORT ............................................................................65 

SIGNAL CHANNEL ..................................................................................................66 

Logic data ..........................................................................................................................................................66 

Process data .......................................................................................................................................................68 

FUNCTION GROUPS ...............................................................................................69 

Creating a function group frame ........................................................................................................................69 

Inserting a group module ...................................................................................................................................69 

Opening the group editor ...................................................................................................................................69 

Setting the group management ..........................................................................................................................70 

Changing the size of a group frame ...................................................................................................................72 

Showing and hiding functional modules ...........................................................................................................72 

Creating the group interface ...............................................................................................................................73 

Setting the usage................................................................................................................................................73 

Restrictions ........................................................................................................................................................74 

Procedure for Creating a Function Group ........................................................................................................75 

1. Step: Adding interface modules ...............................................................................................................75 

2. Step: Adding functional modules to the group ........................................................................................75 

3. Step: Set up connection............................................................................................................................76 

4. Step: Connect group interface ..................................................................................................................76 

5. Step: Set connection restrictions ..............................................................................................................76 

Testing function groups .....................................................................................................................................76 

Disabling a function group ................................................................................................................................76 

Exporting a function group .................................................................................................................................76 


Importing a function group .................................................................................................................................77 

THE SAFETY FUNCTIONS ......................................................................................78 

POSITION AND SPEED SENSORS .........................................................................79 

Parameterization of the measuring section ........................................................................................................80 

Sensor 1 or Sensor 2 ..........................................................................................................................................82 

Encoder type ......................................................................................................................................................82 

None ........................................................................................................................................................82 

Incremental ..............................................................................................................................................82 

SIN / COS ................................................................................................................................................82 

Absolute ...................................................................................................................................................83 

Data format ..............................................................................................................................................83 

SSI binary ................................................................................................................................................83 

SSI-GrayCode ..........................................................................................................................................83 

SSI-WCS .................................................................................................................................................83 

Proxi Switch 1Z .......................................................................................................................................83 

Proxi Switch 2Z 90°.................................................................................................................................83 

Direction of rotation ..........................................................................................................................................83 

Resolution .........................................................................................................................................................83 

Sensor info field ................................................................................................................................................84 

Determination of the Resolution with Regard to Different Characterized Measuring Lengths: ..................86 

Rotational measuring length ..............................................................................................................................86 

Input example 1 .................................................................................................................................................87 

Linear measuring length ....................................................................................................................................89 

Input example 2 .................................................................................................................................................90 

The Sensor Info Field shows the following result entries: ................................................................................93 

SAFETY MODULES .................................................................................................94 

SEL (Safe Emergency Limit) ..............................................................................................................................95 

Input example 1 .................................................................................................................................................98 

SLP = (Safe Limited Position) ...........................................................................................................................100 

SCA (Safe Cam) .................................................................................................................................................103 

Input example: .................................................................................................................................................106 

SSX (Safe Stop 1/ Safe Stop 2) ..........................................................................................................................107 

Input example: .................................................................................................................................................111 

SLI (Safe Limited Increment) ...........................................................................................................................112 

Activation example: ........................................................................................................................................114 

Input example: .................................................................................................................................................114 

SDI (Safe Direction Indication) .........................................................................................................................115 

Activation example: ........................................................................................................................................116 

Input example: .................................................................................................................................................116 

SLS (Safe Limited Speed) ..................................................................................................................................117 

Input examples: ...............................................................................................................................................121 

SOS (Safe Operating Stop) ................................................................................................................................123 

Input example 1 ...............................................................................................................................................125 


Input example 2 ...............................................................................................................................................125 

SAC (Safe Analog Control) ...............................................................................................................................126 

PDM (Position Deviation Muting) ....................................................................................................................128 

ECS (Encoder Supervisor) ................................................................................................................................131 

I/O MODULE EXTENSION SMX31 .........................................................................133 

Equipment selection ...........................................................................................................................................133 

Management of additional inPorts/outPorts ....................................................................................................133 

Selection of inPorts and outPorts ....................................................................................................................133 

Identification of inPorts: ..................................................................................................................................134 

Identification of outPorts: ................................................................................................................................134 

Input of Logic Address for Communication ....................................................................................................134 

APPENDIX PROCESS IMAGE ...............................................................................136 

Introduction ........................................................................................................................................................136 

Description of Function Elements .....................................................................................................................137 

PLC – Commands ...........................................................................................................................................137 

Designation of safety functions .......................................................................................................................138 

Input variables in logic diagram ......................................................................................................................139 

PLC Processing ..................................................................................................................................................142 

PLC - Syntax ...................................................................................................................................................142 

PLC – Commands ...........................................................................................................................................143 

PLC – Elements (I/O) ......................................................................................................................................144 

PLC - Output variables ....................................................................................................................................145 

PLC - Processing elements ..............................................................................................................................147 

PLC - Processing list .......................................................................................................................................147 

Assignment of resources .................................................................................................................................148 

APPENDIX ENCODER COMBINATIONS ..............................................................149 

FAULT TYPES SMX ...............................................................................................150 

DISPLAY OF FAULT TYPES ..................................................................................151 

SMX.. without expansion modules ...................................................................................................................151 

SMX.. with expansion modules .........................................................................................................................151 

ALARM LIST SMX ..................................................................................................152 

FATAL ERROR LIST SMX .....................................................................................172 


Terms 

PLC 

Programmable Logic Controller, equals the German designation for 

Speicherprogrammierte Steuerung (SPS). The term PLC is exclusively used within 

the SMX system. 

SafePLC 

Program editor for the graphical preparation of sequencing programs using the 

functional block method, as well as the parameterization of sensor, actuators and 

other technological functions used. 


Modular safety control with integrated technological functions. The behaviour of the 

SMX system is defined by a user configuration and the associated logic operations. 

Function block (functional module) 

Module in a PLC-control that influences the program sequence of a PLC-program 

either physically or logically. A physical (hardware) function block is e.g. a push 

button or an output on the SMX module. However, the logic operation (such as AND 

or OR) of input and output signals within a PLC is also referred to as a function block. 

Function block diagram (function block diagram (FBD) language ) 

Graphically oriented, function block based, descriptive "programming language" acc. 

to IEC 1131, serving the purpose of visualizing logic operations of inPorts and 

outPorts on function blocks of a PLC control. The logic diagram shows the functional 

modules and their logic operations in a graphical form. (engl. Function Block Diagram 

FBD) 

InPort / OutPort 

Location on a function block which can be used for linkage to other function blocks. 

Linkage 

a named connection between 

a.) a function block outPort and a function block inPort. 

b.) a PLC inPort and a function block inPort. 

c.) a function block outPort and the PLC outPort. 

Connector 

Connecting point between the beginning and the end of a linkage with an inPort and 

an outPort of a function block 

Attribute 

Non-graphical feature of a function block. An attribute consists of a designator and a 

value. 

Routes 

Horizontal and vertical alignment of linkages in a logic diagram, so that intersections 

with function blocks are avoided and linkages with identical connector are merged at 

an early stage (related to distance to the target function block). 

Signal list 

Signal lines into and out of the PLC, represented in a table. 

Signal cell 

Selectable area within the signal list, which can be provided with a comment. 


PLC input signal list 

Signal lines entering into the PLC, represented in form of a table. In SafePLC the 

PLC inPorts can be designated by the user. They have an unambiguous number and 

must be assigned to the inPorts of a function block. 

PLC output signal list 

Signal lines leaving the PLC, represented in form of a table. In SafePLC these 

outPorts can be designated by the user and, just like the inPorts, have an 

unambiguous identification number. 

Instruction list (IL) 

Assembler-like programming language that can be loaded into a central SMX 

module. The duty of SafePLC is the generation of an instruction list based on defined 

function blocks, as well as their attributes and linkages. 

Compilation 

Compilation and verification of the function plan created in SafePLC and the 

associated parameters. 

Function block group 

Classification of function blocks according to their positioning ability in the logic 

diagram (inPort, outPort, logic). 

Function block types 

More detailed identification of function blocks within a group. (e.g. "Emergency Stop") 

Message window 

Output window with several lines, embedded in a Windows Toolbar element. This 

display window is used for the output of errors, warnings and information from the 

program to the user. The message window can be switched on and off. 

Info display 

Delayed display of information about a function block, following the Windows Tool Tip 

mechanism. The mouse pointer must be dragged across an object to display this 

information. 

Configuration 

Configuration is the generic term for a monitoring program and the associated 

parameter for permissible deviations or minimum and maximum values. In this 

context it is important to note that a monitoring program always comes with further 

data, the program can refer to. 


Mouse and keyboard commands 

Mouse dependent actions 

Left mouse button on a function block Selected representation 

(highlight), whereby previous selections become invalid. 

Note: If the CTRL key is pressed while "Setting Markers", the associated 

"Marker OutPort" blocks will also be selected. 

Shift + Left mouse button on function block: Multiple selection (adding 

to an existing selection). 

Ctrl + Left mouse button on selected function block: Deselection of 

block (removal from selection). 

Delete key: Deletes the elements of an existing selection incl. connections! 

Double-clicking on function block: Editing of settings. 

Right mouse button on a function block: Display of context menu for 

function block. 

Right mouse button in drawing area: Display of context menu for 

drawing area. 

Left mouse button on connector: Highlights the existing linkage(s). 

Ctrl + movement of mouse pointer over an object: Display of 

information data, even if the display has been disabled via the menu. 

Turning the scroll wheel on the mouse: Dynamic zooming of the logic 

diagram. 

Moving the mouse with the scroll wheel depressed: Moving the logic 

diagram. 


Keyboard commands 

Ctrl + Q: Start zoom-in command 

Ctrl + W: Start zoom-out command 

Ctrl + A: Zoom all command 

Ctrl + I: Switch automatic info display on/off 

Ctrl + O: Open file 

Ctrl + S: Save file 

Ctrl + M: Switch message window on/off 

Ctrl + N: New file 

Esc: Deselection of marked elements 

Erase: Erases selected objects 

Ctrl+arrow left: Logic diagram LineScroll left 

Ctrl+arrow right: Logic diagram LineScroll right 

Ctrl+arrow up: Logic diagram LineScroll up 

Ctrl+arrow down: Logic diagram LineScroll down 


Brief Description of Procedure 

The program SafePLC is a graphically oriented editor for the creation of a PLC-based 

monitoring program for an SMX-system. 

General note 

The program requires write and read rights of the user logged in to the PC that is 

used for programming. Missing access rights can lead to side effects in logic diagram 

debugging or cause problems when saving logic diagrams to directories with limited 

rights. 

"Push & Pop" when inserting function blocks 

Click on an icon in the toolbar or a menu option ("Push") to switch to insert mode. 

This mode is identified by a changed mouse pointer. Simply click on the 

corresponding location to insert ("Pop") the selected function block. The "Esc"-key 

cancels this mode. 

Please proceed as follows to create an application: 

1. Selection of the device type to be programmed 

Once SafePLC has been started, or if a new logic plan is to be created, the following 

selection dialog will appear. 


In a first step the system resources to be used must be selected on module level. 

- Selection of basic module 

- Number of I/O expansion modules See also: Equipment expansion 

- For equipment with analog processing set the corresponding switch 

Note: 

Due to the associated resources and their management in the programming 

environment, the set equipment type cannot be changed any more at a later date. 

2. Determination of periphery in terminal diagram 

The terminal diagram represents the connections to sensors and actuators of the 

SMX-system. 

The following procedure is recommended: 

For modules with speed and position monitoring the definitions of sensors 

used and their parameters are required. 

The editor can be opened by double-clicking on the sensor configuration 

icon: 

Note: 

A red icon indicates the missing parameterization. 

For a module with analog processing the interfaces used must be 

parameterized. 

Note: 

A red icon indicates the missing parameterization. 

Selection of input and periphery modules (Emergency Stop, safety doors, 

sensors, etc.) via the toolbar "Input elements" 

Selection of required output modules (semi-conductor output, relay output, etc.) 


3. Definition of monitoring functions and logic modules in the logic 

diagram 

The logic diagram shows the logic modules and their internal linkage 

Programming of the logic diagram by using: 

Logical and processing elements. 

Monitoring modules for drive monitoring (this is only possible, if the 

associated sensors had been defined). 

Timers, flip-flops (trigger elements) and terminal blocks. 

After choosing the required modules, these are subsequently linked with each other. 

For this purpose drag the mouse pointer across a "start connector", press 

the left mouse button and connect via a "target connector" in active state. Conclude 

this process by deactivating the left mouse button. 

Programming support by other diagnose and analysis tools. 

This includes the Info display, signal tracking, display of function block 

attributes in the message window , as well as quick localizing of modules in the logic 

diagram by double-clicking on the coloured BlockID in the message window. 

4. Compilation of monitoring program 

After completion of the programming process the logic diagram is compiled and 

transformed into a machine readable format. 

This process consists of: 

Examination of open connectors in the logic diagram 

Examination of boundary conditions for the monitoring functions 

Examination of the correct assignment of input signatures 

Creation of a machine readable format for the SMX-system 

5. Program transfer to basic SMX module 

Setting the COM outPort 

Transfer of the machine program 

Testing the program on the SMX module 

Disabling the logic plan after approval 

Preparation of the configuration report and validation of the configuration 


Logic Diagram 

SafePLC saves the configuration, the program sequence and the chosen 

parameterization as a Windows documents with the file name extension "*.plcSMX". 

The logic diagram is subdivided into field, which can take up the function blocks. The 

function blocks are inserted and displaced within this raster. Overlapping of function 

blocks is not possible. 

Within the logic diagram the two views "terminal diagram" and "logic diagram" are 

available for the user. 

The programmer is able to toggle between these views as desired: 

Menu: View -> Change layout 

Keyboard: Crtl + Tab 

Control button in the toolbar "Drawing Aids" 

Permanent status display: 

In the left upper corner of the logic diagram you find a status display with the 

following meanings: 

Active logic diagram view: Text "terminal diagram" or "logic diagram" in 

compliance with the chosen context. 

Actual diagram access: Padlock symbolizes locked diagram. 

Compiler status: The background colour of the status display has the 

following meaning: 

o Red: Logic diagram has not been compiled or is faulty 

o Green: Logic diagram has been compiled without faults, diagram 

can be transferred to the SMX-system. 

Terminal Diagram 

The terminal plan describes the external port assignments in a SMX-system to the 

chosen sensors and actuators. When creating a new diagram (File->New...) the 

terminal diagram shows all available inPorts and outPorts, as well as further sensor 

interfaces (encoders, analog sensors). 

Definition of sensor interface: 

Determination and parameterization of sensor interface and analog interface 

Definition of inPorts and outPorts: 

Selection and parameterization of inPorts and outPorts 

When inserting a new or double-clicking on an already existing function block, the 

associated attribute editor is opened and the parameters can be modified. 


Status display of logic 

diagram 

Semi-conductor - 

outPorts on SMX 

module 

Relay - outPorts on 

SMX module 

Sensor function block 

Input signal list 

Periphery elements tro 

be inserted 

OutPorts for EMU 

monitoring 

InPorts for short-circuit 

monitoring 

Analog signal blocks 

internal relays and 

semi-conductor 

elements to be inserted 

If function blocks are inserted into the terminal diagram, the elements will 

automatically be wired. In some instances it may happen, that the connections are 

unfavourably displayed. However, this does not affect the function! When moving the 

corresponding block, the connecting wiring will be redrawn and may appear more 

distinctly. 

Tip: Start at the left edge of the logic diagram and add modules from top to bottom. 

Note: Since no logic elements must be defined in this view, the corresponding 

commands are disabled. 


Logic Diagram 

In the logic diagram linkages take place between inPort, monitoring, outPort and logic 

modules. 

In this respect the outPort connectors on the inPort elements correspond with the 

input data of the logic diagram. In the same way the inPort connectors of the outPort 

elements must be viewed as output data of the diagram. 

In order to be able to create a clearly structured logic diagram, one can define socalled 

terminal blocks. These represent a named connection between inPort and 

outPort connectors of function blocks. One or several marker outPort blocks (outPort 

terminals) can be defined for a marker setting block (inPort terminal) . 


Elements automatically selected 

via signal tracking 

Marker setting 

(e.g. Emergency Stop) 

InPort function block 

Logic module "AND" 

Monitoring module 

permanently activated 

Monitoring module 

signal dependent activated 

Marker outPort 

(e.g. 2 x Emergency Stop) 

Logic module 

(e.g. timer) 

Assigned relay - 

outPort on SMX 

module 

Assigned semiconductor 

- outPort on 

SMX module 

Tip: 

Use the comment line for connecting point inPorts. This information simplifies the use 

of complementary connecting point outPorts. This contributes to clarity! 

Note: Parameters of the inPort elements cannot be modified in this view. 


Preparing the Wiring 

The assignments in the logic diagram are created by linking the inPort and 

outPort connectors of the functional modules. An outPort of a module may, if 

necessary, be multiply connected with inPorts on other modules, whereby any inPort 

must only be assigned once. Apart from this, certain module groups cannot be 

interconnected for technical reasons. In case of an invalid connection the program 

will display a corresponding message. 

Connection set-up: 

Select a start connector with the left mouse button 

Hold the left button activated and position the mouse pointer 

deactivate the button when the pointer is on the target connector 

Note: Connections can only be selected with a mouse click or by choosing a 

connector. 

Tip: If all connections of a module are to be deleted, one should delete the 

associated function block. The connected connections will in this case be 

automatically deleted. 

Automatic connection 

The editor routes a new connection automatically. The graphics display can be varied 

and the overall presentation optimized by simply moving the function blocks. In 

complex diagrams it may happen that a connecting line will intersect with a function 

block. This behaviour has no influence on the internal function of the linkage. 

User defined connection 

A command for the drawing of user defined connecting lines is additionally available. 

These will remain existent, until the dislocation of an associated function block forces 

the recalculation of the control points (see automatic connection) 

A user defined connection is set up as follows 

1.) either by selecting the connection to be edited and invoking the command: 

"User defined connecting points" in the "Edit" menu. 

2.) or by opening the context menu (right mouse button) while the mouse pointer 

is positioned on the corresponding connection and selecting the command 

"User defined connecting points". 

3.) Input of control points for orthogonal connecting lines , i.e. the connecting lines 

always run horizontally and vertically. The program connects the entered 

points, until the drawing command is terminated. 

4.) Termination of command with the Enter-key (Return) and drawing of the 

connection by the editor. 

Note: The program matches the first and the last control point to the 

associated function block connector. The inPort and outPort connector is not 

considered a control point and does therefore not need to be specified. 


Tip: Visual corrections to the logic diagram should only be made just before the logic 

digram is blocked. Only then the layout is complete and the blocks do not need to be 

displaced any more. 

Message Window 

Besides the output of status and error messages as well as the display of results 

from the examination of the logic diagram, the messages window also is a powerful 

tool for checking function block data within their context. 

Quick Jump 

By double-clicking on the colour-coded BlockID's in the message window one can 

have the associated block centred in the logic diagram window. This enables quick 

localization of function blocks belonging to an output. 

Context menu in message window 

Message window Hides an active message window. 

Clear window Deletes the contents of the message window. 

Select all and copy Copies the entire contents of the message window into the 

clipboard, making the text available for other Windows programs via the "Insert" 

command. 

Search To find text within the message window. 

Help on message window Opens the help page 

Docking of message window Two-way switch to enable the message window to 

dock to the frame of the main program or to position the window freely on the screen. 

Note: The "docking" behaviour for the message window of the application can be 

configured in the menu "File->Settings". 


Program Creation 

After the program has been finished, the compilation process can be started by 

invoking the compiler. The compilation process starts the following internal 

processes. 

Verifying for open connectors 

SafePLC makes sure that all connections between function blocks can be opened. 

Unconnected connectors are recognized as faults. 

Verifying for unreferenced "Connecting point" Blocks 

SafePLC makes sure that all "connecting point" blocks inserted in the logic diagram 

are used. Unsolved references are recognized as faults. 

Verifying the value ranges of the monitoring functions 

SafePLC verifies whether the parameters of the monitoring functions comply with the 

currently chosen value ranges of the sensor interfaces, before the machine readable 

code is generated. This verification does not replace the context related evaluation of 

data after changes made by the user! 

Creation of the instruction list (IL) 

The IL-code created on basis of the function blocks is output in the message window, 

where it can also be verified, The code segments associated with the function blocks 

are identified by the corresponding BlockID. 

Creating the OP code 

Generation of a machine readable code for the SMX-system, which is then 

transferred together with the parameter data. 

Message window 

All results of the compilation process are reported in the message window. Should 

faults be found, the message window will automatically pop up. 

Security CRCs 

After a successful compiler run a total of three CRC-signatures are made: 

Equipment configuration CRC: Signature concerning program and 

parameter data 

Parameter CRC: Signature concerning parameter data 

Program CRC: Signature concerning the program 

The calculated CRC-values can be displayed in off-line mode (no connection to 

module) via the menu "File->Diagram Management". 

Important: 

This display is only informative and must not be used for the safety related 

documentation! 


Transferring the Program on the SMX 

Module 

This paragraph describes the data and program transfer to a basic SMX module. 

When starting a connection request ("File-> Connection Dialog" or via the toolbar 

) the following window is displayed. 

Connection settings 

In order to be able to set up a connection with a SMX-system, the transfer 

parameters must be set accordingly. 

Note: 

The connection between PC and SMX-system is based on a USB/RS485 interface. 

This requires fault-free installation of the correct driver. This driver is included in the 

scope of delivery and is located in the installation directory of the SafePLC 

programming environment (directory RS485_USB_Treiber). 


PC-COM 

The COM interface used by the Windows driver must be set. 

CAN Bus 

Address setting for diagnostics channel via CAN bus. The setting uses the hex data 

format. 

Address of the 1st CAN telegram: 0x001 to 0x063 or 0x83 to 0x7FF. 

Aktivating extended data with CAN bus 

Address of the 2nd CAN telegram: 0x001 to 0x063 or 0x83 to 0x7FF. 

The value must not be the same as the 1st CAN address. 

Cyclic transmission 

This option can be used to set the SMX-system transmission interval in cycles 

(1 cycle = 8ms). 

Connection dialog 

Connect: Starts the connection to the SMX-system 

Quit: Cancels an active connection. 


Send configuration: Transmits the configuration of the logic diagram to the 

SMX-system. This is only possible in "Stop" mode. 

Start: Starts the sequencing program 

Stop: Stops the sequencing program 

Diagnose >>: Extends the dialog by the diagnose function 

(see diagnose of a transferred program). 

Validation: 

Opens the validation dialog 

Validation dialog 

The proper performance of a validation in conformance with the demanded safety 

regulations is described in the chapter "Validating an SMX-system". 


Generate report 

Generation of a validation report. 

Disable configuration 

After each transfer of configuration data to an SMX-system, these data are marked 

as "not validated". The basic group signalizes this by means of a yellow flashing of 

the status LED. The command "Disable configuration" disables access to the 

configuration data in the basic group. This is indicated by a green flashing status 

LED. 

Read out binary file from SMX… 

Reads out the current SMX equipment configuration in a machine readable from. 

These data are not changed by SafePLC and can be saved to the drive in this form. 

Send binary file to SMX… 

Transfer of a machine readable equipment configuration from the PC drive to the 

SMX-system. 

Note: 

When transferring machine readable program and parameter data, organizational 

measures must be applied to ensure that the currently valid equipment configuration 

conforms with the safety related documentation of the machine or system. 

Diagnostic Functions 

When clicking on the diagnostics button the connection dialog is extended by 

additional diagnostics elements. 

Diagnose Start: Two-way switch to start and stop the diagnose: The corresponding 

mode ( = Off = On) is also displayed in the dialog text, so that feedback about 

the current status is available, even in case of a minimized dialog. After successful 

starting of the diagnose, the inscription of the switch will change to "Diagnose Stop". 

Note: A correct diagnose requires the adjustment of data between logic diagram and 

equipment configuration. A missing logic diagram or a discrepancy between the 

available logic diagram and the equipment configuration only permits a limited 

diagnose. The functionality "Diagnose function modules" is in this case not available. 


(Scope): Opens the Scope monitor dialog. This enables the representation of 

various process data. 

Process image: Visualization of the inPort/outPort image of the SMX-system. 

FLogic diagram: Enables selective monitoring of memory states of pre-selected 

function blocks. 

System info: System information about the SMX-module. As follows: 

Parameters 

CRC equipment configuration 

CRC parameters 

CRC program 

Transfer counter 

Serial number 

Version number 

Description 

CRC signature concerning program and 

parameter data 

CRC signature concerning the 

parameters 

CRC concerning the program 

Status of an internal transfer counter 

This counter is incremented during each 

transfer action to the SMX-system and 

can be used as reference for the 

purpose of documentation. 

Current serial number of the equipment 

Firmware version number 


Sensor position: Shows the original value of the connected speed/position sensors. 

Encoder interface: 

Shows the transverse mode voltages of the encoder driver modules interface 1 and 

interface 2 as well as the status of the inPort bridges in the encoder interface. 

If one of the values for the voltage condition is 0, the encoder is defective or not 

connected. 

Voltage values of the two analog voltage inPorts on system A and system B (e.g. 

SMX 12A) are also shown: 

System A analog pass1: Analog voltage AIN1 

System B analog pass1: Analog voltage AIN2 

System A analog pass2: Analog voltage AIN3 

System B analog pass2: Analog voltage AIN4 

System A / system B AnalogFilter1: Evaluate voltage AIN1 with AIN2 

System A / system B AnalogFilter2: Evaluate voltage AIN3 with AIN4 

Analog adder: Voltage after adding circuit 

Procedure for logic diagram diagnose 

When running a logic diagram diagnose, the current inPort and outPort states of the 

function blocks are displayed according to their logic condition "0" or "1" on the 

selected module. 

Please proceed as follows: 

Step 1: Selecting the diagnostic function 

Select the diagnostic function by activating the "function modules" tab via: 

Connection->Diagnose->Function modules. 

Step 2: Selecting the data to be displayed 

Selection of the function blocks desired for diagnose in the current context . The 

connectors for the highlighted modules are added to the diagnose list via the control 

button "Add". In contrast to this, entries can also be deleted from the list by marking 

these and clicking on the control button "Remove". 

Double-clicking on a list entry shows the associated data path in the logic diagram. 

This functionality can also be achieved vy using the control button "Show". 

Note: The symbol addresses shown in the list are also used in the compilation and in 

the validation report. 

Tip: The "Select all" command from the context menu (right mouse button) can be 

used to select all data from the logic diagram. 


Step 3: Starting the debugger 

The selected data can only be diagnosed if the information in the logic diagram 

corresponds with the information in the actively connected SMX-system. The 

adjustment is made by clicking on the control button "Diagnose Start". 

Note: The implemented debugging function requires intensive data transfer between 

SMX-system and SafePLC. This results in a temporally delayed display of data. 

Quick status changes on module outPorts may therefore not be detectable. 

The diagnose is solely available in operating mode "Run". In any other mode of 

operation the process image is passivated. 


The Scope Monitor 

Parameterization of drive monitoring requires exact knowledge of process data 

when viewed from the SMX-system. Knowledge about the temporal course of speed, 

acceleration and position is of utmost importance. Only this enables the setting of 

correct threshold values and limiting parameters. 

All available graphics functions read the required process data ONLINE from the 

active basic SMX-group through the communication interface for time-based 

representation. Up-to-date values are inserted at the right border of the Scope 

Monitor, moved further to the left during recording, until they finally disappear at the 

left border of the screen. Although these data have disappeared from the visible 

window, they are still maintained in a buffer memory and can still be moved back into 

the visible area by sliding the scroll bar below the graphics window. 

Note: With an active Scope Monitor the output of debugging of process image and 

logic diagram is hidden and the diagnostics tabulator is blocked throughout the 

connection dialog. These data cannot be made available in this mode. 


Cursor 1, Cursor 2: With these slide controllers two cursor positions for displaying 

specific diagram values are available. Changing the position of the slide controller 

moves a display line in the diagram. The Scope window shows values for the 

corresponding cursor positions in form of a legend. Time related assignments of the 

cursor positions are also available. 

Scaling 

Opens a dialog to scale the displayed diagram function. This enables the adaptation 

of the Y-values in the individual graphs by means of a multiplication factor. 

Start / Stop 

Start or stop recording 

Maximize >> 

Enlarges the Scope Monitor to the complete available screen area. With the control 

button "Normal

Preparing the measurement 

Choose the desired measuring scheme first! 

In case of a speed oriented measurement the current recording time for the 

corresponding axis is displayed on the X-axis. The measuring data for the graph are 

read by the module, standardized and displayed with the correct time reference. The 

recording memory is approx. 15 minutes. 

The measuring process is automatically stopped when the buffer memory is full. The 

previous measurement is automatically saved under "ScopeTempData.ScpXml". 

With position oriented measurement the configured measuring range of the set axis 

is displayed on the X-axis. Cursor 1 is in "Actual Position" of the axis and is 

continuously updated via the data link. Cursor 2 can be displaced as required for the 

determination of data. 

Note: When changing the scheme, any recorded data from previous measurements 

will be lost. 

When changing the dialog size the display data must be rescaled. This requires 

position oriented measuring and resetting the data buffer (SSX). 

"Start" measurement 

The control button "Start" is only available in case of an active connection to the 

SMX-system. After clicking on this control button the data will be cyclically transferred 

to the buffer memory and displayed in the diagram from left to right. Active recording 

can be stopped with the "Stop" control button. 

"Stopping" a measurement and viewing data 

After completion of the measurement the data can be analysed by moving the slide 

controllers accordingly. 

Measuring schemes 

Encoder data 

Functionality 

Recording of scaled position values of system A 

and system B over the course of time. 

Recording of process values for speed and 

acceleration over the course of time. 

Note: 

Internally the position value of system A is used to generate 

the process value for the position. 


Application 

Encoder speed 

Functionality 

Scaling of the encoder systems A and B in case 

of position monitoring. In case of a correctly 

scaled encoder system there should be no 

significant deviation between positions A and B, 

or the deviation should not exceed the 

"permissible deviation" set in the encoder dialog. 

Analysis and course of encoder signal for 

diagnostic purposes (e.g. trouble shooting, etc.). 

Acceleration and speed behaviour of the drive. 

Detection of thresholds. 

Recording the current speed of system A and 

system B over the course of time. 

Recording the difference of speed signals from 

system A and system B over the course of time. 

Note: 

Internally the speed value from system A is used to 

generate the process value for the speed. 

Application 

SSX data 

Functionality 

Application 

Scaling of the encoder systems A and B in case 

of speed monitoring. In case of a correctly scaled 

encoder system there should be no significant 

deviation between speeds A and B, or the 

deviation should not exceed the permissible 

"speed threshold" set in the encoder dialog. 

Analysis and course of encoder signal for 

diagnostic purposes (e.g. trouble shooting, etc.). 

Recording of process data for speed and 

acceleration over the course of time. 

Recording of speed limit for the monitoring 

function over the course of time. 

The diagram shows the dynamic behaviour of the 

drive via the visualization of speed and 

acceleration. 

With the SSX not activated, the limiting speed 

remains zero. 

When activating the SSX-function, the limiting 

speed is taken from the current speed and 

projected down. 

If the drive with its current speed remains below 

the limiting speed, the system will not be shut 

down. 


SEL 1 / SEL 2 data 

Functionality 

Application 

Recording of process data for speed and 

acceleration over the position or the course of 

time. 

Visualization of current position in form of the 

parallel moving cursor: 

Visualization of the current stopping distance in 

form of a trailing pointer. 

The diagram shows the dynamic stopping 

distance value as minimum value for the braking 

distance. 

Examination of the set parameter values in the 

SEL-function, examination of the available 

reserve for shut-down. 


Diagram Management 

With the diagram management the logic diagrams can be locked against unintended 

or unauthorized modifications. It also provides documentation possibilities for 

program creation. 

Diagram access 

Here one can disable or enable access to the function blocks in the current logic 

diagram. This means, that in a locked logic diagram all menu options and toolbars for 

adding function blocks appear in grey (= locked). Moreover, parameters in function 

blocks, that had already been added, cannot be changed. 

"Unlocking" requires a password. The configured values and the functional modules 

of a locked diagram may in this case be viewed, but cannot be modified. This 

functionality make sure that no changes can be made to the logic diagram by 

unauthorized persons. 


When a logic diagram is locked, the dialog "Save File" will appear when exiting the 

diagram management, so that possible changes will not be lost. 

Note: 

Logic diagrams can only be unlocked using the password that was applied when the 

diagram was locked. A locked logic diagram can no longer be compiled ! However, 

access to the SMX-module is still possible. 

Program information 

This information serves the documentation and identification of the logic diagram. 

Programmer: 

Name of the responsible programmer. 

CRC equipment configuration: 

Signature concerning program and parameter data. 

Parameter CRC: 

Signature concerning parameter data, i.e. adjustment values of sensors, actuators, 

timers, etc. 

Program CRC: 

Signature of the PLC-program. 

Compiler ID: 

Identification of activation dongle. 

Indicated CRC on the SMX-module 

Indication of the actually available CRCs on the SMX-module by operating the "Func" 

button, in the following sequence 

Indication of the actually available CRCs on the SMX-module by operating the "Func" 

button (hold depressed for 1 second) in "RUN" mode: 

P xxxxx1 - C xxxxx2 - Lxxxxx3 

xxxxx1 -> Signature concerning program and parameter data 

xxxxx2 -> Signature concerning parameter data 

xxxxx3 -> Signature of the PLC-program 

Note: 

If the CRC is used for the test report, it is recommended to lock the logic diagram, 

since this prevents accidental modification. 

Comment: 

This input field provides a descriptive field for the input of any text. Here one can 

document e.g. program or parameter changes during the life cycle of the currently 

used device. 


Configuration Report 

SafePLC uses the validation function (Connection->Validation) to create a 

configuration report for the equipment configuration. This function is only available in 

case of an active connection to an SMX-system. 

The report is saved in a file and can subsequently be edited. 

Attention 

The printed out file serves as model for the safety related examination! 

Note 

The report can only be created after the logic diagram has been saved. 

The generated text file (*.txt) has the same name and is located in the same 

directory as the associated logic diagram. 

1. Step: Editing the report header 

The following fields can be edited in the header. 

Equipment: Code designation of equipment 

Customer: 

Supplier: 

Installer: 

Operator of equipment 

Manufacturer of machine / equipment 

Information about commissioning of equipment 


2. Step: Filling in the equipment description 

Equipment designation: describes the functionality or field of application of the 

equipment 

Installation location: describes the exact location of the equipment 

End customer: Operator of equipment 

Short description: safety related equipment features 

Description of function: safety related equipment features to be monitored by 

the safety module. 

3. Step: Individual proof 

Serial-no. from: 

Element: 

Designation: 

Place of installation: 

Designation in wiring diagram 

Module type (see sticker) 

File name of logic diagram 

Designation of control cabinet that contains the safety 

module 

Manufacturer and type are fixed. 

Serial number: Serial-number of the safety module (sticker) 

Identical with sticker: must be activated acc. to the entered serial number. 

Equipment variant: 

PLC-function 

Position processing 

: Me without safety bus 

: Module with position processing 

(can be set in the encoder dialog) 

The CRC-signature of the configuration set must be entered in hand writing 

after the repirt has been printed out (CRC is displayed in the "Logic Diagram 

Management" or in the 7-segment display). 

Identical with module: Here the responsible tester confirms that the CRC's 

displayed in the programming desktop are identical with the CRC stored in the 

equipment.. 

(Note: The CRC in the equipment can be read out via the seven-segment 

display by simply pressing the function key in "RUN-Mode") 


Checking the correct function: 

1. The correct program and parameter data must be loaded to be able to 

generate the validation report! 

2. The test engineer must once again validate all configured data in the printed 

report by providing evidence of the programmed functions on the equipment / 

machine. 

3. All parameterized limiting values of the monitoring functions used must be 

checked for correctness. Attention must be paid to the response times 

mentioned in the installation manual. 

4. A successfully executed validation should be completed by clicking on the 

control button "Lock validation". 

Note: 

If a new configuration is loaded to the SMX-system, the system LED will, in 

case of fault-free operation, subsequently light YELLOW. This signalizes a 

non-validated application! When actuating the control button "Lock validation" 

while actively connected with the module, the LED will subsequently flash 

GREEN. 


Program Development Aids 

Program development aids can be found in the "Drawing Aid" toolbar in the top left 

corner. 

Info display 

With the info display activated the attributes of the element touched by the mouse 

pointer will be displayed. The dynamics of this display can be adapted in the "File 

settings" dialog. The info display can also be activated with the "Ctrl"-key. The 

display will continue, until this key is released again. 

Signal tracking 

This command selects all other functional modules, which are linked with a 

currently selected block. This way all coherent linkages of modules can be 

represented. 

Tip: This function visualizes coherent areas which are interconnected via connecting 

points. 

Note: This command is only active, when exactly 1 function block has been selected. 

Copying attributes into the message window 

All attributes belonging to a block selection can also be output in the message 

window. This is possible either with the menu command "Edit->Attributes into 

Message Window" or via the function block context menu. 

Tip: The attributes of all functional modules can be copied using the command 

"Attributes into Message Window". In this case no functional module must be 

selected. 

Note: When selecting the command via the context menu, the mouse pointer must 

be positioned on a selected block. 


Quick selection 

By double-clicking on the colour-coded BlockID's in the message window one can 

have the associated block centred in the 

logic diagram window. This enables quick localization of function blocks belonging to 

an output and to make necessary changes, if this is required. 


Predefined Function Blocks 

Representation of the available inPorts and outPorts of the SMX-system. 

Sensor interface 

This block describes the speed and position sensors, the signal list for the digital 

inPorts and, if available, the analog inPorts. The parameter editor for the 

individual elements is started by double-clicking, or via the context menu 

"Properties…". 

Speed and position sensors 

Double-clicking on one of these elements opens the encoder configuration dialog. 

The parameters to be entered are described in detail in the section "Encoder 

configuration". 

Visualization of a PDM function used for fuinction control of sensor 

monitoring 

Digital inPorts 

Determination of properties for digital input signal Linkage takes place 

automatically when inserting function blocks described below. Double-clicking on 

a signal list opens a comment window with the possibility of entering describing 

text. 


Analog inPorts 

Double-clicking on this logic diagram element opens the configuration dialog to 

determine the analog signal monitoring. (See: Analog signal input). 

SMX outPorts 

This block consists of the signal lists for the freely programmable outPorts, 

consisting of relay, semi-conductor and auxiliary outPorts. As with the input 

signals wiring also takes place automatically when adding the associated function 

blocks. 


Adding InPort Blocks 

The inPort elements create the digital connection between one or several 

connected sensors and/or further lower-level switching devices in the SMX 

System. Each inPort element, except the mode selector switch, provides one 

logic output signal "0" or "1" for further processing in the PLC. 

The inPort elements are added and edited in the "Terminal Diagram" view. 

The resource control of the function block elements for the SMX-system 

manages the available elements, the number of which may be limited. 

If no further elements are available when programming the terminal diagram, the 

commands for adding the corresponding modules or function blocks will be 

disabled. This is visualized by menu options or toolbars appearing in grey. These 

resources can be released again by deleting the corresponding function blocks. 

The inPort elements are structured according to their application 

(example enable button). 

Note 

The assignment of the selected inPort elements and their parameterization 

has a direct effect on the performance level to be achieved. The explanations 

in the installation manual for the SMX-System must for this purpose be strictly 

followed! 


The configuration of inPort elements generally takes place in the same way. The 

parameter editor to define the following properties opens upon selection: 

Switch type 

Determination of the planned input signals. A logic input signal for further linkage 

in the PLC may consist of one or several external signal paths. The description of 

the individual elements lists the respective possibilities and combination in tabular 

form. 

For time-out monitored signal types a limited number is available. 

Signal-No. 

Determination of the external signal to a terminal connection of the SMX-system. 

The number of available terminal connections is determined by the actually 

available SMX-module configuration. Signals that are already in use no longer 

appear in the selection dialog. The editor always shows resource limitations within 

the corresponding context in a message window. 

Cross-shorting test 

Source of the input signal used. Two signal pulses, Pulse1 and Pulse2, are 

available. The "OFF" option can be alternatively selected. Cross-shorting in the 

external wiring can be detected by using the signatures. 

Starting behaviour 

Determination of the behaviour of an inPort element when changing the state of 

the logic output value in the logic diagram from "0" to "1". 

automatic 

Processing of the defined input signals without confirmation or acknowledgement. 

Start type Function Scheme 

Automatic Automatic start after an 

start 

equipment reset or after 

activation of switching 

function. 

OutPort of the inPort 

Geräte-Anlauf 

Schaltfunktion 

element becomes "1" when 

the safety circuit is 

closed/active acc. to the 

OutPort Ausgang 

definition of the switch type 

Equipment start 

Switching function 

monitored 

Release of the monitored inPort element in case of descending edge on the 

specified monitoring inPort. This is required at any time when the monitored inPort 

element is to be switched. 

Example: Start of a drive only after this has been confirmed by the operating 

personnel. 


With monitored starting mode an additional connector for linking with a start 

element is provided. Here one can configure the continuous behaviour for 

monitoring the inPort element during the start phase. 

Start test 

Manual starting after equipment reset or interruption of the defined safety circuit, 

including testing of the connected control station. The control station must trigger 

once in monitoring direction and switch back on again. Followed by normal 

operation. This non-recurrent triggering of the inPort element when starting (or 

resetting) the monitored equipment ensures the function of the inPort element at 

the time of starting. A start test can be performed for all inPort elements, except 

the mode selector switch. 

An activated start test is indicated by a red rectangle on an added function block. 

Normally closed 

contact 

Comment 

Input of a comment text to appear on the module. 

Enable switch 

Switch type Designation Comment 

1 (eSwitch_1o) 1 normally closed Enable switch standard 

2 (eSwitch_1s) 1 normally open Enable switch standard 

3 (eSwitch_2o) 2 normally closed Enable switch higher 

requirements 

4 (eSwitch_2oT) 2 normally closed time 

monitored 

Enable switch monitored 


Emergency Stop 


1 (eSwitch_1o) 1 normally closed Emergency Stop standard 

3 (eSwitch_2o) 2 normally closed Emergency stop higher 

requirements 

4 (eSwitch_2oT) 2 normally closed time 

monitored 

Emergency Stop monitored 

Door - Monitoring 


3 eSwitch_2o 2 normally closed Door monitoring higher 

requirements 

4 eSwitch_2oT 2 normally closed time 

monitored 

5 eSwitch_1s1o 1 normally open + 1 normally 

closed 

6 eSwitch_1s1oT 1 normally open + 1 normally 

closed time monitored 

7 eSwitch_2s2o 2 normally open + 2 normally 

closed 

8 eSwitch_2s2oT 2 normally open + 2 normally 

closed time monitored 

Door monitoring monitored 

Door monitoring higher 

requirements 


Door monitoring higher 

requirements 


9 eSwitch_3o 3 normally closed Door monitoring higher 

requirements 

10 eSwitch_3oT 3 normally closed time 

monitored 

Two-hand button 


Switch type Comment Classification 

11 eTwoHand_2o 2 normally open + 2 normally 

closed 

Two-hand button higher 

requirements type III C 

12 eTwoHand_2s 2 normally open Two-hand button monitored type 

III A 

Note: With these inPort elements a fixed pulse assignment takes place, which cannot 

be influenced by the user! 

index 


Light curtain 


3 eSwitch_2o 2 normally closed Light curtain higher 

requirements 

4 eSwitch_2oT 2 normally closed time Light curtain monitored 

monitored 

5 eSwitch_1s1o 1 normally open + 1 

normally closed 

Light curtain higher 

requirements 

6 eSwitch_1s1oT 1 normally open + 1 

normally closed time 

monitored 

Light curtain monitored 

index 

Mode selector switch 


13 eMode_1s1o Selector switch normally 

closed/normally open 

Mode selector switch 

monitored 

14 eMode_3switch Selector switch 3 steps Mode selector switch 

monitored 

Safety note: When changing the status of the switch the SafePLC program to be 

created must ensure that the outPorts of the module are deactivated (note: 

Standard 60204-Part1-Paragraph 9.2.3). 


Sensor 

1 eSwitch_1o 1 normally closed Sensor input standard 

2 sSwitch_1s 1 normally open Sensor input standard 

3 eSwitch_2o 2 normally closed Sensor input higher 

requirements 

4 eSwitch_2oT 2 normally closed time Sensor input monitored 

monitored 

5 eSwitch_1s1oT 1 normally open + 1 

normally closed time 

monitored 

Sensor input monitored 

Start-up Test 

Each switch element has the ability for running an automatic function test (= start-up 

test). Altogether two switch elements can be configured with start-up test. 


Start type Function IL Scheme 

Start test Manual staring after a new 

start or an alarm reset, 

including testing of the 

LD E1 

ST MX.y1 

Equipment Geräte-Anlauf start 

connected monitoring 

equipment. 

LD NOT MX.y1 

Switching Schaltfunktion function 

The monitoring equipment ST MEAA_EN.1 

must trigger once in 

Output Ausgang 

monitoring direction and 

switch back on again. 

LD MX.y1 

ST MEAA_EN.2 

Followed by normal operation. 

E1: Switching function 

y1: auxiliary marker 

LD MEA.1 

AND MX.y1 

ST MX.2 

Start and RESET Element 

This inPort element offers both extended monitoring functionality, as well as the 

possibility to reset an occurring alarm. 

use for start monitoring 

With start monitoring activated, an AWL code segment for monitoring an assigned 

inPort segment during restarting or an alarm reset of the equipment/machine to 

be monitored is automatically generated. 


This function related testing of a periphery element (e.g. actuation of the emergency 

stop switch) is intended to ensure its functionality when the equipment is started. 

List of starting types by means of a enable button: 

Start type 

Start type Function IL Scheme 

Manual start 

(by hand) 

Manual start after equipment 

reset. 

OutPort of the inPort element 

becomes 1 when the safety 

circuit is closed/active acc. to 

the definition of the switch type 

and the start button has been 

pressed 1 x. 

OutPort becomes 0 after safety 

circuit is open. 

LD E1 

ST MX.y1 

LD MX.y1 

AND E2 

S MX.y2 

LD NOT MX.y1 

R MX.y2 

Switching 


function 

Start-Taster button 


Start 

monitored 


E2: Start button 

y1: Auxiliary marker 1 



Manual start after equipment 

reset with monitoring of start 

circuit for static 1-signal. 

OutPort of the inPort element 

becomes 1 when the safety 

circuit is closed/active acc. to 

the definition of the switch type 

and the start button has been 

pressed 1 x and released 

again. 

OutPort becomes 0 after safety 

circuit is open. 


E2: Start button 





LD MX.y2 

AND MX.y1 

ST MX.y3 

LD E1 

ST MX.y1 

LD MX.y1 

AND E2 

S MX.y2 

LD NOT MX.y1 

R MX.y2 

LD MX.y2 

AND MX.y1 

AND NOT E2 

S MX.y3 

LD NOT MX.y1 

R MX.y3 

LD MX.y3 

AND MX.y1 

ST MX.y4 


Switching 

function 

Start-Taster button 


The monitoring inPort of the start element must be connected to the outPort of the 

inPort elements labelled "Start element". Several elements can be monitored. 

e.g. 


Note: When editing the associated inPort element, the connection with the start 

element is deleted and cannot be restored automatically. It must be subsequently 

supplemented manually. 

InPort - Signal No. 1 

As with the inPort elements, this selection list is used to determine the inPort to 

which the button for for the start element is to be connected. This inPort is 

internally limited to the assignment to a basic module (E0.1 to E0.14). When the 

AlarmReset option is used, no cross-shorting monitoring can be permitted for this 

inPort. In the dialog the corresponding input field is fixed to "OFF". 

use as AlarmReset (normally open) 

With this option currently present malfunctions (= ALARM) or triggered monitoring 

functions can be reset through a connected normally open contact. 

The following table shows an overview of all monitoring functions and their 

acknowledgement in triggered state. 

Monitoring functions 

SEL 

SLP 

SCA 

SSX 

SLI 

SDI 

SLS 

SOS 

SAC 

PDM 

ECS 

Acknowledgement required 

Yes 

Yes 

No 

Yes 

Yes 

Yes 

Yes 

Yes 

No 

No 

Yes 

Note 

The same functionality is achieved when using the "Function" button of the 

basic SMX module. 

Error messages of type "FatalError" require a restart of the basic SMX 

module. 

The alarm reset input can be operated with 24V continuous voltage and is 

edge triggered. 


use as Logic Reset (normally open) 

This option makes the reset-acknowlegement functionality in the logic diagram 

available for further processing. In this case a function element is automatically 

generated, which can be used for linkage with a logic functionality. This logic reset 

signal is normally used for the acknowledgement of RS-FlipFlops. 

e.g. 

saving and resetting of SCA-module errors via RS-FlipFlop. 

Switch type Comment Classification Classification SIL 

category 

1 normally open Alarm reset 

-- -- 

standard (evaluation 

of edge) 

1 normally open Logic reset standard Category 3 SIL 2 

1 normally open Start monitoring 

standard (optional 

function) 

-- -- 


Analog interface 

A special parameter editor is available for parameterizing the analog interface. The 

associated block symbol in the terminal diagram will appear against a red 

background, as long as this interface has not been parameterized. After 

parameterization the background colour changes to green. 

For safety tasks two physically analog input signals each are required. These can be 

scaled according to their signal characteristics and wired with low-pass filters. 

In the terminal diagram the analog inPorts and the associated filter modules are 

shown accordingly. Double-clicking opens the editor for the selected element. 

Analog inPort Ain1 / Ain2 

This dialog enables scaling of the applied analog sensor signals. 

The sensor signals Sensor1 and Sensor2 are used by the SMX System to 

generate a secure analog information Ain1 for further processing by special 

monitoring modules. There is also the possibility to use the sensor signals Sensor 

3 and Sensor 4 to calculate the secure standardized analog information Ain2. 

SMX uses a calculation method which transfers an analog input information in a 

standardized image area ranging from 0 to 100 %. 


Perm. deviation sensor 1/2 

Max. permissible deviation between the two analog input signals Sensor 1/Sensor 

2 or Sensor 3/Sensor 4 respectively. Default value in percent of the standardized 

maximum signal range. 

Nominal value minimum 

Lower limit of the input signal in millivolt. After standardization this signal level has 

a value of 0 %. 

Nominal value maximum 

Upper limit of the input signal in millivolt. After standardization this signal level has 

a value of 100 %. 

Input filter 

Low-pass filter for the assigned input signal 

Note 

The filter response times specified in the installation manual must be taken 

into account! 

Analog adder 

The analog adder enables weighting of the standardized analog signals. 


Two input signals, which have already been standardized, can be added together 

in a defined ratio to each other. The corresponding signal components are 

determined in percent. 


Inserting OutPort elements 

The outPort elements create the digital connection between one or several 

connected external switching circuits in the SMX System. Each outPort element is 

triggered by a logic input signal "0" or "1" via the logic diagram. 

The outPort elements are added and edited in the "Terminal Diagram" view. 

The resource control of the function block elements for the SMX-system 

manages the available elements. 

Relais outPort 

OutPort type 

Single 

2 single relays (K1 to K2) can be selected independently from each other. 

Redundant 

Two relay outPorts are combined and always switched together. 

Note 

Follow the explanations in the installation manual when using relay outPorts in safety 

applications. 

For exact contact monitoring see chapter EMU-function 


Semi-conductor outPort 

Semi-conductor outPort as standard outPort 

Certain semi-conductor outPorts can solely be used as auxiliary outPorts and are 

thus not suitable for safety applications (refer to the installation manual for details). 

The editor can only be used to set the initial assignment. 

Semi-conductor outPort with safety function 

Semii-conductor outPorts with safety function are internally structured with two 

channels and can be combined with external contact monitoring (EMU). 

For exact contact monitoring see chapter EMU function 


HiLo Outport 

Semi-conductor outPort as standard or safety outPort 

HiLo semi-conductor outPorts can be used individually as standard outPorts and 

grouped as safety outPorts (refer to the installation manual for details). 

The editor can be used to set the initial assignment. 

OutPort type 

Single 

"HISIDE" (= P-switching) or "LOSIDE" (= M-switching) can be selected as standard 

outPort. The use of single standard outPorts is not suitable for safety outPorts. 


Redundant 

With the option "Redundant" the editor compellingly specifies a combination of 

"HISIDE" and "LOSIDE" outPorts. 

For exact contact monitoring see chapter EMU-function 

EMU Function 

The multiplication of contacts and power normally requires additional switching 

devices, which are triggered through the outPorts of the SMX-system. EMU 

monitoring realizes the "Safety relay" function by processing an external feedback 

circuit. 

Applications with higher safety requirements among others require functional 

monitoring for these switching devices. For this purpose the switching devices must 

be equipped with positively driven auxiliary contacts. Contacts to be monitored are 

switched in series and are closed when in idle state. It is verified whether all contacts 

are closed when the outPort is not switched on and open in switched on state. Time 

related expectations can be parameterized. The same sources as for the inPorts are 

also used to supply the contacts to be monitored. 

Note 

Details to this subject can be found in the circuitry examples of the installation 

manual. 

Feedback circuit 

Switch to activate EMU monitoring 

Feedback channel 

Digital inPort of the feedback circuit. The outPorts for activation of the external 

switching function and the feedback circuit are located on the same SMX-system 

module (basic module or expansion module). 

Pickup time 

Variable time slot (closing delay) for testing the safety contacts 

Min{T EMU } = 8 msec 

Max{T EMU } = 3000 msec 

Dropout time 

Variable time slot (release delay) for testing the safety contacts 

Min{T EMU } = 8 msec 

Max{T EMU } = 3000 msec 


The Logic Modules 

These modules form the basis for creating a program for the safety application. 

They enable the logic linkage of the inPorts with monitoring functions with and the 

outPorts. Inserting logic modules is only possible in the "logic diagram" view, 

otherwise the associated menu commands are disabled. This is the case when 

the resources for a module are already exhausted, e.g. after all timer modules 

have been inserted. 

Logic AND 

"AND"-operations of maximum 5 output signals from other function blocks. 

The AND-operation provides the signal state "1" for all input signals "1" as logical 

result, otherwise "0". 

Note: The number of inPort connectors can only be reduced in case of free 

connectors. If all connectors have linkages assigned, these must be deleted 

beforehand. 

Logic OR 

"OR"-operations of maximum 5 output signals from other function blocks. 

The OR-operation provides the signal state "1" for at least one inPort with signal 

state "1", otherwise "0". 


Logic EXKLUSIV OR 

"EXCLUSIVE OR"-operations of 2 output signals from other function blocks. 

The XOR-module provides "1" as logic result, if one inPort has the input signal "1" 

and the inPort has the input signal "0", otherwise "0". 

Logic NOT 

The logic result of this function block is the negation of the input signal. The 

term negation means that the logic result is reversed (negated). 

index 


RS Flip Flop 

Set / reset contact element. This switching element shows the following 

characteristics: 

The logic result during initialization of the element is "0". 

The logic result becomes "1", if an edge change from "0" to "1" takes place at 

the "Set" inPort. The outPort remains at "1", even if the state of the "Set" 

inPort changes back to "0". 

The logic result becomes "0", if an edge change from "0" to "1" takes place at 

the "Set" inPort. 

With both inPorts set to "1", the result is "0"! 

Reset 

Set 

Note: The desired switching state of this element is only achieved by linking as 

specified in the labelling. 

index 


Timer 

Function block that starts a counter in the event of an edge change. After 

the specified temporal delay the logic result will become "1" or "0". 

Block ID: Instance of the timer module. 

Delay: Parameterized time 

T min = 8 ms 

T max = 533 min (31999992 ms) 

Note: The programmable values always correspond with the integer multiple of 

the SMX cycle time of 8 msec! 

Characteristic 

pickup delayed 

InPort 

OutPort function 

"0" The outPort continuously remains at "0" 

Edge "0" to "1" Once the parameterized time has expired the initial 

status of the timer module will change from "0" to "1". 

Status change "1" to "0" The outPort immediately changes to "0" 


Dropout delayed 

InPort 


"0" The outPort continuously remains at "0" 

Edge "0" to "1" The outPort immediately changes to "1" When the 

counter has run out the outPort will change to "0" 

Status change "1" to "0" The outPort immediately changes to "0" 

Permanently logic "1" module 

This module constantly provides the value "1". This function can be used to 

program static states in the logic diagram. 

Example: Assignment of an unused inPort on a direction dependent SDI 

Result of the EMU module 

This module delivers the result of the EMU-function that has been 

parameterized in the outPort module. Fault-free EMU-function is fed back as 

status "1". 


Connecting Point InPort 

The "Connecting Point InPort" supports the clearly arranged representation 

of logic diagrams. These modules provide virtual connections in the logic diagram. 

The connecting point reference numbers are automatically generated and cannot 

be changed, but the comment box enables appropriate allocation of the virtual 

connection. Activating the CTRL-key and selecting a "Connecting Point InPort" 

also selects the associated "Connecting Point OutPort" modules. 

Terminal number: Identification number of the connecting point. 

Note: When deleting "Connecting Point InPort" elements the dependent 

"Connecting Point OutPort" elements will automatically also be deleted. Before 

the deletion process the user will be warned. 

Tip: The use of a comment line simplifies the assignment of elements. 

index 


Connecting Point OutPort 

This element is the equivalent to the "Connecting Point InPort". Selecting a 

terminal number sets up a virtual connection to a "Connecting Point InPort" 

function block. 

Terminal number: Identification number of the "Connecting Point InPort" 

element. 

Note: After assignment to a "Connecting Point InPort" element, the comment 

managed by this point is taken over by the "Connecting Point OutPort" element. 

index 


Signal Channel 

The signal channel enables the functional transfer of data from the process 

image to a connected field bus. It is made up of two parts: the first part consists of 

56 bit logic data, the second part of a 64 bit wide process data channel. The data 

to be transferred can be freely assigned via a profile generator. 

Logic data 

A profile of the data to be transmitted from the logic diagram can be defined using 

a list: 

The signal channel list contains the references to the selected bit 

information in the logic diagram. 

Enter the selected bit information at the position of the set BitID (= bit 

position in signal channel) 

The bit positions are displayed based on 1 

The DeviceID enables reference to various modules 

ModuleID: Number of function block in logic diagram. 

Module: Further information to the module 

Symbol address: Designation of the connector 

The numbers under the designation "Module outPorts" indicate: 

Number of status bits used / number of max. possible status bits 


Add… 

Opens the "Add status bit" dialog. The module selected here is added at the end 

of the reference list. 

Delete 

Deletes the currently selected line from the reference list. The BitID's of the 

following entries remain unchanged. 

Up 

Changes the currently selected line in the reference list by one line upwards and 

takes over this line's BitID. 

Down 

Changes the currently selected line in the reference list by one line downwards 

and takes over this line's BitID. 

Assign BitID 

Enables any desired BitID assignment. 

The assignment dialog can only be opened under the following conditions: 

- There must still be at least one free BitID available. 

- A line must be selected in the signal channel list 

The dialog can also be opened by double-clicking on a line 

- Setting the new bit position. The numbering system is 1-based. 

Sort BitID 

Sorts the signal channel list in the sequence of the assigned bit positions. 

Note: The assignment of status bits can only take place after a successful 

compiler run, because the addresses calculated by the compiler must be 

accepted. These are displayed in the "Symbol addresses" column. The entries in 

this column remain empty or are not updated, as long as the logic diagram has 

not been completely compiled. 


Process data 

This part of the signal channel defines process data which are transferred from 

the SMX-system to another field bus. 64 bit are available in total. The values set 

in the dialog are entered into the signal channel from "top" to "bottom" 


Function Groups 

Function groups connect several functional modules to a superordinate logic 

structure. This matching group of modules is created inside the function group frame 

and connected via this frame. 

This grouping gives the logic diagram a much clearer structure and, with the export / 

import functionality, enables the creation of an own function library. 

Creating a function group frame 

Inserting a group module 

First the command "Insert group frame" is started by clicking on the toolbar button 

"Insert". 

The menu: Group->Insert group frame… can alternatively be invoked. 

The size of the group frame is determined with the mouse pointer. 

1.) First position the mouse pointer with the left mouse button in the left upper 

corner of the group frame and hold the mouse button depressed. 

2.) Then drag the mouse pointer while holding the left mouse button depressed 

and determine the bottom corner of the group area. 

3.) Releasing the mouse button will insert the group frame and open the group 

editor. 

Opening the group editor 

The group editor can optionally be opened by double-clicking in the status line of the 

group frame, or via the context menu (right mouse button) of a selected module. 


The tab-dialogs "Settings" and "Description" contain group related settings, as well as 

the function related description of the group. The control button "File" can be used to 

export the group into a file, or to import the group from a file. 

Setting the group management 

With the switch "Disable group management" the group modules can be disabled or 

enabled. 

With the switch set. the function block management of the frame is disabled and the 

modules are tied to the group: 

Modules can no longer be removed from the group, whereby the configuration 

of parameters is still permitted. 

Deleting a group frame also deletes all group modules. 

No new modules can be added to the group. 

Group members appear "grey shaded". 

When disabled, the group has a time stamp assigned, which is also displayed 

when the group editor is opened. 

The control buttons for the info fields "Name", "Created by" and "Released by" 

are disabled. 


The group status "disabled" is indicated by the padlock symbol in the status bar of 

the group module at the top left. 

When inserting a new group frame the switch "Disable group management " is set to 

unlocked state by default. After closing the group editor the drawn frame appears in 

the logic diagram and represents the active area of the group. 

Function blocks can be inserted, moved or deleted on this area. The modules 

will automatically be accepted in the group, unless the group is in disabled state. The 

functional modules in this case additionally show the number of the function group. 

Note: 

The following module types cannot be contained in a group. These are filtered out 

when the modules are moved into the frame area. 

o InPort modules 

o OutPort modules 

o All function blocks pre-defined in the logic diagram /e.g. encoders, analog 

modules, filters) 

o Signal channel module 

o Terminal blocks 

The group is able to accept maximum 200 function blocks. 


Changing the size of a group frame 

A selected module can be adapted in size via its "Hotspot". For this purpose it is 

selected with the mouse pointer and changed in size with the left mouse button held 

depressed. 

Showing and hiding functional modules 

The modules contained in the group can be shown or hidden be clicking on the 

control button in the status bar with the mouse pointer. When showing its content, the 

size of the group module automatically adapts to the elements it contains. 

Note: 

Do not use the show/hide function while editing modules, as otherwise the available 

free space may be optimized for further modules. In this case the group needs to be 

manually enlarged again via the "Hotpoint". 

Tip: 

The size of the group frame can be fixed by using a text element in the bottom right 

hand corner. 

The visibility of the associated function blocks in the logic diagram can also be set in 

the group dialog using the switch "Show associated modules". 

Show modules 

The size of the group module is determined by the position of the functional modules 

contained therein. 

Hide modules 

The group module is set to a size of approx. 2 x 3 fields of the logic diagram. The 

bitmap for the symbol is display. 

If several function groups are available, all group modules can be shown or hidden 

by using the symbol in the group toolbar. The same functionality is achieved 

via the "Group" menu. 


Creating the group interface 

The group interface modules represent the interface of the function group to the 

elements outside the group. Connections to function blocks outside the group can 

only be made via this interface module. 

Inserting a group interface module is started by clicking on the button in the 

group toolbar (alternatively menu: Group->Insert interface module...) After placing a 

module inside a group frame the group interface editor is opened. 

Setting the usage 

This setting is used to determine the connection properties of the module as inPort or 

outPort. 

"as group inPort" 

This element represents the connection of function blocks outside the group to 

the external group elements. The module should be positioned on the left side of the 

group area, if this is possible. The outPort connector must be wired further inside the 

group. 

"as group outPort" 

This module transfers a result from the group to externally located logic 

diagram elements. 


Restrictions 

The dialog "Connection restrictions" can be used to set switches for group inPort and 

group outPort elements and prevent impermissible allocations. 

Note: When reusing group elements, these restrictions prevent faulty or unintended 

connection of external function elements. Restrictions should always only be set after 

complete definition of the group context. 

Context: Defining a module: 

The interface module reads the type and the restriction criteria of the connected 

module and offers these as restriction. The restriction is shown when the associated 

switching element is set. 

Example: A mode selector switch is connected to the group interface module. In user 

mode the group module always expects to be connected with the function block type 

"Mode selector switch" 

Context: Using a module 

When connecting to an external functional module, the interface module expects the 

set restriction criteria. If these are not fulfilled a compiler error will occur and the 

program cannot be compiled. 


Procedure for Creating a Function Group 

A function group is created via a group frame. Function blocks within the colour 

contrastive area of a group frame are assigned to this group. As long as a group 

module is still enabled, functional modules can be added to or deleted from the area 

of the group frame. A module contained in a function group indicates this status by 

showing the message "Contained in function group: No." in the info-display. 

Tips: 

- The function groups should remain in enabled condition for as short a time as 

possible. 

- If possible, only edit one group in the logic diagram. 

- Do not move enabled groups unnecessarily in the logic diagram. 

- Disable groups before saving! 

- Set up connections inside the function group as late as possible. 

- Ensure a sufficient size of the group frame. 

1. Step: Adding interface modules 

The functional modules contained in a group can only be linked with the function 

elements outside the group frame via the interface modules described above. In 

these interface modules restrictions can be set as required, which will demand the 

same connection constellation when importing the group into another logic diagram. 

The interface modules enable a description of the input and output parameters of the 

function group. The setting of restrictions should be documented in the description 

tab. 

2. Step: Adding functional modules to the group 

Functional modules can only be added to the group frame in enabled condition. This 

is indicated by the symbol in the status bar. 

If function blocks are to be added to a group, a module must either be inserted within 

the group area, or it must be moved into this area. 

Note: 

No function blocks can be inserted by simply moving the group frame. 

Function blocks will only be accepted if these modules are moved in from 

outside. 

Only logic modules and monitoring modules can be accepted in the group. 

InPort and outPort modules, pre-defined elements such as signal lists, analog 

modules or encoder modules are not permitted. 

Existing connections inside the functional modules are deleted upon transition 

into the group element 


3. Step: Set up connection 

4. Step: Connect group interface 

5. Step: Set connection restrictions 

Testing function groups 

Imported group elements do not have a safety signature! Within the application the 

function of the group element must be proven and verified by means of the validation 

process. 

Disabling a function group 

When disabling a function group, the functional modules contained in this group are 

tied to the group module. The modules can in this case no longer be deleted 

individually and only moved via the group module. 

Exporting a function group 


The modules of a group can be exported into a *.fgr file. An exported group can be 

imported into another group frame. This enables the creation of a library with predefined 

function groups, which can then be imported into new projects. 

Note: 

The function library should only be considered a editing aid, but does not relieve the 

user from the necessity of validating the group elements used in the application. 

The switch "Disable permanently" is a special export feature. If this option is set, the 

group can no longer be modified after it has been imported. 

Please note: 

If this option remains set and the dialog is quit with OK, the group is disabled within 

the logic diagram and the dialog element "Disable group management" is 

permanently hidden. 

It is highly recommended to make a backup copy of the still enabled function group. 

After the option "Disable permanently" has been set, the structure of the function 

group can no longer be changed! 

Importing a function group 

A function group file can only by imported using an already inserted group frame. For 

this purpose start the group editor and start the function "Import group..." 

Note: Modules already available in the group, will be deleted. 

The import process includes the verification of the sensor configuration and the still 

existing resources in the logic diagram. The group can only be imported if all 

resources needed for the modules are available. The necessary sensor settings must 

be checked, particularly in case of position dependent monitoring modules. 

If a resource is no longer available, this is indicated by an error message and the 

import is not possible. 


The Safety Functions 

The safety functions are an essential functionality of the SMX-system. Pre-defined 

functions for: 

- speed monitoring 

- position detection 

- monitoring of limits and target positions 

- functional emergency p monitoring 

- standstill monitoring 

- direction monitoring 

- function monitoring of external shut-down devices 

- rest functions 

are available. 

The functionality for monitoring position, speed and shut-down is only activated 

after successful encoder configuration in the terminal diagram. For each 

monitoring functionality a limited number of modules is available. If these are used 

up, the menu entry for the corresponding function block is disabled. 

Function name acc. to EN 61800–5–2 

SLS - Safe Limited Speed 8 

Number of 

modules 

SOS - Safe Operational Stop 

SDI = Safe Direction Indication 

1 per axis 

1 per axis 

SSX = Safe Stop 1/2 4 

SLI = Safe Limited Increment 

1 per axis 

SCA = Safe Cam 16 

SEL = Safe Emergency Limit 

1 per axis 

SLP = Safe Limited Position 2 

ECS – Encoder Supervisor 

1 per axis 

SAC = Safe Analog Control 8 

EMU – Emergency Monitoring Unit 2 

PDM – Position Deviation Mode 

1 per axis 

Note: If no position monitoring is activated in the encoder configuration, the 

dependent control elements are disabled in the dialogs. 


Position and Speed Sensors 

Selection of encoder type and measuring section as well as the parameterization of 

both sensors for position and speed detection takes place via the "Sensor Interface" 

input mask. 

Note: 

The parameterization of the sensors must always be defined by starting with one 

of the two connected signal sources. For the second sensor possibly available 

transmission ratios of gearboxes or similar system components must be taken 

into consideration. 


Parameterization of the measuring section 

The following options and inputs are possible in the field "Parameters of measuring 

section" 

Linear: 

Rotational: 

Activating position 

processing: 

Measuring length: 

Maximum speed: 

The measuring section has a linear characteristic. The 

unit for the position in this case is "mm" and the speed 

can be given either in "mm/sec" or in "m/sec". 

The measuring section has a rotational characteristic, i.e. 

the movement is a rotation. The position is processed in 

"mgrd" or in "revolutions", the speed in "mgrd/sec", 

"revolutions/sec" or in "revolutions/min". 

Processing of an absolute measuring section. This 

functionality is only available for selection if an absolute 

sensor has been parameterized beforehand! 

With position processing activated all position related 

monitoring functions are enabled. 

Specification of the max. measuring length for the 

position in mm, m or mgrd, rev. With position processing 

activated, the application must always maintained within 

the limits of the set measuring length. Each actual 

position outside the defined measuring length causes an 

alarm of the SMX axis. 

Specification of the max. speed of the reference axis 

given in the currently selected unit. 

The permissible maximum speed describes the highest 

speed that can possibly be reached with the current 

technological system configuration. Here one should 

enter the max. value that may possibly be reached by the 

axis to be monitored. This may, under certain 

circumstances, only refer to a theoretical maximum 

speed of the actual application. The parameterized value 

does not refer to the safety-related shut-down (e.g. shutdown 

via SLS), but to the reliability, i.e. consistency of 

encoders or consistency of the mechanical situation. 

Exceeding this value triggers an alarm with shut-down 

and error / alarm status. This is no planned shut-down 


ecause of safety-relevant speeding, but the reliability of 

the encoders or the mechanical situation is in doubt 

(encoder fault, electric power converter fault,...), because 

this speed can normally not be achieved under drive 

technological aspects. 

Should this occur, the SMX-module will change into 

alarm state and switch off all outPorts. 

This means, that the "maximum speed" must always be 

higher than the shut-down speed of a safety function. It 

serves the purpose of detecting a fault on the safe axis 

by means of measuring systems. 

The value that is entered into this field, at the same time 

changes the dimensioning of the encoder consistency in 

regard to the "Increment shut-down threshold" and the 

"Speed shut-down threshold". A higher maximum speed 

permits higher shut-down thresholds between the 

encoders. The maximum value should therefore not be 

chosen too high, as otherwise the shut-down thresholds 

could be to high for the reliability of the sensors amongst 

each other. The "Info field sensors" value table shows 

these calculated limiting values for the variables V_max, 

V_min. 

Shut-down thresholds 

Speed filter: 

The shut-down threshold defines the tolerable 

speed/position deviation between the two detection 

channels / encoder channels. It may be dependent on 

the arrangement of the sensors and the maximum 

mechanical play (e.g. gearbox and spring rate) between 

the two detection locations. The lowest possible value, at 

which monitoring is not yet triggered in normal operation, 

should be chosen, under due consideration of the 

dynamic processes (e.g. load/play in gearbox). 

Average filter covering the detected speed values of the 

encoder to dampen peak speeds in case of low 

resolution or variance of the connected sensor With the 

filter switched on the specified response time of the 

overall system will increase by the set time. The filter has 

an effect on the speed related parameters of the 

monitoring modules. 


Note: 

- Determining the characteristic of the measuring length as linear or rotational 

generally influences all position and speed inputs in the other input masks of 

the monitoring functions. It generally changes the input from mm, m or mm/s, 

m/s to mgrd, rev or mgrd/s, rev/s or rev/min and vice versa. 

- The specification of max. measuring length and max. speed is mandatory. A 

missing or incorrect entry can cause undesired responding of the monitoring 

functions. 

- In general sensor 1 has the function of a process sensor and sensor 2 acts as 

a reference sensor. For the combination of absolute/incremental sensor the 

absolute system is always used as process sensor. If sensors with different 

resolutions are used, the sensor with the higher resolution should be 

configured as process sensor. 

Sensor 1 or Sensor 2 

These two option and input fields are used to parameterize the sensors. 

The following options and inputs are possible: 

Encoder type 

Selection of function type of sensor: 

None 

No sensor connected 

Incremental 

Incremental encoder 

SIN / COS 

SineCosine encoder Absolute 


Absolute 

Absolute value encoder 

Selecting an absolute value encoder enables further parameters: 

Data format 

SSI binary 

Serial Synchronous Interface in binary encoding 

SSI-GrayCode 

Serial Synchronous Interface in GrayCode encoding 

SSI-WCS 

Way Coding System (Manufacturer Pepperl & Fuchs) 

By choosing this file format the data width is a fixed Offset 

Relative offset in relation to the specified sensor position 

Proxi Switch 1Z 

1-channel incremental counting signal 

Proxi Switch 2Z 90° 

2-channel incremental counting signal with 90-degree phase 

Direction of rotation 

Selection of sensor counting direction 

Resolution 

Encoder resolution referring to the measuring axis in the pre-defined context (linear 

or rotational) 

Note: For position monitoring at least one of the two sensors must be designed as 

absolute encoder. If none of the two sensors is of the "Absolute" type, the position 

input fields in all other input masks of the monitoring function are inactive. 

With the "Incremental" type an impulse multiplication takes place inside the device. 

The resolution of the sensor must always be entered into the "Resolution" field as 

pulses per revolution (PPR) The multiplication depends on the set sensor 

configuration and runs internally automatically. Further information can be found in 

the installation manual. 


Sensor info field 

After successful parameterization an infor field with various selection and result data 

related to the currently used sensors can be displayed by simply clicking on the 

button "Sensor Info Field". 

Axle area 

Column name 

Class-ID 

General flags 

Modes 

Axis CFG ID 

Measuring length 

PosFactor 

FactorSpeed 

MaxSpeed 

Shut-down thresh. 

pos. 

Shut-down thresh. 

speed 

Unit 

Meaning 

Unambiguous ID of axis configuration 

Reserved for internal processing 



Measuring length of position processing 

Internal multiplication factor for position 

Internal multiplication factor for speed 

Maximum standardized speed 

Shut-down threshold value incremental in system units 

Shut-down threshold value speed in system units 


Area sensor 

Column name Meaning 

Class-ID 


General flags Reserved for internal processing 

Modes 


EXT-Modes Reserved for internal processing 

V_Standardization Standardization value for speed 

(internal calculation value) 

PosStandardization Standardization value for position (internal calculation value) 

ShiftvalPos Interger exponent for basis 2. 

Internal calculation value for position standardization. 

ShiftvalSpeed Interger exponent for basis 2. 

Internal calculation value for speed standardization. 

Offset 

Corresponds with the input field Offset in the sensor interface 

Resolution 

Corresponds with the input field Resolution in the sensor 

interface 

FilterTime 


Data width 

Input field for data width in sensor interface 

Cycle time 

Cycle time of the SMX-module 

V_max 

Maximum value for speed in the monitoring dialogs. Defined 

via "Maxium speed encoder dialog" x factor 1.5 

V_MinUsed Internal minimum speed for standardization calculation 

V_min 

Minimum value for speed in the monitoring dialogs. 

Measuring length Defined measuring length. 

Pos_MinUsed 

Pos_min 

Minimum internal position for standardization calculation 

Minimum internal position for parameterization of monitoring 

dialogs 


Note: 

The displayed values serve the purpose of technical support of the encoder 

configuration and are used of the standardization calculation in the SMX-module! 


Determination of the Resolution with Regard to Different 

Characterized Measuring Lengths: 

Rotational measuring length 

i layshaft assembly 

ENCODER 

Motor axis 

Encoder 

i gearbox 

Encoder 


i measuring gearbox 

Reference axis Input values Resolution related to measuring length 

Feed axis Encoder 1: 

(process axis) Resolution Gb 1 

i measuring 

gearbox 


Encoder 2: 

Resolution Gb 2 

i gearbox 


for drive 

Motor axis Encoder 1: 


i measuring 

gearbox 


measuring gear 

i gearbox 


A_Gb1 in 

[steps/rev] 

I_MG 

I_VG 

A_Gb2 in 

[steps/rev] 

I_G 

I_VA 

A_Gb1 in 

[steps/rev] 

I_MG 

I_VG 

D_MR in 

[mm] 

I_G 

I_VA 

Gb 1 I _ MG I _ VG A_ 

Gb1 

Gb 2 I _ G I _ VA A_ 

Gb2 

Gb1 

I _ MG I _ VG A_ 

Gb1 

I _ G I _ VA 


Input example 1 

In a manufacturing device the speed of certain manual processes is to be monitored 

for a safe reduced value, as well as standstill and movement direction. The 

movement to be actively monitored is a rotary movement. The drive works with an 

electric motor with integrated motor feedback system and intermediate gear. 

Selecting the module 

Selecting the encoder type 

No monitoring of positions requested -> Absolute encoders are not required, speed 

detection by means of incremental encoders is quite sufficient. 

Determination of the measuring length 

The axis of rotation of the manufacturing device is selected as reference axis. The 

following parameters are selected: 

Rotational 

Measuring length unknown 

Reference axis is rotational axis => designation = mgrd 

Determination of parameters for Sensor1 

Sensor 1 is directly connected with the output axis of the gearbox = load axis A 

sensor with the data: Pulse generator A/B-track, 5000 pulses/revolution is used. 

The following parameters are selected: 

Encoder type incremental 

Resolution: 

Sensor 1: 




5000 [steps/rev] 

1 

1 


Gb1 

1 1 

5000 

5000; 

Determination of parameters for Sensor2 

The existing motor feedback system is used as sensor 2. The motor is connected to 

the rotational axis of the manufacturing device by means of an intermediate gear. 

The sensor interface is connected to the pulse outPorts of the power converter. The 

sensor data are as follows: Hiperface, 1024 I/rev. According to the data sheet of the 

power converter manufacturer the sine/cosine tracks of the Hiperface encoder are 

output in the fom of pulses -> emulated encoder on the pulse outPort of the power 

converter = pulse generator, A/B-track, 1024 I/rev. The following parameters are 

selected: 


Resolution: 

Gb2 

I _ G I _ VA A_ 

Gb2 

Sensor 2: 


i gearbox 

i layshaft assembly for drive 

1024 350 1 

35840 


350 

1 


Specification of max. speed 

The max. speed of the output axis is derived from the max. motor speed. In rev./s 

related to the load axis and with Nmax = 1500 rev./min it is 

(1500 [rev./min] / 60 [s] ) / 350 = 0, 

Converted to mgrd/s this results in 0.07142 [1/s] * 360 *10³ [mgrd] = 25 714 [mgrd/s] 

Input of max. deviation 

The empirical measurement reveals a maximum difference between both detection 

points of 80 mgrd. A value of 100 mgrd is chosen. 


Linear measuring length 

Ø of drive gear 

Encoder 

Motor axis 


Ø measuring 

gear 

i layshaft 

assembly 

i gearbox 

Encoder 


Reference axis Input values Resolution related to measuring 

length 

Feed axis 

(process axis) 

Sensor1: 


i measuring 

gearbox 



Sensor 2: 


i gearbox 



drive gear 

A_Gb1 in 

[steps/rev] 

I_MG 

I_VG 

D_MR in 

[mm] 

A_Gb2 in 

[steps/rev] 

I_G, 

I_VA, 

D_AR in [mm] 

1000 


Gb1 

D _ MR 

1000 

Gb 2 I _ G I _ VA A_ 

Gb2 

D _ AR 

Motor axis Sensor 1: 


i measuring 

gearbox 



i gearbox 



drive gear 

A_Gb1 in 

[steps/rev] 

I_MG 

I_VG 

D_MR in 

[mm] 

I_G 

I_VA 

D_AR in [mm] 

Gb1 

1000 

I _ MG I _ VG A _ Gb1 

D _ MR 

1000 

I _ G I _ VA 

D _ AR 



On a manufacturing machine access to the working area is to be enabled at certain 

positions of the main feed axis for manual feeding or setup work. The drive remains 

active in this position and is only monitored for standstill. The limits of the working 

stroke are variable and are to be monitored electronically in safety-relevant mode, as 

a replacement of the mechanical safety limit switch. The movement to be actively 

monitored is a linear movement. An absolute encoder is positively connected with 

this main drive axis of the linear length measuring system. The drive works with an 

electric motor with integrated motor feedback system and intermediate gear. The 

output shaft of the intermediate gear is connected with a drive gear 31.83 mm (= 

100 mm circumference). 

Selecting the module 

Selecting the encoder type 

Monitoring of positions is requested -> Absolute encoder required, for the second 

encoder an incremental detection + reference switch is sufficient. 

Determination of the measuring length parameters 

The main axis of the machine is selected as reference axis. The following parameters 

are selected: 

Linear 

Measuring length = 600 mm 

Reference axis is rotational axis => designation = mm 

Determination of parameters for sensor 1 

Sensor 1 is directly connected to the drive axis. A sensor with the data: Absolute 

encoder SSI, 4096 steps/rev. is used. 


Encoder type absolute 

Data format SSI 

Resolution: 

Sensor 1: 




drive gear 


1 

1 

31.83 

1000 


Gb1 

D _ MR 

1000 

31,83 

1 1 

4096 

40960 

Determination of parameters for sensor 2 

The existing motor feedback system is used as sensor 2. The motor is connected 

with the drive gear via an intermediate gearbox. The ratio of the gearbox is 4.51 

times the Ø of the drive gear 31.831 mm. 

The sensor interface is connected to the pulse outPorts of the power converter. The 

sensor data are as follows: Hiperface, 1024 I/rev. According to the data sheet of the 


power converter manufacturer the sine/cosine tracks of the Hiperface encoder are 

output in the fom of pulses -> emulated encoder on the pulse outPort of the power 

converter = pulse generator, A/B-track, 1024 I/rev. 



Resolution: 

Sensor 1: 


i gearbox 


drive gear 


4.51 

1 

31.83 

1000 

Gb 2 I _ G I _ AV A_ 

Gb2 

D _ AR 

1000 

31,83 

4,51 1 1024 

46182; 

Specification of max. speed 

The max. speed of the output axis is derived from the max. motor speed. In rev./s 

related to the load axis and with Nmax = 1500 rev./min it is 

(1500 [rev/min] / 60 [s] ) * 0.012 [m] = 0.3 [m/s] = 300 [mm/s]. 

Input of max. deviation 

The empirical measurement reveals a maximum difference on


The Sensor Info Field shows the following result entries: 

These can be switched to the second axis by cloicking on the "Axis Change" button. 


Safety Modules 

The monitoring functions are calculated within the cycle time of the SMX-system and 

deliver a 1-bit result at the outPort. The result can be interconnected with logic 

operators, all the way to an outPort. 

Example for a logic linkage of monitoring functions. 

Axis: 1 

Axis: 1 

Axis: 1 


SEL (Safe Emergency Limit) 

Monitoring of the maximum movement range 

Number: 2 

Access-ID: 

Axis assignment: 

Function: 

InPort: 

RESET-function: 

Identification of function element 

maximum 1 function per axis 

Monitoring of the permissible speed related to the relative 

distance to the maximum limit of the movement or adjustment 

range. This function replaces the conventional safety limit 

switches! 

Standardized position sigbnal X from the encoder interface 

The violation of the permissible monitoring range is saved and 

requires a RESET acknowledgement. This occurs alternatively via: 

• RESET function in the group of inPort elements 

• Function key on the front side of a basic module 

Description of function: 

Calculation of actual speed V using position signal X 

Determination of the stopping distance related to the current status of 

acceleration and speed 

=> Cyclic determination of the Stop_Distanz Akt. = f (V, a) with a = acceleration 

Comparison: Pos Akt. + Stop_Distanz Akt. < Ziel_Pos + Overtravel 

A trapezoidal or S-shaped speed profile serves as basis for the calculation. For a 

trapezoidal speed profile the limit curve is the result of the parameterized 

acceleration, whereas an S-shaped speed profile additionally uses the change in 

acceleration for the calculation. 

Trapezoidal speed profile: 

V 

V0 

BX 

BX 

X1 

X2 

X 

X1 = Min. position 

X2 = Max. position 

V0 = Maximum speed for ( X1 + BX ) < X < ( X2 – BX ) 

F= Type of speed profile (trapezoidal or S-shaped) 


Trapezoidal 

BX = Braking/approaching range 

S-shaped 

AM= Maximum acceleration 

DA = Type of acceleration 

S-shaped speed profile 

Position course 

Speed 

Acceleration with 

da/dt = const 

Actual speed 

at time T 

= Stopping distance 

related to the actual 

speed at time T 

T Aktuell 



Range 

X < X1 

X > X2 

X >= X1 

X = (X2 – BX) 

X = X1 

X = Limit curve 

X >= (X2 – BX) 

X = Limit curve 

OR 

AND 

AND 

AND 

AND 

AND 

AND 

AND 

AND 

HI LO 

X 

X 

X 

X 

X 

Limit curve = Speed profile derived from the actual parameterization 

Parameters: 

Activate permanently 

The monitoring function is permanently active and has no inPort connector. 


Lower limit position X1 

Lower limit position 

Upper limit position X2 

Upper limit position 

Curve type linear 

Linear calculation method for the stopping distance with respect to the limit position 

Curve type = linear 

Curve type S-shaped 

Square calculation method for the stopping distance with respect to the limit position 

Curve type = square 

Max. acceleration 

Max. acceleration value within BX 

Max. change in acceleration 

Max. value of acceleration change within BX 











1. Limit position 

The reference zero point of the main drive axis is located in the top dead centre The 

mechanical trailing distance subordinate is = X1 = -5mm. 

The lower end position is at 600mm + 5 mm safety limit. 

=> X2 = 605mm 

2. Form of speed selection 

The drive/position controller uses a ramp limitation (jolt limitation) for the acceleration 

with resultant S-slip of the speed, in order to minimize deviations and processing 

marks => Select S-form option 

3. Limit value selection 

All other limit values are taken from the machine parameterization. 

Maximum acceleration = 1000 mm/s² 

Maximum change of acceleration = 3000 mm/s³ 


SLP = (Safe Limited Position) 

GOTO monitoring 

Number: 2 

Access-ID: 


Function: 

InPort: 




Monitoring of the permissible speed related to the relative 

distance to a parameterized Teach-In recorded target position. 

Standardized position sigbnal X from the encoder interface 


requires a RESET acknowledgement. This occurs alternatively 

via: 




Calculation of actual speed V using position signal X 

Determination of the stopping distance related to the current status of 

acceleration and speed 

=> Cyclic determination of the Stop_Distanz Akt. = f (V, a) with a = acceleration 

Comparison: Pos Akt. + Stop_Distanz Akt. < Ziel_Pos + Overtravel 


Parameters: 

Target position 

Absolute position value of target position 


Linear calculation method for the stopping distance with respect to the target position 


Square calculation method for the stopping distance with respect to the target 

position 


Max. acceleration value within BX 

Max. change in acceleration 

Max. value of acceleration change within BX 

Recording the target position using Teach-In 

The "Teach-In" option can be used to have the target position recorded by the SMXsystem 

without the need of manual subsequent parameterization. This requires the 

following steps: 


Activating the switch "Teach-In" changes the input field "Target position" to 

"Position tolerance". At same time the input dialog increases by the SOSfunctionality. 

Recording a position using the "Teach-In" option can only take place at 

standstill and with the SOS-function activated. 

Recording a position requires the two signals "SET" and "QUIT". These 

appear when activating the TEACH-IN option as inPort connector of the 

functional module. 

The QuUIT signal can only be directly connected with an inPort module 

Time characteristic of the SET/QUIT process: 

QUIT 

SET 

SOS_Enable 

Take-over 

Übernahme 

position 

Position 

Save position 

Position 

speichern 

k k+1 k+2 k+3 k+4 

Verarbeitungszyklen 

Processing cycles 

The sequence is time monitored and triggers an ALARM if the expectations 

are exceeded. 

The maximum time slot is 3 seconds ! 

Position tolerance 

Tolerance window of the accepted Teach-In value 

Note: 

When using the Teach-In function, the monitoring threshold is extended 

by the value of the position tolerance. Without the Teach-In functionality 

the value of the position tolerance is zero. 

Parameters of the SOS-dialog: 

See SOS-function 


SCA (Safe Cam) 

Monitoring of position range with rotational speed/speed monitoring 

Number: 16 

Access-ID: 

Axis allocation: 

Function: 

InPort: 



any 

Monitoring of a parameterizable position range with allocated 

minimum and maximum limits. Additional monitoring of the 

maximum rotational speed/speed in the permissible range. 

Standardized position and speed signal X and V from encoder 

interface 

Violation of the permissible monitoring range is not saved. No 

RESET acknowledgement required. 


Comparison of actual position with the parameterized range limits 

Comparison of actual speed with the parameterized range limit 

Comparison of actual acceleration with the parameterized range limit 

Monitoring of the position limits using a ramp function 

Direction dependent release 

Permanent activation of the module 

V 

V0 

X1 

X2 

X 


Range HI LO 

X < X1 OR X 

X > X2 

X >= X1 AND 

X = X1 AND 

X = V0 


Ranges can be defined as overlapping and nested. 

Parameters: 

Control button for basic settings 



Lower limit position X1 

Lower limit position 

Upper limit position X2 

Upper limit position 


Speed threshold 

Maximum permissible speed in the parameterized position range 


Maximum permissible acceleration in the parameterized position range 

Extended monitoring 

Direction dependent release 

Enables the activation of downstream functional modules in dependence on the 

direction. This functionality can only be utilized without speed and acceleration 

monitoring. 

Position signal rising: 

Functional module delivers the output value = "1" for a rising position signal 


Position signal falling: 

Functional module delivers the output value = "0" for a falling position signal 

Activation speed direction release 

The evaluation of the direction dependent release only takes place from the specified 

limit. Below this speed threshold the output value is = 0; 

Travel curve monitoring 

Monitoring of speed at the limits using the monitoring characteristics parameterized in 

SEL or SLP.This switch can only be activated with the SLP or SEL function block 

inserted. 

Fault distance monitoring 

This additional functionality enables filtering of peak speeds in case of irregular travel 

operation (speed peaks in signal). 

Further information see SLS-function. 

Attention: 

When using this function, the response behaviour of the application will change. In 

this case strictly follow the explanations in the installation manual. 

Input example: 







this main drive axis of the linear length measuring system. The main axis serves as 

reference axis for the SMX-module. 

1. Selecting the range 

Position monitoring is to be used to monitor the position of the main axis in top zero 

position. Top zero position also serves as reference zero position in the length 

measurement of the feed axis. If the range is recognized, a protective device is 

released for opening. 

Range limit X1 = top position = 0mm 

Range limit X2 = lower tolerance limit for position = 2 mm 

Speed = tolerated speed to maintain position= 3 mm/s 

Acceleration = tolerated acceleration to maintain position= 5 mm/s 


SSX (Safe Stop 1/ Safe Stop 2) 

Function monitoring for emergency stop 

Number: 4 

Access-ID: 


Function: 

InPort: 



any 

Monitoring of an EMERGENCY STOP function 

Standardized position signal X from the encoder interface 



via: 




Monitoring the sequence of a controlled EMERGENCY STOP by comparing the 

speed drop with a parameterizable monitoring curve over the course of time. The 

monitoring curve is a result of latency, max. speed distance to the limit curve, as well 

as their characteristic, calculated on the basis of acceleration and acceleration 

change. After activating the monitoring function, the course of the limit curve is 

calculated on the basis of the current speed. 

V 

V0 

BX 

BX 

X1 

X2 

Trapezoidal course of speed 

X 


Expected course of speed 

Monitoring limit curve 

speed detected when 

activating the function 

adapted monitoring 

limit curve 

Monitoring limit curves with S-shaped course of speed 


Range HI LO 

T < T Latency 

X 

T > T Latency AND X 

V < V Limit curve 

T > T Latency AND X 

V > V Limit curve 

Each function block can be parameterized to stop category 1 or 2. In stop category 2 

the SOS-function is automatically activated after the expected standstill. 

Reset characteristic: 

The violation of the permissible monitoring range is saved and requires a RESET 

functionality. This occurs alternatively via: 

"Alarm Reset" module 

Function key on the front side of a basic module 


Parameters: 

Stop category 1 

This option realizes monitoring of the controlled EMERGENCY STOP acc. to EN 

60604. According to the normative definition the energy supply should here be 

disconnected after the drive has come to a halt. This is supported by a transition of 

the SSX-function output value from "1" to "0". 

Stop category 2 (SOS after expected standstill) 

This option realizes monitoring of the controlled EMERGENCY STOP acc. to EN 

60604. After the ramp monitoring has expired, the drive is stopped without 

disconnection from the energy supply (Safe Operational Stop = Standstill). For this 

reason the output value remains art "1" after the SSX-limit curve has expired. 

If no SOS-module has yet been defined in the logic diagram, the SSX-dialog is 

extended by this function. All parameters required for the SOS-function, can thus be 

entered immediately. If an SOS-element is inserted into the logic diagram at a later 

date, the dialog in the SSX-mask is omitted. 


Note: 

If the SSX-function is used in connection with SOS, the following circuitry must be 

used. If standstill is detected, the operating system will automatically activate the 

SOS-monitoring. 

Axis: 1 

Axis: 1 


Linear curve for the stop sequence 

Actual speed 

Curve form = constant 

Monitoring limit 

curve 

Latency 


* determined on basis of actual speed and configured 

acceleration 



Square monitoring curve for the stop sequence 

Curve form = square 

Actual speed 

Monitoring limit 

curve 

Latency 


* determined on basis of actual speed and configured 

acceleration 

Standard latency 

Latency until the occurrence of active deceleration 

Max. speed (speed threshold) 

Relative speed over the calculated limit curve. 


Default acceleration value to calculate the limit curve. 

Max. acceleration change 

Default acceleration change value to calculate the limit curve. 

Axis assignment 

Input of axis assignment. 










1. Selecting the stop category 

In order to keep times of standstill and restart as short as possible, the stop category 

2 acc. to DIN 60604-1 (controlled stop with drive subsequently actively controlled to 

V=0) is to be used => Selection stop category 2 


2. Form of speed selection 

The drive/position controller uses a ramp limitation (jolt limitation) for the acceleration 

with resultant S-slip of the speed, in order to minimize deviations and processing 

marks => Select S-slip option 

3. Limit value selection 

For the purpose of monitoring one must enter the worst-case latency starting with the 

occurrence of the Emergency Stop event, until the start of the braking process, which 

is executed with the standard control. The program sequence time of the standard 

control results in: Latency = cycle time*2 = 50 ms 

All other limit values are taken from the machine parameterization. 

Maximum feed speed = 300 mm/s² 

Maximum acceleration = 1000 mm/s² 

Maximum change of acceleration = 3000 mm/s³ 

SLI (Safe Limited Increment) 

Monitoring of the max. step measurement 

Number: 2 

Access-ID: 


Function: 

InPort: 




Monitoring of the max. permitted step measurement 

Standardized position / speed signal V and X from encoder 

interface. Direction indication LEFT/RIGHT 


requires a RESET acknowledgement. This occurs alternatively via: 




Monitoring of the max. permitted step measurement = relative travel range for 

uninterrupted travelling in jog mode. 

Calculation of the current sense of rotation RX on basis of position / speed 

signal X 

Determination of the relative travel after the start of the movement. 

Monitoring for compliance with the predetermined direction and the max. 

relative travel 



Range HI LO 

V < 0 

AND 

DIRECTIONMARKER = LEFT AND X 

relative travel < max. step measurement 

V >= 0 

AND 

DIRECTION MARKER = RIGHT AND X 

relative travel < max. step measurement 

V < 0 

AND 

(DIRECTION MARKER = RIGHT OR X 

relative travel > max. step measurement 

V > 0 

AND 

(DIRECTIONMARKER = LEFT OR AND X 

relative travel > max. step measurement 

Parameters: 

Step measurement 

Maximum relative travel after activating the monitoring function 

XI threshold 

Tolerance threshold for monitoring the travel in opposite direction 




Activation example: 

Axis: 1 


The max. travel in the material feed system of a manufacturing facility is to be safely 

monitored in jog mode. According to the risk analysis this travel is max. 50 mm. A 

faulty travel in opposite direction is to be monitored. 

1. Step measurement 

The relative travel (only incremental encoder present) is monitored => input of the 

max. permissible travel acc. to risk analysis with tolerance = 55 mm 

2. Travel direction monitoring 

Tolerable travel in opposite direction (=creeping motion of drive) = 1 mm/s 

3. Monitoring inPort 

The monitoring module has two inPorts to specify the direction. An active direction 

signal activates the monitoring function. 

Note: 

Both input signals "1" are detected as non-permitted condition, causing an alarm 

message. 


SDI (Safe Direction Indication) 

Direction detection 

Number: 2 

Access-ID: 


Function: 

InPort: 




Monitoring the pre-defined sense of rotation / direction of 

movement 

Standardized position / speed signal X from encoder interface. 

Direction marker LEFT/RIGHT 



via: 





Range HI LO 

V < 0 

AND 

DIRECTIONMARKER = LEFT 

X 

V >= 0 

AND 

DIRECTION MARKER = RIGHT X 

V < 0 

AND 

DIRECTION MARKER = RIGHT 

X 

V > 0 

AND 

DIRECTIONMARKER = LEFT 

X 


Parameters: 

Maximum 

Tolerance threshold for position or speed in opposite direction 



Activation example: 

Axis: 1 







1. InPort for monitoring function 

Monitoring of speed (only incremental encoder present) 

=> Speed 

2. Speed monitoring 

Tolerable speed in opposite direction (=Creeping of 

drive) from machine parameter = 1 mm/s 

Monitoring inPort 

The monitoring module has two inPorts to specify the direction. An active direction 

signal activates the monitoring function. 

Note: 

Both input signals "1" are detected as non-permitted condition, causing an alarm 

message. 

SLS (Safe Limited Speed) 

Monitoring of a minimum speed 

Number: 8 

Access-ID: 


Function: 

InPort: 



any 

Monitoring of a minimum speed 

Standardized position signal X from the encoder interface 



via: 




Monitoring the maximum speed or rotational speed of a drive. 

Calculation of the current speed V on basis of position or digital speed signal X 

Comparison of the actual speed with the parameterized speed threshold 

Monitoring of a speed transition from fast to slow. 


V 


V0 

X 


Range HI LO 

V < V0 X 

V >= V0 

X 


Parameters: 



Speed tolerance switch 

To activate speed monitoring 

Use fast channel 

The "Fast Channel" option can be used to achieve a shorter response time of the 

system. The two semi-conductor outPorts can alternatively be chosen in combination 

as shut-down channel. 

Attention: Response time see installation manual ! 


Specification of maximum speed, alternatively max. rotational speed. 


Specification of the max. acceleration 


Ramp monitoring 

This option monitors the transition of speed from fast to slow by using an SSXfunctionality. 

The selected SSX-element must be available in the logic diagram. 

Fault distance monitoring 

This additional functionality enables filtering of peak speeds in case of irregular travel 

operation (speed peaks in signal). 

The path integer is calculated on basis of the difference between the current speed 

and the parameterized speed monitoring value and compared with the entered value. 

If the entered value is exceeded the monitoring function is triggered. 

The function can only be activated if the acceleration monitoring function is switched 

off. 


Example of fault distance monitoring: 

The graph shows an example for fault distance monitoring. A drive exceeds the 

threshold "vlimit", which is parameterized in the SLS-function. By exceeding this 

value, the speed above the threshold is integrated (= akku_norm). If the current 

speed drops below the threshold, the integer will also decrease down below the 

limitation. During the continuing process the speed will rise again and remain above 

the parameterized threshold. As a consequence the integer will also increase again, 

triggering an alarm when it exceeds the fault distance (= integrated speed 

proportion). The course of the fault integrator can be visualized with the SCOPEfunction. 

v 

vlimit 

overspeed_distance 

t 

akku_norm 

Alarm 

t 

Attention: 

When using this function, the response behaviour of the application will change. In 

this case strictly follow the explanations in the installation manual. 

Input examples: 






The safely reduced speed in manual mode is to be monitored => speed monitoring 

active with max. value from machine parameter = 50 

2. Acceleration monitoring 

The safely reduced acceleration in manual mode is to be monitored => acceleration 

monitoring active with max. value from machine parameter = 100 


3. Ramp monitoring 

Speed monitoring and ramp monitoring acc. to SSX must be activated. In this case 

the SSX used must already be inserted or configured in the project. The transition 

from a fast to a slower (= parameter max. speed) speed can now be monitored (see 

graph). 

Expected course of speed 

Monitoring limit curve 

Latency 

When activating the SLS, the parameterized SSX is automatically activated via the 

SLS. The SSX monitors the ramp course of the speed. If the actual speed is lower 

than the SLS threshold, the SLS will take over the further monitoring, until the SLS is 

deactivated again. 

The ramp course can be diagnosed with the SCOPE monitor as a diagnostic 

function. 

Notes: 

• If the SSX used is activated during "SLS ramp monitoring" (i.e. normal 

EMERGENCY STOP function via SSX-enable), the parameterized SSXconnection 

is always prioritized. 

• The SSX-function is always activated by the SLS, if the current speed is 

higher than the SLS-threshold. 

• The SLS threshold must be higher than 0! 

• If the calculated speed profile is exceeded when changing the speed from 

fast to slow, this is saved in both monitoring functions SLS and SSX. 

• If several SLS-functions with ramp monitoring are activated, the lowest 

parameterized SLS-threshold value is used as threshold value for the SSXramp. 


SOS (Safe Operating Stop) 

Standstill monitoring 

Number: 2 

Access-ID: 


Function: 

InPort: 




Standstill monitoring 

Standardized position / speed signal V and X from encoder 

interface. 



via: 



Standstill monitoring of drive at the current position with drive enabled and 

possibly activated position controller. 

Calculation of the current speed V on basis of position or digital speed signal X 

Comparison of the actual speed with the parameterized monitoring slot 

V 

-DX 

X0 

DX 

X 


Range 

X > ( X0 – DX ) AND 

X < ( X0 + DX ) 

X = (X0 + DX ) 

HI LO 

X 

X 

X 


Type of monitoring 

Determination of the monitoring type for standstill to a minimum speed threshold or a 

position slot 

Maximum 

Minimum speed or a permissible relative deviation from the actual position at the time 

when the SOS-functionality is activated. 

Use fast channel 

The "Fast Channel" option can be used to achieve a shorter response time of the 

system. The two semi-conductor outPorts can alternatively be chosen in combination 

as shut-down channel. 

Attention: Response time see installation manual ! 

Acceleration monitoring 

Optional maximum value for acceleration monitoring during an active SOS-function. 







1. Selecting the type 

Only the speed is monitored (e.g. by means of incremental encoder) => speed 

monitoring 


Specification of the tolerable speed monitoring value 










1. Selecting the type 

The position is monitored (absolute encoder available) => position monitoring 

2. Position monitoring 

Specification of the tolerable position monitoring value 


SAC (Safe Analog Control) 

Monitoring of an analog input signal 

Number: 8 

Access-ID: 


Function: 

InPort: 



none 

Monitoring of an analog threshold value 

Standardized input signals Uin1 and Uin2 



via: 



Umax 

Umin 

Uin 


Range HI LO 

Uin > Umin 

X 

Uin < Umax X 

Uin = Umax 

X 


Parameters: 



Lower limit 

Minimum value - threshold 

Upper limit 

Maximum value - threshold 

Hysteresis 

Hysteresis for threshold values 

Source 

Adjustable analog signal source 

Analog signal 1 

Ain1 is made up of input signals fro sensor1 and sensor2 of the interface. 

Analog signal 2 

Ain2 is made up of input signals fro sensor3 and sensor4 of the interface. 

Filtered values of analog signals Ain1 and Ain2 

Add Ain1 and Ain2 


Attention: 

When using filter functions the response times specified in the installation manual 

must be taken into account ! 

PDM (Position Deviation Muting) 

Temporal hiding of the 2-channel sensor evaluation in case of encoder position 

deviation or an encoder "RESET" 

Number: 2 

Access-ID: 


Function: 



Hiding (muting) the encoder diagnostics 

Note: 

This function may have a considerable effect on the safety of an 

application. One must make absolutely sure that the use of the PDMfunction 

will not cause any situations that may adversely affect safety! 


• Automatic activation in case of an alarm 

Switching off the encoder diagnostics for an existing A3303/A3304 

Autom. adjustment of encoder data (in case of Incr./SSI Configr.) 

The encoder diagnostics is suppressed over the parameterized activation 

period 


InPort: 

The PDM-function should be activated by means of a safety directed button or a 

similar facility. 

In normal condition the activation signal for the PDM-function is "1". The inPort is 

time monitored and needs to execute an edge change from "1" to "0" and from "0" to 

"1" within two seconds. Only then is the PDM-function available. 

Making behaviour 

InPort 

Output 

Activation period 

OutPort 

In deactivated condition this function sends the result "0" and in activated condition a 

"1" to the process image. 

Parameters: 

Automatic activation in case of alarm A3303/A3304 

Suppression of the plausibility test for speed and position over the duration of the 

activation time from a fault A3303/A3304. 


Application example: e.g. lifting platform with 2 encoder systems 

A lifting platform is equipped with two drive systems and assigned encoder systems 

(both SSI-encoders). The encoders are connected with the SMX-module and monitor 

the horizontal position of the platform. If the platforms drifts to a slanted position 

(position deviation of encoders) the alarm triggered by this condition can not be reset. 

By activating this PDM-function the user is able to bring the platform back to 

horizontal position. 

Notes: 

• Perhaps a speed fault (A3301/A3302) is first detected in case of an 

encoder deviation. After resetting the fault with the drive at standstill the 

position deviation fault A3303/A3304 is then displayed. 

• When activating this function the encoder monitoring is switched off for the 

configured period of time. In this case the user must ensure that the moved 

drive does not pose any danger to persons or property. 

Automatic adjustment of encoder data 

Suppression of the plausibility test for speed and position over the duration of the 

activation time without any further pre-conditions. 

Application example: Compensation of position drifting in a friction wheel application 

A drive system is equipped with a position encoder with friction wheel drive. After 

several operation cycles a difference in form of an incremental feedback occurs 

between absolute encoder and second channel. The absolute encoder needs to be 

reset at a defined position, but the drive system is to remain active (= RUN) during 

that time. Resetting the encoder during operation would possibly result in high speed 

or acceleration values, which would cause a shut-down, even though the drive is 

already at rest at the time of the encoder preset. 

Notes: 

• The user needs to ensure that the drive is at standstill when the encoder is 

preset. 

• In a "Preset" the encoder can only be set to a value range 0 < x < measuring 

length! 

Activation period 

Time in milli-seconds after which the suppression is automatically removed. 

Input range: 100ms … 25s 

Note: Once the monitoring function can be temporarily deactivated with the 

help of this function, particular attention must be paid when it is used! 

PDM-representation in the terminal diagram 


ECS (Encoder Supervisor) 

User defined evaluation of encoder status. 

Number: 2 

Access-ID: 


Function: 




Evaluation of the encoder status using the PLC-function 

no RESET required 

Note: 

This function may have a considerable effect on the safety of an 

application. One must make absolutely sure that the use of the ECSfunction 

will not cause any situations that may adversely affect safety! 


The detection of safe speed and position is based on a multitude of measures and 

various fault reactions in the form of alarm messages. Without the use of an ECS– 

element the operating system will switch the SMX-system to status RUN ALARM 

when a speed/position fault is detected. All outPorts will be blocked immediately. 

Inserting an ECS-element into the logic diagram suppresses this state change and 

the operating system remains in RUN condition. The PLC-program now needs to use 

the status of the ECS-element to trigger the required measures to avoid dangerous 

conditions in the application. Alarm messages of the encoder interface with identical 

reference number are identified with the prefix "E". 


Example for the use of the ECS-function: 

Enable 

emergenc 

y travel 

Drive 

Encoder 

monitorin 

g 

Axis: 1 


I/O Module Extension SMX31 

Equipment selection 

In the Compact series SMX a basic module can be combined with up to two I/Oextensions. 

This is only possible when opening a new equipment diagram. This 

option is used to extend the available inPort/outPorts. 

Management of additional inPorts/outPorts 

Each SMX31 extends the number of available I/Os as follows: 

12 digital inPorts 

2 auxiliary outPorts 

10 I/O that can be configured as inPorts or outPorts 

Note: 

I/Os can only be used as inPort or outPort once and have a common terminal 

to the outside! 

Selection of inPorts and outPorts 

By using an SMX31 module you increase the number of available inPort/outPort 

elements. 


Identification of inPorts: 

E0.1 .. E0.14 Digital inPort basic unit 

E1.1 .. E1.12 Digital inPort SMX31 – unit 1 

EAE1.1 .. EAE1.10 Digital SMX31 I/O used as inPort – unit 1 

E2.1 .. E2.12 Digital inPort SMX31 – unit 2 

EAE2.1 .. EAE2.10 Digital SMX31 I/O used as inPort – unit 2 

Identification of outPorts: 

A0.1 .. A.0.2 Digital standard outPort basic unit 

A1.1 .. A1.2 Digital standard outPort SMX31 – unit 1 

A2.1 .. A2.2 Digital standard outport SMX31 – unit 2 

EAA1.1 .. EAA1.10 Digital SMX31 I/O used as outPort – unit 1 

EAA2.1 .. EAA2.10 Digital SMX31 I/O used as outPort – unit 2 

AK01 .. AK0.2 Relay outPort basic unit 

AD0.0_P .. AD0.1_M Digital HI/LO outPort basic unit 

Input of Logic Address for Communication 

The allocation of addresses to the physical unit in the logic diagram takes place via 

the logic address. This is entered in the multiple equipment configuration dialog. 

The dialog is invoked by double-clicking on the signal list (blue selected in the 

illustration). 


The following dialog appears 

Parameters 

Logic address SMX31 unit 1 or 2 

Input of logic address for extension unit 1 or 2. This address must correspond with 

the address deposited in the module. 

OutPorts group 1 or 2 

The digital I/O outPorts of the module SMX31 can either be used as standard or as 

safety outPorts. 

Note: 

The term safety outPort in any case refers to the classification as a safe 

function for application up to Pl e acc. to EN ISO 13849-1 or SIL3 acc. to EN 

61508. Follow the explanations in the installation manual for classifying the 

outPorts. 

Standard outPorts are not permitted for safety related duties and can only be 

used for functional tasks. The EMU-function is not available for standard 

outPorts. 


Appendix Process Image 

Introduction 

The SMX-system is able to execute interpreter code saved in the module with PLCfunctionality 

in real-time. 

With an external, not safety related PLC-editor ( SafePLC) a program can be created 

in function block representation as specified in IEC 61131, compiled and saved in the 

format SMXAWL . The same program adds the SMXAWL - instructions to the 

configuration data and transmits the data to the module SMX10/11/12/12A. 

PLC – Editor ( SafePLC ) 

External PC, 

operating system 

Windows XP 

SMX AWL 


Interpreter System A 

Interpreter System B 

Evidence of the correct assignment of inPorts and outPorts must be provided by the 

user within the scope of a safety documentation (validation report). 


The SMX AWL-CODE is executed by both systems in each cycle. For this purpose 

the input variables used in the program are linked in compliance with the interpreter 

code. The result of the interpreter run is obtained by: 

setting/deleting one or several variables in the initial process image 

enabling/disabling monitoring functions 

setting/deleting outPorts 

setting/deleting markers 

starting and stopping timers 

The AWL-code generated by the compiler must be verified within the validation 

process. Exceptions are the so-called MACRO-functions, which are internally 2- 

channel tested by the SMX-system. In the MACRO-function only the connection of 

inPorts must be verified. MACRO-functions refer e.g. to two-hand operation. 

Description of Function Elements 

The following description is required for executing the application validation. 

PLC – Commands 

The following list contains all commands used within the SMX-system: 

Operator Operand Description 

LD 

all inPort and outPort Equates current result with operand 

operands 

LD NOT all inPort and outPort 

operands 

Equates current result with operand and 

inverts the operand 

ST only outPort operands Saves current result to operand address 

AND 

all inPort and outPort Boolean AND 

operands 

AND NOT all inPort and outPort Negated Boolean AND 

operands 

OR 

all inPort and outPort Boolean OR 

operands 

OR NOT all inPort and outPort Negated Boolean OR 

operands 

XOR 

all inPort and outPort Boolean Exclusive OR 

operands 

NOT 

all inPort and outPort Inverts the accumulator value 

operands 

SET MARKER PLC_MARKER in output Sets marker 

image 

RESET PLC_MARKER in output Resets marker 

MARKER image 

SET 

all inPort and outPort Sets operand to 1 

operands 

RESET all inPort and outPort 

operands 

Sets operand to 0 


MACRO_INFO Description of macro 

element 

MACRO_CRC CRC the previous macro 

field 

Operand field: 

2 byte for macro identification 

Operand field: 

1. Operand: 

CRC_LO ( 8 Bit ) 

2. Operand: 

CRC_HI ( 8 Bit ) 

INFO Info field Operand field: 

1. Operand: 

reserved free ! 

2. Operand: 


Designation of safety functions 

The designation of safety functions are as follows: 

Function 

Function name acc. to EN 61800–5–2 or SMX - designation 

SLS Safe Limited Speed 

SOS Safe Operational Stop 

SDI Safe Direction Indication 

SSX Safe Stop 1 or 2 

SLI Safe Limited Increment 

SCA Safe Cam 

SEL Safe Emergency Limit 

SLP Safe Limited Position 

SEC Safe external circuit 

PDM Position Deviation Muting ( SMX-function ) 

ECS Encoder Monitoring Status ( SMX-function ) 


Input variables in logic diagram 

Note: 

The output values of the monitoring functions must be considered as 

inputs in the process image! 

Index PAE-variable Bit Pos. Bit-variable Description 

1 Config_ID 0x3001 fixed 

2 DriveBASE 0 

1 

2 

3 

4 

5 

0 .. 2 always "1" 

3 Reset monitoring functions 

4 ECS result axis 1 

5 ECS result axis 2 

3 DriveSLI 0 SLI.0 

Results SLI 

1 SLI.1 

4 EA2_In8 0 .. 7 EA2.1 .. EA2.8 Extension inPorts 

5 DriveEMU 0 EMU.1 

Results EMU 

1 EMU.2 

6 DriveSCA 0 .. 7 SCA.1 .. SCA.8 Results SCA 

0 .. 7 

7 DriveSSX 0 

1 

2 

3 

8 DriveSOS 0 

1 

9 DriveSLP 0 

1 

10 DriveSEL 0 

1 

SCA.9 .. SCA.16 

SSX.1 

SSX.2 

SSX.3 

SSX.4 

Results SSX 

SOS.1 

Results SOS 

SOS.2 

SLP.1 

Results SLP 

SLP.2 

SEL.1 

Results SEL 

SEL.2 

11 DriveSLS 0 .. 7 SLS.1 .. SLS.8 Results SLS 

12 DriveSDI 0 SDI.1 

Results SDI 

1 SDI.2 

13 DriveSAC 0 .. 7 SAC.1 .. SAC.8 Results SAC 

14 DriveSF 0 PDM_EN.1 Results PDM 

1 PDM_EN.2 

15 DI8 0 .. 7 E0.1 .. E0.8 Hardware inPorts basic group 1 .. 

8 

16 DI16 0 .. 7 E0.9 .. E0.16 Hardware inPorts basic group 9 .. 

16 

17 DI24 0 .. 7 E1.1 .. E1.8 Hardware inPorts SMX31 

Extension with log. address 1 

inPorts 1 – 8 

18 DI32 0 .. 7 E1.9 .. E1.12 Hardware inPorts SMX31 

Extension with log. address 1 

inPorts 9 – 12 and extension with 

log. address 2 inPorts 9 - 12 

19 PLCTimer16 0 .. 7 PLCT.9 .. PLCT.16 Results PLC Timer 

20 Reserve1 Reserve 

21 StartTimer 0 .. 1 

2 .. 3 

4 .. 5 

6 .. 7 

MET.1 

MET.2 

MET.3 

MET.4 

OutPort start element with time 


22 Outp2HandTimer 0 MEZ.1 OutPort two-hand with time 

23 Start element 0 MES.1 OutPort starts element 

24 Start-up Test 0 MEA.1 

OutPort start-up test 

1 MEA.2 

25 PLC Timer 0 .. 7 PLCT.1 .. PLCT.8 Results PLC_Timer 

26 DriveTTS 0 

1 

2 

3 

EAE2.7 

EAE2.8 

EAE2.9 

EAE2.10 

27 AIn1 Analog inPort 1 




31 SysACC Axis1 SysAcc[0] current system acceleration axis 1 

32 SysACC Axis2 SysAcc[1] current system acceleration axis 2 

33 Limit20Axis1 Limit20[0] Limit for GOTO monitoring axis 1 

34 Limit20Axcis2 Limit20[1] Limit for GOTO monitoring axis 2 

35 Pos20Axis1 Position20[0] Current position axis 1 

36 Pos20Axis2 Position20[1] Current position axis 2 

37 BG20Axis1 BG20[0] Range limit axis 1 

38 BG20Axis2 BG20[1] Range limit axis 2 

39 StopDistAxis1 StopDistanz20[0] Current stop distance axis 1 

40 StopDistAxis2 StopDistanz20[1] Current stop distance axis 2 

41 SysSpeed Axis1 SysSpeed[0] Current speed axis 1 

42 SysSpeed Axis2 SysSpeed[1] Current speed axis 2 

43 AnalogAdder Analog adder 

44 EA_IN8 0 .. 7 EAE1.1 .. EAE1.8 Extension inPorts SMX31 with log. 

address 1 

45 EA_IN16 0 .. 7 EAE1.9 .. EAE1.10 

EAE2.1 .. EAE2.6 

46 Start element Timer2 0 

1 

2 

3 

47 EMU 31 1 1 0 

1 

2 

3 

4 

5 

6 

7 

48 EMU 31 1 1 0 

1 

49 EMU 31 1 2 0 

1 

2 

3 

4 

5 

6 

7 

MET.5 

MET.6 

MET.7 

MET.8 

EMU31_1.1 

EMU31_1.2 

EMU31_1.3 

EMU31_1.4 

EMU31_1.5 

EMU31_1.6 

EMU31_1.7 

EMU31_1.8 

EMU31_1.9 

EMU31_1.10 

EMU31_2.1 

EMU31_2.2 

EMU31_2.3 

EMU31_2.4 

EMU31_2.5 

EMU31_2.6 

EMU31_2.7 

EMU31_2.8 

Log. address 1 




OutPort start element with time 

EMU results SMX31 with log. 

address 1 


address 1 


address 2 


50 EMU 31 1 2 0 

1 

EMU31_2.9 

EMU31_2.10 


address 2 

51 Reserve3 PAE Reserve 

52 Reserve Reserve 

53 Reserve Reserve 

54 Reserve 2_0 PAE Reserve 







PLC Processing 

PLC - Syntax 

The PLC-program is CRC-protected and part of the SMX configuration data. Each 

PLC-command is identically structured as follows: 

Syntax of list entry: 

Size of list entry = 4 byte 

Byte index 0 1 2 3 

Assignment PLC – 

Byte-Address Bit-Address Downcount 

Command Operand 

0..255 

Comment: 

Downcount = (number of AWL-commands) – (line number of list entries - 1) 

At 256 the counter jumps back to 0. 


PLC – Commands 

Operator Operand OPCODE Description 

LD 

all inPort and 

outPort operands 

02 Equates current result with 

operand 

LD NOT all inPort and 


04 Equates current result with 

operand and inverts the operand 

ST 

only outPort 

operands 

06 Saves current result to operand 

address 

AND 

all inPort and 08 Boolean AND 


AND NOT all inPort and 10 Negated Boolean AND 


OR 

all inPort and 12 Boolean OR 


OR NOT all inPort and 14 Negated Boolean OR 


XOR 

all inPort and 16 Boolean Exclusive OR 


NOT 

all inPort and 18 Inverts the accumulator value 


SET MARKER PLC_MARKER in 20 Sets marker 

output image 

RESET PLC_MARKER in 22 Resets marker 

MARKER output image 

SET 

all inPort and 24 Sets operand to 1 


RESET all inPort and 26 Sets operand to 0 


MACRO_INFO Description of 

macro element 

28 Operand field: 

2 byte for macro identification 

MACRO_CRC CRC the previous 

macro field 

30 Operand field: 

1. Operand: 

CRC_LO ( 8 Bit ) 

2. Operand: 

CRC_HI ( 8 Bit ) 

INFO Info field 32 Operand field: 

1. Operand: 


2. Operand: 



PLC – Elements (I/O) 

The PLC inPort and outPort elements are defined in the document "TS-37350-340-02 

Switch Types PLC"! 

InPort elements 

I/O 

Type 

ESwitch_1O 1 

ESwitch_1S 2 

ESwitch_2O 3 

ESwitch_2OT 4 

ESwitch_1S1O 5 

ESwitch_1S1OT 6 

ESwitch_2S2O 7 

ESwitch_2S2OT 8 

ESwitch_3O 9 

ESwitch_3OT 10 

TwoHand_2O 

n/a 

TwoHand_2S 

n/a 

Mode_1S1O 13 

Mode_3Switch 14 

OutPort elements 

I/O 

Type 

DO.0_P 1 

DO.0_M 1 

DO.1_P 1 

DO.1_M 1 

DO.2_P 1 

DO.2_M 1 


PLC - Output variables 

Output variables for the PLC-system are identified by: 

Affiliation to the system image of the SMX-system 

the unambiguously determined address (byte index in system image, bit index in 

entry of system image). 

PAEOFFS = Size of segment PAE = 96 

by the 1-bit value of the input variable (TRUE or FALSE) 

Syntax and addressing: 

Index PAE-variable Bit Pos. Bit-variable Description 

1 Config_ID 0x3002 fixed 

2 DriveBASE 0 

1 

2 

3 

4 

DRB_STAT.1 = ESTOP 

external DRB_STAT.2 = 

RUNNING 

DRB_STAT.3 = LOCK 

DRB_STAT.4 = RESET 

5 

3 DriveSLI 0 SLI_EN.1 

Activation SLI 

1 SLI_EN.2 

4 DriveEMU 0 EMU_EN.1 

Activation EMU 

1 EMU_EN.2 

5 DriveSCA 0 .. 7 SCA_EN.1 .. SCA_EN.8 Activation SCA 

SCA_EN.9 .. 

0 .. 7 SCA_EN.16 

6 DriveSSX 0 SSX_EN.1 

Activation SSX 

1 SSX_EN.2 

2 SSX_EN.3 

3 SSX_EN.4 

7 DriveSOS 0 SOS_EN.1 

Activation SOS 

1 SOS_EN.2 

8 DriveSLP 0 SLP_EN.1 

Activation SLP 

1 SLP_EN.2 

9 DriveSEL 0 SEL_EN.1 

ActivationSEL 

1 SEL_EN.2 

10 DriveSLS 0 .. 7 SLS_EN.1 .. SLS_EN.8 Activation SLS 

11 DriveSDI 0 SDI_EN.1 

Activation SDI 

1 SDI_EN.2 

12 DriveSAC 0 .. 7 SAC_EN.1 .. SAC_EN.8 Activation SAC 

13 DriveSummary 0 PDM_EN.1 

Activation PDM 

1 PDM_EN.2 

14 DO8 0 

1 

2 

3 

4 

5 

6 

7 

DO.0_P 

DO.0_M 

DO.1_P 

DO.1_M 

K.1 

K.2 

EAA1.9 

EAA1.10 


HISIDE1 


LOSIDE1 


HISIDE2 


LOSIDE2 

Relay K1 

Relay K2 


SMX31 log. addr 1 


SMX31 log. addr 1 


15 HW_Output 0 

1 

2 

3 

4 

5 

6 

7 

A0.1_O 

A0.2_O 

A1.1_O 

A1.2_O 

A2.1_O 

A2.2_O 

EAA2.9 

EAA2.10 

16 PLC_Marker 0 .. 7 M.1 .. M.8 

18 PLCTimer_EN 0 .. 7 PLCT_EN.1 .. 

PLCT_EN.8 

19 – 64 MX8 MX16 MX 24 .. 

MX368 

Each 

0 .. 7 

MX.1 .. MX.368 

Auxiliary outPorts SMX 

Auxiliary outPorts SMX 

Auxiliary outPort SMX31 log. 

addr 1 


addr 1 


addr 2 


addr 2 

PLC_MX Marker 

65 Diag 17_24 0 .. 7 Diagnostic Bit 16 .. 23 

66 Diag25_32 0 .. 7 Diagnostic Bit 24 .. 31 

67 EnableEingangTimer 0 

1 

2 

3 

4 

5 

6 

7 

META_EN.1 

METB_EN.1 

META_EN.2 

METB_EN.2 

META_EN.3 

METB_EN.3 

META_EN.4 

METB_EN.4 

Activation of inPort element 

with time monitoring 

68 EnableEingangZweih 

andTimer 

0 .. 2 MEZ_EN.1 .. MEZ_EN.3 Activation of two-hand 

button 

69 EnableStartelement 0 MES_EN.1 

Activation of start element 

1 MES_EN.2 

70 EnableAnlauftest 

71 EAA1_8 0 .. 7 EAA1.1 .. EAA1.8 Extension outPort SMX31 

log. addr 1 

72 EAA2_8 0 .. 7 EAA2.1 .. EAA2.8 Extension outPort SMX31 

log. addr 2 

73 Diag_1_16 Diagnostic Bit 0 .. 15 

74 Diag_33_40 Diagnostic Bit 30..39 



77 EnableEingangTimer2 0 

1 

2 

3 

4 

5 

6 

7 

META_EN.5 

METB_EN.5 

META_EN.6 

METB_EN.6 

META_EN.7 

METB_EN.7 

META_EN.8 

METB_EN.8 













Activation of inPort element 

with time monitoring 


PLC - Processing elements 

Number = 8 

PLC-markers can be set and reset with the commands "S" or "R". PLC-marjkers are 

part of the process outPort image "OutPorts". The user can only address markers 

through the macro "RS-Flipflop". 

PLC - Timer 

The runtime system of PLC-processing holds a total of 8 PLC-timers available. These 

have the following properties: 

Generation of time events 1…31.999.992ms 

Downwards counter limited to ZERO, starts from configured initial value (part of 

configuration data) 

In the system image the timers only occupy 2 bits for ENABLE and RESULT 

(TRUE = timer elapsed, i.e. internal value at ZERO). Start of timer by setting 

ENABLE. ENABLE = FALSE resets the timer to the initial value (initial value = 

FALSE). 

ENABLE Timer value Initial value Activity 

FALSE Initial value on 

FALSE Counter inactive 

configuration 

TRUE 1 ... < INITIAL VALUE FALSE Counter active 

TRUE ZERO TRUE Counter inactive 

PLC-Timer - ENABLE can only be started or disabled with the command "ST". 

Release and status of timers are part of the process image. The initial values of the 

timers are saved in the configuration data in the PLC segment. 

PLC - Processing list 

he PLC-instruction list consists of a header and a linear list of single PLCinstructions, 

consisting of operator and operands, in the format specified under 2.2.1. 

Contents Index Contents Description 

Header 0 ID_PLC Identification of the PLC-list 

2 CRC CRC over the structure 

4 Date1 Date of creation/change 

6 Date2 

8 PLC_Len Number of AWL-instructions 

10 free 

12 free 

14 free 


PLC-Timer 16 Timer 1 Time events from 1 Tcyc to 

..... 

44 Timer 8 

3.999.999 Tcyc 

Each timer occupies 4 bytes 

Reserve 48 free 

50 free 

52 free 

AWL – 

List 

54 free 

56 Instruction 1 AWL acc. to format section 

..... 

2.2.1) 

48 + 

Instruction no. 

(PLC_Len*4) –4 PLC_Len 

Reserve 1056 free 

1058 free 

Assignment of resources 

Element In Out Qty. 

MX 

IN/OUT 

Process 

image 

PLC-Code 

AND2 2 1 1 0 LD x1.y1 

AND x2.y2 

ST MX.z 

AND5 5 1 1 0 LD x1.y1 

AND x2.y2 

AND x3.y3 

AND x4.y4 

AND x5.y5 

ST MX.z 

Qty. 

IL 

OR2 .. OR5 Analog AND 3 … 6 

XOR 2 Analog AND 3 

NOT 1 1 1 0 LD x1,y1 

NOT 

ST MX.z 

3 

RS-Flipflop 2 1 0 Output = 1 LD x1.y1 (source S) 

S M.z 

LD x2.y2 (source R) 

R M.z 

Timer 1 1 0 Output = 1 Timer enable : 

LD x1.y1 

ST PLCT_EN.z 

Monitoring 

functions 

Semi-conductor 

outPort 

Single 

Semi-conductor 

outPort 

Redundant 

1 1 0 Output = 1 Monitoring function enable : 

LD x1.y1 

ST uuu_EN.z 

1 1 0 Output = 1 LD x1.y1 

ST DO.x_y 

1 2 0 Output = 2 LD x1.y1 

ST DO.x_P 

ST DO.x_M 

Processing of inPort elements see document TS-37330-340-02 PLC switch types! 

3 

… 

6 

4 

2 

2 

2 

3 


APPENDIX Encoder Combinations 

Version: 

SMX 11 / SMX 12 in 2-axis operation 

Type Encoder A Encoder B Disabled Configu Entry Info field 

Type 

Pulse Enable Type Pulse Enable Modes rable Fault 

Pl 

multiple direction 

multip 

le 

direction 

axis exclusion/com 

ment 

0 NC 0 No NC 0 No all 1 and 2 B 

1 Incremental 2 No NC 2 No ZSC, 

DMC, 

ELC, OLC, 

PSC(positi 

on),JSS 

1 and 2 Fault exclusion 

mech. shaft 

breakage, 

positive encoder 

shaft connection 

required. 

d 

2 SINCOS 4 Yes NC 4 No ELC, OLC, 

PSC(positi 

on) 

3 Incremental 2 Yes Proxi sw. 

1 count. 

inp. 

4 SINCOS 4 Yes Proxi sw. 

1 count. 

inp. 

5 Incremental 4 Yes Proxi sw. 

2 count. 

inp. w. 90° 

- signal 

6 SINCOS 4 Yes HTL/incre 

mental 

7 SSI 1 Yes Proxi sw. 

1 count. 

inp. 

8 SSI 1 Yes Proxi sw. 

2 count. 

inp. w. 90° 

9 Proxi sw. 

1 count. inp. 

10 Proxi sw. 

2 count. inp. w. 

90° - signal 

11 Proxi sw. 


90° - signal 

12 HTL/incrementa 

l 

13 Proxi sw. 

1 count. inp. 

14 Proxi sw. 


90° - signal 

- signal 

1 No Proxi sw. 

1 count. 

inp. 

4 Yes Proxi sw. 

2 count. 

inp. w. 90° 

- signal 

4 Yes Increment 

al 

1 No ZSC,DMC, 

JSS,ELC, 

OLC, 

PSC(positi 

on) 

1 No ELC, OLC, 

PSC(positi 

on) 

4 Yes ELC, OLC, 

PSC(positi 

on) 

1 and 2 Fault exclusion 

mech. shaft 

breakage, 

positive encoder 

shaft connection 

required. 

d 

1 and 2 e 

1 and 2 (not 

implemented in 

phase 1) 

e 

1 e 


PSC(positi 

on) 

1 e 

1 No 1 (not 

d 


phase 1) 

4 Yes 1 e 

1 No ZSC, 

DMC, 

ELC, 

OLC,JSS, 

PSC(positi 

on) 


PSC(positi 

on) 


PSC(positi 

on) 

4 Yes SINCOS 4 Yes ELC, OLC, 

PSC(positi 

on) 

1 d 

1 d 

2 e 

2 e 

1 No SSI 1 Yes 2 (not 


phase 1) 

4 Yes SSI 1 Yes 2 e 

d 


Version: 

SMX 12 in single axis operation 

Type Encoder A Encoder B Disabled Configur Entry Info field 

Type Pulse Enable Type Pulse Enable Modes able axis Fault Pl 



exclusion/ 

comment 

32 Incremental 4 Yes Incremental 4 Yes ELC, OLC, 1 e 

PSC(position) 

33 SINCOS 4 Yes Incremental 4 Yes ELC, OLC, 1 e 

PSC(position) 

34 SINCOS 4 Yes SINCOS 4 Yes ELC, OLC, 1 e 

PSC(position) 

35 Incremental 4 Yes SSI 1 Yes 1 e 

36 SINCOS 4 Yes SSI 1 Yes 1 e 

37 SSI 1 Yes SSI 1 Yes 1 e 

Fault types SMX 

The SMX generally differentiates between two types of faults as per assignment 

below: 

Fault type 

Fatal Error 

Alarm 

ECS-Alarm 

Description 

Severe exceptional error caused by 

the program run in the SMX. Cyclic 

program sequence is no longer 

possible for safety related reasons. 

The last active process is the 

operation of the 7-segment display by 

system A. System B is in stop mode. 

Functional fault, caused by an 

external process. Both system 

continue to run cyclically and serve 

all requests from the communication 

interfaces. Sensing of the external 

process is also maintained. 

When using the ECS function in the 

programming desktop, the encoder 

alarm messages are marked "E" 

instead of "A". 

Effect on the 

system 

All outputs are 

switched off! 

All outputs are 

switched off! 

ECS function 

block delivers 

"0" as a result. 

Reset condition 

Reset possible by 

switching the 

SMX(POR) off/on. 

Reset via 

parameterizable 

inPort 

Reset via 

parameterizable 

inPort 

Recognizing faults system, A and system B: 

System A: odd-numbered 

System B: even numbered 


Display of Fault Types 

There are two possible ways of displaying the fault number 

SMX.. without expansion modules 

F,A or E __ __ __ __ 

Fault number 

SMX.. with expansion modules 

F,A or E __ __ __ __ __ 

1) Fault number 

Note 1) 

0: Base module 

1: Expansion module with logic address 1 

2: Expansion module with logic address 2 


Alarm list SMX 

Alarm code A 2101 / A 2102 

Alarm message Timeout receive message SMX31 (address 1) 

Cause 

Message from expansion module not received in time 

Remedy 

Check connection to expansion module 


Alarm message CRC fault transmission message SMX31 (address 1) 

Cause 

Transmission message faulty 

Remedy 

Check configuration of SMX31 serial number 


Alarm message 

Cause 

Remedy 

CRC fault transmission message 





Alarm message 

Cause 

Remedy 

Alarm code A 2111 

CRC fault receive message 

Receive message faulty 



Alarm message Timeout communication with expansion module SMX31 (address 1) 

Cause 

Installation of expansion module faulty 

Remedy 



Alarm message 

Cause 

Remedy 

Expansion module SMX31 (address 1) present, but not configured 

Faulty configuration 

Check configuration 


Alarm message Timeout receive message SMX31 (address 2) 

Cause 

Message from expansion module not received in time 

Remedy 



Alarm message CRC fault transmission message SMX31 (address 2) 

Cause 


Remedy 




Alarm message Timeout communication with expansion module SMX31 (address 2) 

Cause 

Installation of expansion module faulty 

Remedy 



Alarm message 

Cause 

Remedy 

Expansion module SMX31 (address 2) present, but not configured 




Alarm message 

Cause 

Remedy 

Pulse1 plausibility fault on expansion inlet EAEx.1 

Configured Pulse1 voltage not applied to this input. 

Check the configuration of the digital input acc. to planning and 

circuit diagram 

Check wiring 


Alarm message 

Cause 

Remedy 





Check wiring 


Alarm message 

Cause 

Remedy 





Check wiring 


Alarm message 

Cause 

Remedy 

Faulty 24V signal on EAEx.1 

No permanent 24V voltage applied to this input 

Check the voltage on the digital input! 

Check wiring 

Check whether Pulse1 or Pulse2 is applied 


Alarm message 

Cause 

Remedy 





Check wiring 



Alarm message 

Cause 

Remedy 





Check wiring 


Alarm message 

Cause 

Remedy 




Check wiring 



Alarm message 

Cause 

Remedy 





Check wiring 


Alarm message 

Cause 

Remedy 





Check wiring 


Alarm message 

Cause 

Remedy 




Check wiring 



Alarm message 

Cause 

Remedy 





Check wiring 


Alarm message 

Cause 

Remedy 





Check wiring 



Alarm message 

Cause 

Remedy 




Check wiring 



Alarm message 

Cause 

Remedy 





Check wiring 


Alarm message 

Cause 

Remedy 





Check wiring 


Alarm message 

Cause 

Remedy 




Check wiring 



Alarm message 

Cause 

Remedy 





Check wiring 


Alarm message 

Cause 

Remedy 





Check wiring 


Alarm message 

Cause 

Remedy 





Check wiring 



Alarm message 

Cause 

Remedy 





Check wiring 


Alarm message 

Cause 

Remedy 





Check wiring 


Alarm message 

Cause 

Remedy 




Check wiring 



Alarm message 

Cause 

Remedy 





Check wiring 


Alarm message 

Cause 

Remedy 





Check wiring 


Alarm message 

Cause 

Remedy 




Check wiring 



Alarm message 

Cause 

Remedy 





Check wiring 



Alarm message 

Cause 

Remedy 





Check wiring 


Alarm message 

Cause 

Remedy 




Check wiring 



Alarm message 

Cause 

Remedy 





Check wiring 


Alarm message 

Cause 

Remedy 





Check wiring 


Alarm message 

Cause 

Remedy 




Check wiring 



Alarm message 

Cause 

Remedy 

Pulse1 plausibility fault on input DI1 




Check wiring 


Alarm message 

Cause 

Remedy 





Check wiring 



Alarm message 

Cause 

Remedy 





Check wiring 


Alarm message 

Cause 

Remedy 





Check wiring 


Alarm message 

Cause 

Remedy 





Check wiring 


Alarm message 

Cause 

Remedy 





Check wiring 


Alarm message 

Cause 

Remedy 





Check wiring 

Alarm code 

A 3115 / A 3116 

Alarm message 

Cause 

Remedy 





Check wiring 

Alarm code 

A 3117 / A 3118 

Alarm message 

Cause 


No Pulse2 voltage applied to this input 


Remedy 



Check wiring 


Alarm message 

Cause 

Remedy 





Check wiring 

Alarm code 

A 3121 / A 3122 

Alarm message 

Cause 

Remedy 





Check wiring 

Alarm code 

A 3123 / A 3124 

Alarm message 

Cause 

Remedy 





Check wiring 

Alarm code 

A 3125 / A 3126 

Alarm message 

Cause 

Remedy 





Check wiring 

Alarm code 

A 3127 / A 3128 

Alarm message 

Cause 

Remedy 





Check wiring 

Alarm code 

A 3129 / A 3130 

Alarm message 

Cause 




Remedy 



Check wiring 

Alarm code 

A 3131 / A 3132 

Alarm message 

Cause 

Remedy 





Check wiring 

Alarm code 

A 3133 / A 3134 

Alarm message 

Cause 

Remedy 





Check wiring 

Alarm code 

A 3135 / A 3136 

Alarm message 

Cause 

Remedy 





Check wiring 

Alarm code 

A 3137 / A 3138 

Alarm message 

Cause 

Remedy 





Check wiring 

Alarm code 

A 3139 / A 3140 

Alarm message 

Cause 

Remedy 





Check wiring 

Alarm code 

A 3141 / A 3142 

Alarm message 

Cause 




Remedy 



Check wiring 

Alarm code 

A 3143 / A 3144 

Alarm message 

Cause 

Remedy 





Check wiring 

Alarm code 

A 3147 / A 3148 

Alarm message 

Cause 

Remedy 



Check the configuration of the digital input DI9 acc. to planning 

and circuit diagram 

Check wiring 

Alarm code 

A 3149 / A 3150 

Alarm message 

Cause 

Remedy 





Check wiring 

Alarm code 

A 3151 / A 3152 

Alarm message 

Cause 

Remedy 





Check wiring 

Alarm code 

A 3153 / A 3154 

Alarm message 

Cause 

Remedy 





Check wiring 

Alarm code 

A 3155 / A 3156 

Alarm message 

Cause 




Remedy 



Check wiring 

Alarm code 

A 3157 / A 3158 

Alarm message 

Cause 

Remedy 





Check wiring 

Alarm code 

A 3159 / A 3160 

Alarm message 

Cause 

Remedy 

Faulty 24V signal on DI1 



Check wiring 


Alarm code 

A 3161 / A 3162 

Alarm message 

Cause 

Remedy 




Check wiring 


Alarm code 

A 3163 / A 3164 

Alarm message 

Cause 

Remedy 




Check wiring 


Alarm code 

A 3165 / A 3166 

Alarm message 

Cause 

Remedy 




Check wiring 


Alarm code 

A 3167 / A 3168 

Alarm message 

Cause 




Remedy 


Check wiring 


Alarm code 

A 3169 / A 3170 

Alarm message 

Cause 

Remedy 




Check wiring 


Alarm code 

A 3171 / A 3172 

Alarm message 

Cause 

Remedy 




Check wiring 


Alarm code 

A 3173 / A 3174 

Alarm message 

Cause 

Remedy 




Check wiring 


Alarm code 

A 3175 / A 3176 

Alarm message 

Cause 

Remedy 




Check wiring 


Alarm code 

A 3177 / A 3178 

Alarm message 

Cause 

Remedy 




Check wiring 


Alarm code 

A 3179 / A 3180 

Alarm message 

Cause 




Remedy 


Check wiring 


Alarm code 

A 3181 / A 3182 

Alarm message 

Cause 

Remedy 




Check wiring 


Alarm code 

A 3183 / A 3184 

Alarm message 

Cause 

Remedy 




Check wiring 


Alarm code 

A 3185 / A 3186 

Alarm message 

Cause 

Remedy 




Check wiring 


Alarm code 

A 3191 / A 3192 

Alarm message 

Cause 

Remedy 

Short-circuit fault digital inPorts 

Short circuit between the digital inPorts within a module 

Consult the manufacturer 

Alarm code 

A 3197 / A 3198 

Alarm message 

Cause 

Remedy 

Faulty OSSD input test 

OSSD test faulty 

24V check the input voltage on all OSSD inputs 


Fault message 

Cause 

Remedy 

Encoder supply voltage X31 faulty. 

Encoder supply voltage does not comply with configured 

threshold 

Component fault in module 

Check configuration! 

Check encoder supply voltage 

Switch device off/on. 



Fault message 

Cause 

Remedy 

Encoder supply voltage X32 faulty. 

Encoder supply voltage does not comply with configured 

threshold 


Check configuration! 

Check encoder supply voltage 



Fault message 

Cause 

Remedy 

Deviation Ain1 to AIn2 too big 

Different voltages on both inputs 

configured threshold too low 

Check voltages on Ain1! 

Check configuration of threshold/input filter 



Fault message 

Cause 

Remedy 

Deviation Ain3 to AIn4 too big 

Different voltages on both inputs 

configured threshold too low 

Check voltages on Ain1! 

Check configuration of threshold/input filter 



Fault message 

Cause 

Remedy 

Plausibility test for encoder voltage faulty 

Encoder voltage value 

Check encoder voltage supply 

Check wiring of encoder voltage supply 


Fault message 

Cause 

Remedy 

Plausibility test for analog inputs faulty 

Fault in analog input signal 

Check connection of analog inputs 

Analog input voltage out of range 


Fault message 

Cause 

Remedy 

Open-circuit monitoring AIN1 has triggered 

Open-circuit monitoring activated (< 1000mV) 

Check configuration of activation/sensor 

Check sensor connection 


Fault message 

Cause 

Remedy 

Open-circuit monitoring AIN2 has triggered 

Open-circuit monitoring activated (< 1000mV) 

Check configuration of activation/sensor 


Check sensor connection 

Alarm code 

A 3301 / A 3302 

Alarm message Plausibility fault speed sensing axis 1 

The difference between the two speed sensors is higher than the 

Cause 

configured speed shut-down threshold 

Check the theory of the distance once again using the data set in the 

encoder configuration 

Remedy 

Check the speed sensor 

Use the SCOPE function to adjust superimposable speed signals 


Alarm message Plausibility fault position sensing axis 1 

The difference between the two position sensors is higher than the 

Cause 

configured incremental shut-down threshold 

Check the theory of the distance using the configured data or the 

sensor setting 

Check the position signal 

Remedy 

Are all signals correctly connected to the 9-pole encoder plug? 

Check the encoder plug for correct wiring. 

If proximity switches are used, these are correctly connected. 

Use the SCOPE function to adjust superimposable position signals 

Alarm code 

A 3307 / A 3308 

Alarm message Plausibility fault position range axis 1 

Cause 

The current position is outside the configured measuring length 



Remedy 

Check the position signal, if necessary correct the offset 

Use the SCOPE function to read out the position and to set into 

relation to configured values 


Alarm message Plausibility fault because of faulty speed axis 1 

Cause 

The current speed is outside the configured maximum speed 

The drive moves outside the permissible and configured speed range 

Remedy 


Use the SCOPE function to analyse the course of speed 

Alarm code 

A 3311 / A 3312 

Alarm message Configuration fault: Acceleration axis 1 

Cause 

The current acceleration is outside the configured acceleration range 

The drive has exceeded the permissible acceleration range 

Remedy 

Check the configuration of maximum speed 

Use the SCOPE function to analyse the course of speed/acceleration 



Fault message 

Cause 

Remedy 

SSI sensor fault 

Encoder step change SSI-value within a cycle too big 

Check encoder wiring 

Check encoder configuration 

Alarm code 

A 3321 / A 3322 

Alarm message Plausibility fault speed sensing axis 2 

The difference between the two speed sensors is higher than the 

Cause 

configured speed shut-down threshold 

Check the theory of the distance once again using the data set in the 

encoder configuration 

Remedy 

Check the speed sensor 

Use the SCOPE function to adjust superimposable speed signals 


Alarm message Plausibility fault position sensing axis 2 

The difference between the two position sensors is higher than the 

Cause 

configured incremental shut-down threshold 



Check the position signal 

Remedy 

Are all signals correctly connected to the 9-pole encoder plug? 

Check the encoder plug for correct wiring. 

If proximity switches are used, these are correctly connected. 

Use the SCOPE function to adjust superimposable position signals 

Alarm code 

A 3327 / A 3328 

Alarm message Plausibility fault position range axis 2 

Cause 

The current position is outside the configured measuring length 



Remedy 

Check the position signal, if necessary correct the offset 

Use the SCOPE function to read out the position and to set into 

relation to configured values 


Alarm message Plausibility fault because of faulty speed axis 2 

Cause 

The current speed is outside the configured maximum speed 

The drive moves outside the permissible and configured speed range 

Remedy 


Use the SCOPE function to analyse the course of speed 

Alarm code 

A 3331 / A 3332 

Alarm message Configuration fault: Acceleration axis 2 

Cause 

The current acceleration is outside the configured acceleration range 


Remedy 

The drive has exceeded the permissible acceleration range 

Check the configuration of maximum speed 

Use the SCOPE function to analyse the course of speed/acceleration 

Alarm code 

A 3333 / A 3334 

Alarm message 

Cause 

Remedy 

Plausibility fault of SinCos encoder 

Wrong encoder type connected 


Check encoder assignment 

Alarm code 

A 3407 / A 3408 

Alarm message 

Cause 

Remedy 

Difference level RS485Treiber1 fault INC_B or SSI_CLK faulty 

No encoder connection 


Check encoder connection 


Alarm code 

A 3409 / A 3410 

Alarm message 

Cause 

Remedy 

Difference level RS485Treiber2 fault INC_A or SSI_DATA faulty 

No encoder connection 


Check encoder connection 



Fault message 

Cause 

Remedy 

Fault Sine/Cosine plausibility X31 

Plausibility monitoring of individual tracks faulty 


Sine- to Cosine- track must be linear 


Fault message 

Cause 

Remedy 

Fault Sine/Cosine plausibility X32 

Plausibility monitoring of individual tracks faulty 


Sine- to Cosine- track must be linear 


Fault message Read head fault WCS encoder system axis 1 

Cause 

WCS read head has detected a fault 

Remedy 

Read out fault types from WCS encoder system 


Fault message Read head fault WCS encoder system axis 1 


Cause 

Remedy 

WCS read head has detected a fault 

Read out fault types from WCS encoder system 

Alarm code 

A 4001 / A 4002 

Alarm message 

Cause 

Remedy 

CCW and CW rotation monitoring SDI1 activated at the same time 

Multiple activation 

In programming make sure that only one "Enable" is activated 

Alarm code 

A 4003 / A 4004 

Alarm message 

Cause 

Remedy 

CCW and CW rotation monitoring SDI2 activated at the same time 


In programming make sure that only one "Enable" is activated at a 

time 


Alarm message 

Cause 

Remedy 

Monitoring range left and right of SLP1 activated at the same time 



time 


Alarm message 

Cause 

Remedy 

Monitoring range left and right of SLP2 activated at the same time 



time 


Alarm message 

Cause 

Remedy 

SLP1 Teach In status fault 

SET and QUIT input have a faulty switching sequence 

Check input configuration 

Check switching sequence 


Alarm message 

Cause 

Remedy 

SLP 2 Teach In status fault 

SET and QUIT input have a faulty switching sequence 


Check switching sequence 


Alarm message 

Cause 

Remedy 

SLP1 Teach In position fault 

Teach In position outside measuring range 

Check transfer position 



Alarm message 

Cause 

Remedy 

SLP2 Teach In position fault 

Teach In position outside measuring range 

Check transfer position 


Alarm message 

Cause 

Remedy 

SLP1 Teach In SOS activation fault 

The drive moved during Teach In (SOS fault) 

The drive must be stopped when using the Teach In function 

Check whether SOS has already triggered 


Alarm message 

Cause 

Remedy 

SLP 2 Teach In SOS activation fault 

The drive moved during Teach In (SOS fault) 

The drive must be stopped when using the Teach In function 

Check whether SOS has already triggered 

Alarm code 

A 4901 / A 4902 

Alarm message 

Cause 

Remedy 

CCW and CW rotation monitoring SLI1 activated at the same time 



time 

Alarm code 

A 4903 / A 4904 

Alarm message 

Cause 

Remedy 

CCW and CW rotation monitoring SLI2 activated at the same time 



time 


Alarm message 

Cause 

Remedy 

Test deactivation of digital inputs 1...14 faulty 

Inputs are still active after deactivation 

Check wiring of digital inputs 

Alarm code 

A 6701 / A 6702 

Alarm message 

Cause 

Remedy 

Timeout fault MET 

Input element with time monitoring is faulty 

Check wiring of input element 

Input element faulty 



Alarm message 

Cause 

Remedy 

Timeout fault MEZ 

Two-hand control element with time monitoring is faulty 

Check wiring of input element 

Input element faulty 


Fatal Error list SMX 

Fatal Error Code F 1001 

Fault message 

Cause 

Remedy 


Fault message 

Cause 

Remedy 


Fault message 

Cause 

Remedy 


Fault message 

Configuration data were incorrectly loaded into the monitoring 

device 

Disturbed connection when loading the program into the 

monitoring device. 

Reload the configuration data, then switch module off/on. 

Configuration data invalid for software version of module! 

Module configured with incorrect software version of the 

programming desktop. 

Parameterize the module with the approved version of the 

programming desktop, the switch the module off/on. 

Device not programmed with the correct programming desktop 

Program or configuration data transferred to the device using the 

wrong programming desktop 

Check the module design and parameterize again with a valid 

programming desktop. Then switch device off/on. 

Error when deleting configuration data from the Flash Memory 

Fatal Error Code 

Fault message 

F 1311 / F1312 

Internal error – please contact the manufacturer! 


Fault message 


Fatal Error Code F 1401 / F 1402 

Fault message 



Fault message 

Cause 

Remedy 

CRC of configuration data invalid! 

Configuration data were incorrectly transferred 

Transfer the configuration data again 



Fault message 



Fault message 



Fault message 



Fault message 



Fault message 



Fault message 

Range test of device description is faulty. 


Fault message 

Range test of Access Data faulty 


Fault message 

Range test of EMU faulty 


Fault message 

Range test SCA faulty 


Fault message 

Range test SSX faulty 


Fault message 

Range test SEL faulty 


Fault message 

Range test SLP faulty 


Fault message 

Range test SOS faulty 



Fault message 

Range test SLS faulty 


Fault message 

Range test SDI faulty 


Fault message 

Range test SLI faulty 


Fault message 

Range test of PLC faulty 


Fault message 

Range test of shut-down channel faulty 


Fault message 

Range test of outputs faulty 


Fault message 

Range test of digital inputs faulty. 


Fault message 

Range test of analog input 


Fault message 

Range test of encoder type faulty 


Fault message 

Range test of encoder processing faulty 


Fault message 

Range test of encoder position faulty 


Fault message 

Range test of PDM faulty. 


Fault message 

Range test of adder circuitry faulty 



Fault message 

Range test of axis management faulty 


Fault message 

Range test of expansion modules faulty 


Fault message 

Range test of PLC timer faulty 


Fault message 

Range test of system faulty 


Fault message 

Range test connection table faulty 


Fault message 

Range test SAC faulty 


Fault message 

Range test of diagnose faulty 


Fault message 



Fault message 


Fault message 


Fault message 


Fault message 


Fault message 

Timeout when transmitting configuration and firmware data 







Fault message 



Fault message 



Fault message 

Cause 

Remedy 


Fault message 

Cause 

Remedy 


Fault message 

Cause 

Remedy 

Processor voltage 2.5V outside defined range 

Supply voltage for module not correct! 


Check device supply voltage! 


Supply voltage 24V module faulty. 





Internal supply voltage 5.7V faulty 






Fault message 

Cause 

Remedy 


Internal supply voltage 5V faulty 





Alarm message Plausibility fault position switching axis 1 

During position switching SOS, SLI or SDI is permanently 

Cause 

activated. 

Check activation of SOS 

Remedy 

Check activation of SLI 

Activation of SDI (only for monitoring via position) 


Fault message Fault in encoder alignment axis 1 

Cause 

Incorrect position triggering by system A 

Remedy 





Fault message Plausibility fault position switching axis 2 

During position switching SOS, SLI or SDI is permanently 

Cause 

activated. 

Check activation of SOS 

Remedy 

Check activation of SLI 

Activation of SDI (only for monitoring via position) 


Fault message Fault in encoder alignment axis 2 

Cause 

Incorrect position triggering by system A 

Remedy 




Fault message 

Cause 

Remedy 

Faulty switching of relay K1 

Internal triggering of relay faulty 

Switch device off/on 


Fault message 

Cause 

Remedy 


Fault message 

Cause 

Remedy 


Fault message 

Cause 

Remedy 


Fault message 

Cause 

Remedy 


Fault message 

Cause 

Remedy 

Faulty switching of relay K2 

Internal triggering of relay faulty 


Faulty switching of "0V" driver DO1_L 

Switching state of output faulty 


Faulty switching of "24V" driver DO1_H 






Faulty switching of "24V" driver DO2_H 





Fault message 

Cause 

Remedy 


Fault message 

Cause 

Remedy 


Fault message 

Cause 

Remedy 


Fault message 

Cause 

Remedy 


Fault message 


Fault message 


Fault message 


Fault message 


Fault message 


Fault message 


Short-circuit of outPort with "0V" 


Faulty testing of "24V" driver DO1_H 



Faulty testing of "0V" driver DO2_L 



Faulty testing of "24V" driver DO2_H 










Fault message 




Fault message 

Cause 

Remedy 


Fault message 

Cause 

Remedy 


Fault message 

Cause 

Remedy 


Fault message 

Cause 

Remedy 


Fault message 

Cause 

Remedy 


Fault message 

Cause 

Remedy 


Fault message 

Cause 

Remedy 


Fault message 

Cause 

Remedy 


Fault message 

Cause 

Remedy 

Faulty switching of output EAAx.1 

Short-circuit of outPort with "24V" or "0V" 




























Fault message 

Cause 

Remedy 





Fault message 

Cause 

Remedy 

Faulty testing of output EAAx.1 




Fault message 

Cause 

Remedy 





Fault message 

Cause 

Remedy 





Fault message 

Cause 

Remedy 





Fault message 

Cause 

Remedy 





Fault message 

Cause 

Remedy 





Fault message 

Cause 

Remedy 





Fault message 

Cause 

Remedy 






Fault message 

Cause 

Remedy 





Fault message 

Cause 

Remedy 


Fault message 


Fault message 


Fault message 


Fault message 









Alarm message 

Cause 

Remedy 

Faulty calculation of SSX limit curve 

Faulty calculation of SSX limit curve 




Alarm message 

Cause 

Remedy 

Faulty calculation of SSX brake ramp 


Check SSX configuration 



Fault message 



Fault message 



Fault message 




Fault message 



Fault message 



Fault message 



Fault message 



Fault message 



Fault message 



Fault message 


Fault message 




Fault message 



Fault message 


Fault message 


Fault message 


Fault message 







Fault message 



Fault message 



Fault message 



Fault message 



Fault message 



Fault message 



Fault message

SMX Programming Manual for the SMX Module - OEM Automatic AB

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