Sample safety circuits using PROFISafe - IAI Automation · 2 SW 1 ( G) SW 2 ( t) K1 , K2 ( r)...

Sample safety circuits using PROFISafe

Ver. 1 (status: Feburary 2020)

IAI Industrieroboter GmbH Ober der Röth 4

65824 Schwalbach am Taunus

This document covers the following contents:

Samples of making Safety Circuit of MCON and SCON-STO by PROFIsafe

Samples of setting PLC with MCON and SCON-STO by PROFIsafe

Samples of programming PLC with MCON and SCON-STO by PROFIsafe This document is not intended for external use, but for internal use with IAI and its distributors.

In case you need to disclose to external parties, please make the necessary adjustment wherever necessary. The contents of this document is only intended as samples, and IAI does not guarantee any outcomes by this content.

Index 1. Revision History ........................................................................................................ 1 2. Samples of Making Safety Circuits ............................................................................ 1

2.1. Sample with MCON case ............................................................................................................ 1 2.1.1. Safety function ................................................................................................................ 1 2.1.2. A sample of circuit .......................................................................................................... 1 2.1.3. Movement chart .............................................................................................................. 1 2.1.4. Safety block chart ........................................................................................................... 2 2.1.5. Assumption of Use frequency ........................................................................................ 2 2.1.6. The used equipments and machine safety reliability data ............................................. 2 2.1.7. Performance levels of Safety related areas ................................................................... 2

2.2. Samples with SCON-CB/CGB (SS1/STO options) ..................................................................... 2 2.2.1. Safety function ................................................................................................................ 2 2.2.2. A sample of circuit .......................................................................................................... 3 2.2.3. Movement chart .............................................................................................................. 3 2.2.4. Safety block chart ........................................................................................................... 4 2.2.5. Assumtion of Use frequency .......................................................................................... 4 2.2.6. The used equipments and machine safety reliability data ............................................. 4 2.2.7. Performance levels of Safety related areas ................................................................... 4

3. Samples of PLC setting ............................................................................................. 5 3.1. A sample of MCON case ............................................................................................................. 5

3.1.1. Install GSDML file ........................................................................................................... 5 3.1.2. Assign IP address and device name .............................................................................. 5 3.1.3. Network setting ............................................................................................................... 8 3.1.4. Device setting ............................................................................................................... 11 3.1.5. Assign PROFIsafe address .......................................................................................... 15 3.1.6. Write(Assign) settings on CPU unit .............................................................................. 19

3.2. Sample of SCON case .............................................................................................................. 19 4. Sample of PLC programming .................................................................................. 20

4.1. Sample of MCON case ............................................................................................................. 20 4.1.1. Add F-runtime group..................................................................................................... 20 4.1.2. Prepare PLC tag ........................................................................................................... 23 4.1.3. Safety circuit program .................................................................................................. 25 4.1.4. Verify Safety program ................................................................................................... 30

4.2. Sample of SCON programming case ........................................................................................ 31 4.2.1. Add SCON STO circuit ................................................................................................. 32 4.2.2. Add global ACK ............................................................................................................ 33 4.2.3. Password setting and Safety program protection ........................................................ 34 4.2.4. Print out Safety administration summary...................................................................... 38

5. References .............................................................................................................. 39

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1. Revision History

Rev D/M/Y Title Details

2. Samples of Making Safety Circuits

2.1. Sample with MCON case 2.1.1. Safety function

When Emergency stop SW1 is pushed (ON), the power of MCON is shut off(cut off).

The power of MCON is kept shut off until the latch of emergwncy stop SW1 is released and the reset switch SW2 is pushed(ON).

2.1.2. A sample of circuit

C

BaseUn it

6ES71 93-6BP00 -0DA0

E

BaseUn it

6ES71 93-6BP00 -0BA0

D

I n put

6ES71 93-6BP00 -0DA0

F

Outp ut

6ES71 36-6DB00 -0CA0

A

CPU

6ES71 55-6AU01 -0BN0

B

I n ter fa ce

6ES71 55-6AU01 -0BN0

PROFI sa fePROFINET

Em erg ency stop

Reset

Contactor

Contactor

MCON

EDM1

EDM2

MP24V 0V

PROFINET

24V

Safety related pa rt

SW 1

SW 2

K1

K2

2.1.3. Movement chart

2

SW 1(EMG)

SW 2 (Reset)

K1 , K2 (Contactor)

2.1.4. Safety block chart

SW 1-1EMG

SW 1-1EMG

DI n put

ACPU

FOutp ut

K1Contactor

K2Contactor

Detection

Eva lua tion

Reaction

2.1.5. Assumption of Use frequency

Use once per hour

Use 16 hours per day

Use 300 days per year Nop=4,800[times/year]

2.1.6. The used equipments and machine safety reliability data

No. Name Code Manufacturer B10D

[in thousands] MTTFD [year]

DCavg [%]

PFHd [per hour]

PL

SW1 Emergency stop switch

－ 100 *1 208 *2 99 *3 1.19ｘ10-8 *4 e *4

D Input 6ES7136-

6BA00-0CA0 SIEMENS - - - 1.00ｘ10-9 e

A CPU 6ES7212-

1HF40-0XB0 SIEMENS - - - 2.00ｘ10-9 e

F Output 6ES7136-

6DB00-0CA0 SIEMENS - - - 1.00ｘ10-9 e

K1/K2 Contactor - 400 *5 208 *2 99 *6 1.19ｘ10-8 *4 e *4

*1：ISO13849-1:2015 Table C.1 Emergency stop devices

*2：MTTFD＝B10D/(0.1×Nop)

*3：ISO13849-1:2015 Table E.1 Cross monitoring of input signals

*4：ISO13849-1:2015 Table K.1

*5：ISO13849-1:2015 Table C.1

*6：ISO13849-1:2015 Table E.1 Cross monitoring of output signals

2.1.7. Performance levels of Safety related areas

Sub system PFHd[per hour] PL

Detection 1.19ｘ10-8 e

Evaluation 4.00ｘ10-9 e

Reaction 1.19ｘ10-8 e

Total 2.78ｘ10-8 e

2.2. Samples with SCON-CB/CGB (SS1/STO options) 2.2.1. Safety function

When Emergency stop switch SW1 is pushed on, the power of SCON is shut off.

3

The power of SCON is kept shut off until the latch of emergwncy stop SW1 is released and the reset switch SW2 is pushed(ON).

2.2.2. A sample of circuit

C

BaseUn it

6ES71 93-6BP00 -0DA0

E

BaseUn it

6ES71 93-6BP00 -0BA0

D

I n put

6ES71 93-6BP00 -0DA0

F

Outp ut

6ES71 36-6DB00 -0CA0

A

CPU

6ES71 55-6AU01 -0BN0

B

I n ter fa ce

6ES71 55-6AU01 -0BN0

PROFI sa fePROFINET

EMG

ResetEDM2

PROFINET

Safety related pa rt

SW 1

SW 2

SCON-CB/CGB

SRI 1

SRI 2

EDM

G

2.2.3. Movement chart

SW 1(EMG)

SW 2 (Reset)

STO or SS1

4

2.2.4. Safety block chart

SW 1-1EMG

SW 1-1EMG

DI n put

ACPU

FOutp ut

GSCON

Detection

Eva lua tion Reaction

2.2.5. Assumtion of Use frequency Use once per hour

Use 16 hours per day

Use 300 days per year Nop=4,800[times/year]

2.2.6. The used equipments and machine safety reliability data

No. Name Code Manufactuere B10D [in thou-sands]

MTTFD [year]

DCavg [%]

PFHd [per hour]

PL

SW1 Emergenct stop switch

－ 100 *1 208 *2 99 *3 1.19ｘ10-8

*4 e *4

D Input 6ES7136-6BA00-0CA0

SIEMENS - - - 1.00ｘ10-9 e

A CPU 6ES7212-1HF40-0XB0

SIEMENS - - - 2.00ｘ10-9 e

F Output 6ES7136-6DB00-0CA0

SIEMENS - - - 1.00ｘ10-9 e

G SCON SCON-CB/CGB-***-SS/STO

IAI - - - 4.24ｘ10-10 e

*1：ISO13849-1:2015 Table C.1 Emergency stop devices *2：MTTFD＝B10D/(0.1×Nop) *3：ISO13849-1:2015 Table E.1 Cross monitoring of input signals *4：ISO13849-1:2015 Table K.1 *5：ISO13849-1:2015 Table C.1

2.2.7. Performance levels of Safety related areas Sub system PFHd[per hour] PL

Detection 1.19ｘ10-8 e

Evaluation 4.00ｘ10-9 e

Reaction 4.24ｘ10-10 e

Total 1.63ｘ10-8 e

5

3. Samples of PLC setting 3.1. A sample of MCON case This chapter will show you how to set up Safety PLC and Field network, in order to prepare Safety ciruit for MCON in Error! Reference source not found. The following setting is one of the possible examples. You may set up by your own way, which you are familiar with. This setting uses the engineering tool ‘TIA Portal’ (Totally Intergrated Automation Poertal) Version V15. The screen display may differ by the versions.

Only operation on 3.1.5 is unique to setting of PROFIsafe. All other operations are same as normal setting of PROFINET.

3.1.1. Install GSDML file

In case you have not installed GSDML file for IAI products. Please install it by referring to IAI ‘First Step Guide’.

3.1.2. Assign IP address and device name

Create a new project and assign IP address and device name to CPU unit(S7-1200F), Remote I/O(ET200SP) and MCON.

3.1.2.1. Assign to CPU unit(S7-1200F) Connect your PC installed with TIA Portal and CPU unit by Ethernet cable, and double-click “Online accessible devices”.

When CPU unit is shown as “Accessible device(MAC address)”, Click “Online & diagnostics” →

”Functions” → “Assign IP address”. Then, enter “IP address” and “Subnet mask” (this case:

192.168.0.1 and 255.255.255.0) and click “Assign IP address” button.

6

Then, click “Online & diagnostics” → “Functions” → “Assign PROFINET device name”.

Enter “PROFINET device name” (This case: S7-1200F),then click “Assign name” button at the bottom.

3.1.2.2. Assign to Remote I/O(ET200SP) Connect your PC installed with TIA Portal and Remote I/O by Ethernet cable, then double-click “Online accessible devices”.

7

When Remote I/O is shown as ”Accessible device(MAC address)”,then click ”Online & diagnostics” →

”Functions” → “Assign IP address”. Enter “IP address” and “Subnet mask” (This case:192.168.0.2

And 255.255.255.0), then click「Assign IP address」button.

Then click ”Online & diagnostics” → ”Functions” → ”Assign PROFINET device name”.

Enter “PROFINET device name” (This case:ET200SP), then click ”Assign name” button.

3.1.2.3. Assign to MCON Connect your PC installed with TIA Portal and MCON by Ethernet cable, then double-click “Online accessible devices”. IAI products have default device name(iai-prt) at factory setting, we use this name as is for this case.

8

When CPU unit is shown, click ”Online & diagnostics” → “Functions” →”Assign IP address”

Enter”IP address” and ”Subnet mask” (This case:192.168.0.3 and 255.255.255.0), then Click ”Assign IP address” button.

3.1.3. Network setting

Connect each equipment and Swithing Hub by Ethernet cable. Double-click “Devices & networks”.Click ”Network view”, then search for each equipment from ”Hardware catalog” and put them in ”Network view” by double-click. Check the version of each equipment at “Information”, before you put them in “Network view”. Change each equipment name on the left of the icons from original name to the ones which you set in the previous chapter. (CPU unit(S7-1200F), Remote I/O(ET200SP), IAI device(MCON))

("plc_1"→"S7-1200F", "IO device_1"→"ET200SP", Keep "IAI-PRT" as it is).

9

Next, Execute “Assign to new IO controller” by right clicking on “Not assigned” part, which is shown in blue letters with underline.

10

Select IO controller device as shown on screen, and click OK.

Follow the same setting for "IAI-PRT"

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3.1.4. Device setting Connect each equipment and Switching Hub by Ethernet cable. 3.1.4.1. Setting CPU unit(S7-1200F)

Show “Device view”, then select “S7-1200F[CPU 1212FC]”. Select illustration of CPU unit, then show “Properties”.

Click “General” → “Fail-safe”, and make sure that “F-activation” is activated.

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3.1.4.2. Setting Remote I/O(ET200SP) Click “Device view”, then select “ET200SP[IM 155-6 PN ST]”. Search each safety I/O module installed from “Hardware catalog” from the right side, then assign it. Check the version of each module at “Information” befoe you assign it.

13

After you assign it, select an illustration of each safety I/O module, then click

“Properties” → ”General” and set parameters. For this case, we set the parameters of safety input

module (F-DI 8x24VDC HF)of Safety remote I/O(ET200SP) as follows:

Channel 0,4：Discrepancy time 10ms

Channel1,5：Sensor evaluation 1oo1 evaluation

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Channel2,6：Sensor evaluation 1oo1 evaluation

Channel3,7：Discrepancy time 200ms

3.1.4.3. MCON setting Click ”Device view”, and select ”IAI-PRT[RT Standard]”. Assign input-output sizes in “Module” of “Device overview” from “Hardware catalog” input/output list on the right side. Make sure that In-put/Output sizes should match the ones which you have set by ‘GW parameter setting tool’ and the order of input is before the output.

15

3.1.5. Assign PROFIsafe address Assign PROFIsafe address on Safety remote I/O, before you download settings onto CPU unit. This is the only additional operation, which is required for PROFIsafe setting. Change the display from “Device view” back to ”Network view”. Right-click the icon of Safety remote I/O(ET200SP), then click ”Assign PROFIsafe Address”.

16

When the following dialogue is shown, check “Assign” column on left side, then click “Identification” button,as indicated below.

17

18

The dialogue now shows the below screen. Check “Confirm” column on the right side, then click ”Assign PROFIsafe address” button.

Click ‘Yes’ within the indicated time !!

The setting is completed, once the ”Status” column indicates ”assigned”as below.

19

3.1.6. Write(Assign) settings on CPU unit

After you complete the above settings in the previous chapters, you now need to download these changes onto CPU unit. Please build a hardware and transfer to the device. You may execute ”Download to device” on “Online” menu as well (same result) Check whether any error does not occur in CPU unit(CPU unit can operate properly)

3.2. Sample of SCON case Configure SCON safety circuit indicated on 2.2. The version of TIA Portal to be used is same as the previous chapter(MCON case). The required steps and remarks are also same as MCON case, and you just need change the size settings of MCON on 3.1.4.1 to those of SCON, so that you can apply the right data.

20

4. Sample of PLC programming 4.1. Sample of MCON case The sample uses the case of MCON safety circuit on Error! Reference source not found.

4.1.1. Add F-runtime group In case there is no “F-runtime group” on “Program blocks”,Create (Add) a new one by clicking

“Safety Administration” → “F-runtime group” → “Add new F-runtime group”

21

In this case, just click “OK” without adding a new one.

Right-click “Main_Safety_RTG1[FB0]” on the created(added) “Program blocks”, then Execute “Propeties...”. Change the programming language to “LAD” (Ladder) on the dialogue shown,

by clicking “General” → ”Language”.

You may use “FBD” as it is if you are used to it, but this sample use “LAD”.

22

Take the following steps to make ‘Software rebuild’ in order to prevent possible errors.

23

4.1.2. Prepare PLC tag

Prepare PLC tags to be used for Safety programs. Click ”Device view”, then select “ET200SP[IM 155-6 PN ST]”.

Select Safety input module illustration (F-DI 8x24VDC HF), click “Properties” → “IO tags”,

Then input tags data as shown below.

24

Select Safety output module illustration(F-DQ 4x24VDC/2A PM HF), click「Properties」→「IO tags」,

Then input tags data as shown below.

25

4.1.3. Safety circuit program

Click ”Program blocks” → open “Main_Safety_RTG1[FB0]” by double-click.

On the right side, click “Instructions” → “Basic Instructions” → “Safety functions”, and then

Select function blocks for safety circuit. For this case, the function blocks to be used are: “ESTOP1” “FDBACK”. Put “ESTOP1” on “Network1”, as emergency stop should be the first priority to work.

26

Double-click “ESTOP1”, then create as “Multi instance”.

→

Double-click “FDBACK”, then create as “Multi instance”.

→

27

Now the screen should look as follows for the right setting.

28

Next, move to the setting of function blocks input/output.

Click “Details view”, then “PLC tags” → “Default tag tables[52]”, show tag data set for safety I/O

module as shown below.

29

Drag & Drop tag data set for safety I/O module and assign them on input/output of function blocks as shown below screen: Assign “#EMG_OK” in the Temporary of “Main_Safety_RTG1”, then set output “Q” for “ESTOP1” input “ON” for ”FDBACK”.

30

Click ”Program blocks”→ “System blocks” → “STEP7 Safety” → “F-I/O data blocks” →

“F00007_F-DQ4x24VDC/2APMHF_1[DB30003]”, then drag & drop “QBAD” shown in “Detail view” onto the input “QBAD_FIO” at “FDBACK” as follows:

4.1.4. Verify Safety program

Build the software, and transfer it to CPU unit. Check that contactors operate properly by using emergency switch and reset switch.

31

4.2. Sample of SCON programming case This case shows programming sample of SCON safety circuit in the chapter 2.2. The contents are same as the program made in the previous chapter4.1,so we assume the following configuration and add SCON circuit to MCON circuit. Password setting and printing safety administration summary are also explained in this chapter.

24V

power supply

Connector Connector

Power input

System I/O

4.2.1. Add SCON STO circuit STO input/output can be set by “FDBACK” function blocks, same as contactors.

4.2.2. Add global ACK

In case the system error is solved by monitoring input/output of Safety I/O module, you need to add global ACK, so that you can reset back by the reset switch. The function block to be used is “ACK_GL”.

4.2.3. Password setting and Safety program protection

After you confirm the system safety functions operate properly, you can set safety program protection in order to prevent unexpected editing of safety program. Open ”Safety Administration” on CPU unit, Set your own password at “Access protection”,if a password is not yet set.

Click “Safety Administration” → “Settings” → “Advanced settings”, and remove check-mark

“Safety mode can be disabled” in case it is activated (check-marked)

Set your access levels at Properties of CPU unit, depending on your safety requirement.

After you change settings in ”Safety Administration”, you need to download them onto CPU unit. Build a hardware and transfer(download )to the device. You may select “Download to device” on “Online” menu for the same result. Refer to the below screen shot.

4.2.4. Print out Safety administration summary

Print out Safety administration summary for preparing acceptance test. Right-click “Safety Administration”, then select “Print...”.

5. References

Safety of machinery - Guidelines of Functional Safety PLC The Japan Electrical Manufactur-ers' Association PLC Technical Committee Safety PLC WG

Emergency Stop up to SIL 3 / PL e with a Fail-Safe S7-1500 Controller Entry ID: 21064024, V4.0, 07/2015 Siemens AG 2015

OMRON Technical guide Safety circuit samples

Sample8：Decelerate and stop by emergency switch and then cut by STO

SITRAIN(SIEMENS training program): (TIA-PRO1_J) TIA Portal Programming 1 (TIA-SAFETY_J) TIA Portal S7-1500F Safety Advanced Course * Recommend to take the similar courses, in order to understand chapter 0 and 3