Information presented in this brochure is subject to change without prior notice.Available machines or machines shown may vary depending on optional equipment or periodic design changes.The export of products defined as restricted commodities (or technologies) under Japan's "Foreign Exchange and Foreign Trade Act" requires an export license issued by the Japanese Government. Furthermore, similar licenses may be required for re-transfer, re-sale or re-export of such products, therefore please do not fail to contact JTEKT in advance. In order to observe laws and regulations and prevent inappropriate export, re-sale and relocation, JTEKT has equipped all of our NC machine tools with devices that detect relocation. If this device is activated, the machine will cease operation and will not restart until it has been checked by JTEKT. JTEKT may refuse to restart the machine should it be deemed that such an action would amount to the inappropriate export of a commodity or technology, or violate export regulations. In such a case, JTEKT will not be liable for any damages arising from the refusal to restart machine operation and do not bear any liability to perform services pertaining to product warranty.Please contact your JTEKT representative for details. Always read manuals carefully before using any machinery to ensure safe and proper use.
TOYODA MACHINERY USA CORP.HEADQUARTERS316 W.University Drive, Arlington Heights, IL 60004U.S.A.TEL: （1）847-253-0340FAX: （1）847-577-4680
TOYODA MACHINERY USA CORP.AUTOMOTIVE PRODUCTS & SPECIALMACHINES DIVISION51300 W. Pontiac TrailWixom, MI. 48393-1003U.S.A.TEL: （1）248-624-5755FAX: （1）248-624-8597
TOYODA MACHINERY AND ENGINEERING EUROPE SAS2 Grande Allee P.A des Petits Carreaux 94380 Bonneuil sur Marne, FRANCETEL: （33）1-49.56.85.80FAX: （33）1-43.77.47.50
PT.JTEKT INDONESIAMM2100 Industrial Town Jl. Halmahera Block DD-3Cikarang Barat, Bekasi 17520 INDONESIATEL: （62）21-8998 3275 FAX: （62）21-8998 3274
TOYODA KOKI DO BRASIL INDUSTRIAE COMERCIO DE MAQUINAS, LTDA.Alameda Ulderico Ferrari, 100,Itaim Guacu, Itu, SP 13312-655, BRASILTEL: （55）4023-1730
TOYODA MICROMATIC MACHINERY INDIA LIMITED 506-507, 5th Floor, Suncity Business Tower, Golf Course Road, Sector-54 Gurgaon-122002, Haryana, INDIA TEL: （91）-124-4264602FAX: （91）-124-4288355
Optimal for large equipment Optimal for singular equipment Optimal for embedded usage, from large equipment to individual equipment
Production site safety has been greatly enhanced through conformity to international safety standards.Evolves with change, towards the new stage of safety sought by the world!
What is safety ?
1.View of conventional safety 2.View of the present safety(Europe and the U.S.) Riskcontrol
Safetycontrol
A Safety PLC must conform to these two standards and acquire the certifications
What is "Risk is controlled" ? What is the International Safety Standards ?
"Risk is controlled" means"There is no unacceptable risk"
The origin of International Safety Standards is the Machine Directive from European Union
1. Machinery Directive
2. International Safety Standards about a Safety PLC
1 IEC61508 1-7 (2010)
2 IEC13849-1(2008)
It cannot be known withoutseeingpaper drawing.
Reduces amount of wiring through a safety network and safety signal communication.Provides gateway module for connecting to TOYOPUC-PCS and various open networks.
IEC61508 specifies SIL (Safety Integrity Level) from 1 to 4. About SIL, there are two-kinds, the low demand mode, and the high demand/continuous mode.In FA field, usually use the high demand/continuous mode. In this case, SIL is specified by PFH (average of dangerous failure rate per hour).
1. Hardware and software are redundant (Redundant configuration like A+B)2. Diagnostic function(System self-diagnosis and device connection diagnosis are always implemented)
3. Mutual check (operation check between A and B )4. When an error detected, all outputs are shutdown instantly.
Achieves the highest level of program capacity and response speed, despite its small size.
Layout is arbitrary because module expansion can be conducted using a cable.An optimal safety control system can be constructed from small scale to large scale by combining the unit.
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Plus SafetyJTEKT, the No. 1 leading company in the domestic share of safety PLC production, will offer the new safety PLC.Achieves safety control from manually operated equipment to semiautomatic and fully-automatic equipment, through an optimized structure. Plus Safety provides reliable work to improve equipment safety.
Safety is that an accident and disaster must not happen.To pay attention and follow correct operations strictly.
In EU, if someone designs, manufactures, supplies, purchases or uses a machine, must observe the Directive. (EU countries must match their lows to the Directive)
Functional safety of electrical/electronic/programmable electronic safety related system Safety category SIL１-４
Safety of machinery Safety-related parts of control systems Performance Level a - e
Safety is the status that "Hazard (risk) must be minimum status."To estimate equipment risk and conduct safety processing.
1 2
Safety PLC architecture
Fault probablity of the dange side is once every few thousand years
SIL
1
2
3
4
Average of dangerous failurerate per hour
10－6 ≦ × ＜10－5
10－7 ≦ × ＜10－6
10－8 ≦ × ＜10－7
10－9 ≦ × ＜10－8
SIL4 is applicable for nuclear-power-station level.
Equipment adjustment time and fault check time are greatly reduced. (MTTR* reduction)
Significant reduction of man-hours spent on maintenance
JTEKT safety PLC series
What is Safety Integrity Level（SIL）? （IEC 61508）
*MTTR: Mean time to repair (Average time to recover from faults)
Each contact point is confirmed with multimeter based on the circuit diagram
In case of relay safety circuit In case of safety PLC In case of safety PLC
In case of safety PLCIn case of safety relay
In case of safety relay
■ Developed safety PLC for first FA in JapanTOYOPUC-PCS
■ Board type safety PLCTOYOPUC-Plus Safety
■ Small safety PLCTOYOPUC-PCS-J
Each wire is checked based on the circuit diagram.
２００４ ２０10 ２０15
Light curtain
■ Achieves world standard equipment safety suited to international safety standards.■ Guarantees the safety of the operator and contributes to the improved productivity of the plant.■ The safety circuit of conventional hardware can be visualized as software.■ Reduces the number of safety relays and wiring space, enables retrofitting, and contributes to better equipment reliability and miniaturization.
Through the introduction of the safety PLC,
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Addition of safetycomponents
Light curtainLight curtain Plus Safety
E-Stopbutton
Light curtain stop
● Necessary to confirm that the drawing matches the actual part
● Many man-hours spent on wiring
Start
Completion
Hazard identification
Estimate the Risk
Evaluate the Risk
There is no unacceptable risk?
Specify the scope of target machine and specifications
Warning the user about residual risk
Inherently safe design
Protection measures by safety protection
Additional protection measures
YES
NO
Input module
24V 24V
CPU module Output module
Input A
Input B
CPU-A
CPU-B
Output A
Output B
Diagnosis
Diagnosis
Diagnosis
Diagnosis
Diagnosis
Diagnosis
Mutual check
Mutual check
Mutual check
Expandable up to max. 2,024 IO points. Communication distance is max. 50 m between stations. It can be expanded to max. 31 stations. Up to max. 31 remote satellite stations can be connected.
The emergency stop button and light curtain can be connected to the same input by setting the dry contact point input and the light curtain input from PCwin-Safe 2.
+
"Connectable" PLC TOYOPUC-Plus Plus Safety
The ladder circuit is standardized by FBD, Make it easy to design through the attachment of FBD and connection of input/output.
Monitoring of ON/OFF can be performed easily, and there is no wiring. The status can be viewed immediately.
Due to the hardware circuit, measurement by multimeter or similar device is necessary for monitoring the ON/OFF and cable check of the wiring.
The drawing, the contact point table, the coil cross reference, etc. of the ladder circuit can be printed like the drawing.
In addition to the method using a computer, it is also possible to program for reading and writing into Plus Safety by direct operation using USB memory. It is possible to operate easily without using a computer.
Programming can be performed mainly through mouse operation, or mainly through keyboard operation using keyboard shortcuts. The safety circuit and non-safety circuit can be easily identified using the function which checks safety.
* "ETHERNET\イ－サネット" is a registered trademark of FUJI XEROX Co., Ltd. *"EtherCAT" is a registered trademark of Beckhoff Automation GmbH. *"CC-Link" is a registered trademark of Mitsubishi Electric Corp.* "Ethernet/IP" and "DeviceNet" are registered trademarks of OVDA, Inc. * "MECHATROLINK" is a registered trademark of Yaskawa Electric Corp.
It takes time to conduct checks and investigations, and change is difficult.
It takes no time to conduct checks and investigations, and circuit change is easy.
It is possible to streamlineand standarlize ladder circuit
Reading/writing of program can be achievedwithout using a computer.
ETHERNET*
EtherNet/IP* EtherCAT*
FL-net CC-Link*
DeviceNet*FL-remote
MECHATROLINK-Ⅲ*
Displays the "block number"of the area of use
3 4
Expandable up to max. 128 IO points. Communication distance has total extension of 50 m. Expansion IO module can be connected to up to max. 3 units.
■ Internal IO bus ■ Remote IO: 2,048
Displays the coil which exists on the page.PCwin-Safe 2 window
Project window / Library window
Possible to read/write programsdirectly into USB memory.
Ladder circuit programming Reading/writing of program Drawing style printing
■ TOYOPUC-Plus Safety is comprised of 3 types of units.
■ For each unit, the type most suited for usage can be selected from an abundant line-up.■ The basic unit can be switched to CPU, remote satellite station or expansion IO, according to usage. ■ Supports remote communication and can be located in a separate place.■ The optimum safety control system can be constructed according to equipment, from small scale to large scale, by combining the unit.■ Layout is arbitrary because module expansion can be conducted using a cable.
Structure of TOYOPUC-Plus Safety
Example of separate arrangement 1 (process wiring) Example of separate arrangement 2(wiring between control cabinet and operation panel)
Reduced amount of wiring through the installation of Plus Safety to the inside of the operation panel.
Possible to implementOKI-PON (just put down)around the device. Process B
to nextprocess
Process A
Control cabinet
Easy wiring between equipmentusing communication cables!!
Realizes wiring-saving!
InternalIO buscable
IO connection
Input method●Dry contact point input●Light curtain input●Semiconductor input
Drag & dropBS0808
The unit name is reflected.The unit name is reflected.
PCwin-Safe2 with simple operability supports program creation for safety circuits.Abundant structure variation achieves optimum safety control in equipment!
■ A safety circuit comprised of a safety relay, etc., can be created easily as a ladder circuit program of TOYOPUC-Plus Safety.■ The ladder circuit program can be blocked at each function unit, registered to the library as an FBD, and used as standard circuit. ■ For ladder circuit program and FBD, it is possible to check simply the ON/OFF state of each signal from personal computer or operation panel.
■ Programming of safety PLC ladder circuits can be performed with operability similar to the general PLC. ■ Circuits that do not satisfy safety requirements are automatically detected as non-safety circuits by the function which checks the safety of ladder circuit programs.■ Ladder circuit programs can be printed as drawings created by CAD.
Programming, reading/writing of program, printing of drawing
Possible to add units easilythrough drag & drop.
Possible to switch dry contact point input and light curtain input through the use of PCwin-Safe 2.
Operation panel
Control PLCTOYOPUC-Plus +Plus Safety
Control cabinet
Plus SafetyExpansion IO
Supports various networks and miniaturization of the control cabinet through combination with TOYOPUC-Plus.
Example of separate placement using remote communication function of TOYOPUC-Plus Safety
Plus SafetyTOYOPUC-Plus
IO connectionIO connectionOccupied areareduction
Programmer *5 PCwin-Safe 2Japanese version CD-ROMTJA-2071
TJA-2073 English version CD-ROM
SpecificationsItemNo.Board type (when using 5 units and bracket)90（D）×140（H）×101（W）mm (excluding protrusions)Type1
24 V DC +20% 、- 15 % Use the power supply suited to the following standard.IEC/EN 60950-1, EN 50178（UL Class 2, SELV）Power source2
0 - 55 °CAmbient temperature310 ～ 95％RH (must be free from dew)Relative humidity4No corrosive gas allowedAtmosphere5
11 No battery needed
USB Full Speed （12 Mbps）7 Peripheral unit I/F (connection to PCwin-Safe 2)USB flash memory8 External MemoryRS-485 total extension 1 km; however, use double shield cable for 3 m or more.SN-I/F (communication between TOYOPUC and Safety PLC 1: 1 communication)Conforms to MODBUS*-RTU (１: N communication correspondence)
9 General communication
Module display, status display, operation selection display10 Indicator (displayed with 3 original colors of LED)
6 Expansion IO bus
RS-485 3Mbps, Communication distance: total extension 50 ｍ, LAN cable (Cat5), 8-core twisted pair cableUse shield cable for 1 m or more.Expansion IO module: Max. 3 units
Internal IO bus
RS-485 3Mbps, Communication distance: max. 50 m between stationsRemote satellite station: max. 31 unitsRemote IO
Holds for 15 days using super capacitor.ClockBackups of general register and fault history using FRAMData backup
8
No. Item Specifications1 Safety category ISO13849-1 PL e IEC61508 SIL32 Program method Stored program method3 Program control method Cyclic calculation method4 Input/Output control method Image register method5 Programming language LD (+FBD)
DC24V Photo coupler input (-) commonInput current: 5mA/pointDry contact point input depending on parameter,Selection of light curtain input and semiconductor input
Up to five units may be stacked using studs.*1After the program is written in, the IF unit can be detached and used. *2 Necessary for protection. *3 The ratio of input/output varies depending on the unit line-up combination.
USB I/F 1 port
Program capacity 128KB
IO points※3 16 points
Internal IO cable －
○
○
○
○
32 points
－
○
○
○
48 points
CB0005SI ×1 program
○
○
64 points
CB0005SI ×1 program
■An example of TOYOPUC-Plus Safety configuration
5 6
②
140
90
List of studs and screwsParts name Name Type Description
Cable listParts name Name Type Description
Internal IO cable 0.05 m
Internal IO cable 0.15 m
Internal IO cable 5 m
Internal IO cable 10 m
※ Up to 50 m of internal IO cable is provided in units of 5 m. See the user guide for cable type.
※ Up to 50 m of remote IO cable is provided in units of 5 m. See the user guide for cable type.
*5 If you have already purchased PCwin-Safe 2, you may download the compatible version of Plus Safety from our homepage.
*3, *4 Either *3 or *4 is necessary to protect.
Remote IO cable 5 m
Remote IO cable 10 m
CB0005SI
CB0015SI
CB0500SI
CB1000SI
CB0500SR
CB1000SR
CB0005SI
CB0015SI
CB0500SI
CB1000SI
CB0500SR
CB1000SR
SN-I/F cable 3.0 m(for TOYOPUC-Plus)
EX_SIOSNIF_CN2-030 EX_SIOSNIF_CN2-030
140
90
140
90
DIN rail adapter
Direct mounting bracket
DIN rail bracket
Protection coverfor direct mounting bracket *3
Protection coverfor DIN rail bracket *4
M3, 6 mm screw (SCR 6x4)
M3, 6 mm screw (SCR 6x4)
Metal stud 16 mm, female-female (ST16x4FF)M3, 6 mm screw (SCR 6x4)
Metal stud 16 mm, female-female (ST16x4FF)M3, 6 mm screw (SCR 6x4)
Auxiliary tool for mounting the bracket to the 35 mm wide DIN rail
Mounting direction conversion bracket
Assembly parts of bracket BK0000 and DN0000 for mounting the DIN rail
Prevents careless contact with the substrate.It is necessary to mount to the outermost substrate. (For BK0000)
Prevents careless contact with the substrate.It is necessary to mount to the outermost substrate. (For BK0000)
BK0000-01
BK00DN-01
CV0000-01
CV00DN-01
BK0000-01
BK00DN-01
CV0000-01
CV00DN-01
TNP-6938
TNP-6937
TNP-6915
TNP-6936
TNP-6940
DN0000
BK0000
BK00DN
CV0000
CV00DN
Metal stud16 mm, male-male
Metal stud8 mm, male-male
Metal stud8 mm, male-female
ST16X4MM
ST8X4MM
ST8X4MF
16 mm long M3: 4 pcs (male-male)Application: Between mounting face and IF or betweenmounting face and BS, if there is tap on the mounting face.
8 mm long M3: 4 pcs (male-male) Application: Between mounting face and BS, if there is tap on the mounting face.
8 mm long M3: 4 pcs (male-female)Application: Between IF and BS
ST16X4MM
ST8X4MM
ST8X4MF
Parts name Name Type Description
STD16X4
ST16X4FF
SCR6X4
Metal stud16 mm, male-female
Metal stud16 mm, female-female
M3, 6 mm screw
16 mm long M3: 4 pcs (male-female)Application: Between bracket and IF or bracket and IF, BS and BS, BS and OS
16 mm long M3: 4 pcs (female-female)Application:Between BS and cover or OS and cover
4pcs of M3 with 16 mm lengthFixing screws for bracket and cover
STD16X4
ST16X4FF
SCR6X4
Connects IF units 5 m
Connects IF units 10 m
SN-I/F cable 0.5 m(for TOYOPUC-Plus) EX_SIOSNIF_CN2-005 EX_SIOSNIF_CN2-005 Connects the IF unit and TOYOPUC-Plus EX or EX20.5 m (single shield cable)
SN-I/F cable 5.0 m(for TOYOPUC-Plus) CB0500SP CB0500SP Connects the IF unit and TOYOPUC-Plus EX or EX2
5.0 m (double shield cable, with FG terminal)
SN-I/F cable 5.0 m(for TOYOPUC-PC10G) CB0500S10 CB0500S10 Connects the IF unit and TOYOPUC SN-I/F 5.0 m
One side: With sleeve terminal (double shield cable, with FG terminal)
SN-I/F cable 5.0 m(general purpose) CB0500SF CB0500SF Connects the IF unit and TOYOPUC SN-I/F 5.0 m
One side cut-off (double shield cable, with FG terminal)
SN-I/F cable 1.5 m(for TOYOPUC-Plus) EX_SIOSNIF_CN2-015 EX_SIOSNIF_CN2-015 Connects the IF unit and TOYOPUC-Plus EX or EX21.5 m (single shield cable)
Connects the IF unit and TOYOPUC-Plus EX or EX23.0 m (single shield cable)
SN-I/F cable 0.5 m(for TOYOPUC-PC10G) SN-I/F CABLE 0.5 m TXY-6670 Connects the IF unit and TOYOPUC SN-I/F 0.5 m
One side: With sleeve terminal (single shield cable)
SN-I/F cable 1.5 m(for TOYOPUC-PC10G) SN-I/F CABLE 1.5 m TXY-6671 Connects the IF unit and TOYOPUC SN-I/F 1.5 m
One side: With sleeve terminal (single shield cable)
SN-I/F cable 3.0 m(for TOYOPUC-PC10G) SN-I/F CABLE 3.0 m TXY-6672 Connects the IF unit and TOYOPUC SN-I/F 3.0 m
One side: With sleeve terminal (single shield cable)
SN-I/F cable 3.0 m(general purpose)
SN-I/F CABLE 3.0 m(Free) TXY-6673 Connects the IF unit and TOYOPUC SN-I/F 3.0 m
One side cut-off (single shield cable)
Connects basic units 0.05 m Cat5e straight LAN cable (8-core twist pair)
Connects basic units 0.15 m Cat5e straight LAN cable (8-core twist pair)
Connects basic units 5 m Cat5e straight LAN cable (shield, 8-core twist pair)
Connects basic units 10m Cat5e straight LAN cable (shield, 8-core twist pair)
①
③
Control PLC
Example of TOYOPUC-Plus
* "MODBUS" is a registered trademark of Schneider Automation Inc.
Unit combinationUnit (mm)
140
90
⑤ ④ ③ ③ ② ① ⑥⑤ ④ ③ ② ① ⑥④ ③ ② ① ⑤ ⑤ ④ ③ ③ ③ ② ① ⑥
① STD16X4 × 1 set
② ST8X4MF × 1 set
③ STD16X4 × 3 sets
④ ST16X4FF × 1 set
⑤ SCR6X4 × 1 set
⑥ SCR6X4 × 1 set
⑤①②③④
44.2（26.6）
USBmemory I/F
SNI/F
I/OBUS
USBI/F
I/OBUS
FG
61.8
USBmemory I/F
SNI/F
I/OBUS
USBI/F
I/OBUS
FG
⑥⑤ ①②③④
79.4
USBmemory I/F
SNI/F
I/OBUS
USBI/F
I/OBUS
FG
⑥⑤ ①②③④
97.0
USBmemory I/F
SNI/F
I/OBUS
USBI/F
I/OBUS
FG
⑥⑤ ①②③④
Basic unit
Safety
BS0016 TNC-6886 BS0016-01 BS0016-01 ○ － １６ points ○ (Motion is switched via settings) Max. 3 units １ unit
BS0808 TNC-6887 BS0808-01 BS0808-01 ○ ８ points ８ points ○ (Motion is switched via settings) Max. 3 units １ unit
BS1204 TNC-6888 BS1204-01 BS1204-01 ○ １２ points ４ points ○ (Motion is switched via settings) Max. 3 units １ unit
BS1600 TNC-6889 BS1600-01 BS1600-01 ○ １６ points － ○ (Motion is switched via settings) Max. 3 units １ unit
General
○ (Motion is switched via settings)BN16-P TNC-6894 BN16-P-01 BN16-P-01 ○ １６ points (No. of input/outputpoints is set by the setting tool.) Max. 3 units １ unit
Optional unit (possible to mount 1 unit to the basic unit) S
afety
OS0016 TNK-6890 OS0016-01 OS0016-01 ○ － １６ points Attached content of stud and screw attachment type
Unit name Attached content of stud and screw attachment type
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