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PSS 4000 Timely limited automatic suspension of safety functions Structured Text
Product Type: FS_LightCurtain, FS_EnableSwitch, FS_Muting, FS_OutputFBL Name: PSS 4000, Blocks, PAS4000, PLC, STL Manufacturer: Pilz GmbH & Co. KG, Safe Automation Document Release Number: 01 Release Date: 22 April 2013
Application Note - No. 1002664_EN_01
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756 pt
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784 pt
798 pt
812 pt
826 pt
Application Note – No. 1002664_EN_01
PSS 4000 Timely limited automatic suspension of safety functions Structured Text
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 2/37 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: [email protected]
Document Revision History
Release Date Changes Chapter
01 2013-04-22 Creation all
Exclusion of liability
We have taken great care in compiling our application note. It contains information about our company and our products. All statements are made in accordance with the current status of technology and to the best of our know-ledge and belief. However, we cannot accept liability for the accuracy and entirety of the information provided, except in the case of gross negligence. In particular it should be noted that statements do not have the legal quality of assurances or assured properties. We are grateful for any feedback on the contents. April 2013 All rights to this publication are reserved by Pilz GmbH & Co. KG. We reserve the right to amend specifications without prior notice. Copies may be made for the user’s internal purposes. The names of products, goods and technologies used in this manual are trademarks of the respective companies.
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798 pt
812 pt
826 pt
Application Note – No. 1002664_EN_01
PSS 4000 Timely limited automatic suspension of safety functions Structured Text
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 3/37 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: [email protected]
Support
Technical help round the clock! Technical support is available from Pilz round the clock. This service is provided free of charge beyond standard business hours.
Americas � Brazil
+55 11 97190-3239 � Mexico
+52 55 5572 1300 � USA (toll free)
+1 877-PILZUSA (745-9872)
Asia � China
+86 400 088 3566 � Japan
+81 45 471-2281 � Korea
+82 2 2263 9540
Australia � Australia
+61 3 95446300
Europe � Austria
+43 1 7986263-0 � Belgium, Luxembourg
+32 9 3217575 � France
+33 3 88104000 � Germany
+49 711 3409-444 � Ireland
+353 21 4804983 � Italy
+39 0362 1826701 � Scandinavia
+45 74436332 � Spain
+34 938497433 � Switzerland
+41 62 88979-30 � The Netherlands
+31 347 320477 � Turkey
+90 216 5775552 � United Kingdom
+44 1536 462203
You can reach our international hotline on:
+49 711 3409-444 or mailto:[email protected]
Pilz GmbH & Co. KG Safe Automation Felix-Wankel-Straße 2 73760 Ostfildern, Germany
Telephone: +49 711 3409-0 Telefax: +49 711 3409-133 E-Mail: [email protected] Internet: www.pilz.com
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686 pt
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728 pt
742 pt
756 pt
770 pt
784 pt
798 pt
812 pt
826 pt
Application Note – No. 1002664_EN_01
PSS 4000 Timely limited automatic suspension of safety functions Structured Text
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 4/37 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: [email protected]
Contents
1. Useful documentation .................................................................................. 6 1.1. Documentation from Pilz GmbH & Co. KG ............................................................................ 6 1.2. Documentation from other sources of information ................................................................. 6
2. Hardware configuration ................................................................................ 7 2.1. Pilz products ........................................................................................................................... 7 2.2. Hardware configuration .......................................................................................................... 7
3. Application Task ........................................................................................... 8 3.1. Description ............................................................................................................................. 8
3.1.1. Light curtain monitoring function .................................................................................. 9
3.1.2. Mute dependent override ........................................................................................... 11
3.1.3. Muting monitoring function ......................................................................................... 13
3.1.4. Feedback loop monitoring function ............................................................................ 16
3.2. Functional safety .................................................................................................................. 17 3.2.1. Safety-related characteristics in accordance with EN ISO 13849-1 .......................... 17
3.2.2. Safety-related characteristics in accordance with EN 62061 .................................... 18
3.3. PAS-Project .......................................................................................................................... 19 3.3.1. IEC 61131 Programming ........................................................................................... 19
3.3.2. I/O Mapping ............................................................................................................... 26
3.3.3. Process PAS Project ................................................................................................. 27
3.4. Circuit diagram of the application ......................................................................................... 30 3.4.1. Circuit diagram 1/6 ..................................................................................................... 30
3.4.2. Circuit diagram 2/6 ..................................................................................................... 31
3.4.3. Circuit diagram 3/6 ..................................................................................................... 32
3.4.4. Circuit diagram 4/6 ..................................................................................................... 33
3.4.5. Circuit diagram 5/6 ..................................................................................................... 34
3.4.6. Circuit diagram 6/6 ..................................................................................................... 35
Table of figures ............................................................................................... 36
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784 pt
798 pt
812 pt
826 pt
Application Note – No. 1002664_EN_01
PSS 4000 Timely limited automatic suspension of safety functions Structured Text
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 5/37 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: [email protected]
Abbreviations
PAS Pilz Automation Suite (software platform) PSS Programmable Control System (DE: Programmierbares Steuerungssystem) FS-FB Failsafe Function Block POU Program Organisation Unit PRG Program FB Function Block FUN Function STL (ST) Structured Text Language PMI Pilz Human Machine Interface Muting Timely limited automatic suspension of safety functions Override Mute dependent override
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630 pt
644 pt
658 pt
672 pt
686 pt
700 pt
714 pt
728 pt
742 pt
756 pt
770 pt
784 pt
798 pt
812 pt
826 pt
Application Note – No. 1002664_EN_01
PSS 4000 Timely limited automatic suspension of safety functions Structured Text
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 6/37 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: [email protected]
1. Useful documentation
Reading the documentation listed below is necessary for understanding this application note. The availability of the indicated tools and safe handling are also presupposed with the user.
1.1. Documentation from Pilz GmbH & Co. KG
No. Description Item No.
1 Pilz international homepage, download section www.pilz.com
2 Operating Manual PSSu H PLC1 FS SN SD 21939-EN-xx
3 Operating Manual PSSu E F 4DI 21 311-xx
4 Operating Manual PSSu E F DI OZ 2 21 329-xx
5 Operating Manual PSSu E S 4DI 21 340-EN-xx
6 Operating Manual PSSu E S 4DO 0.5 21 346-EN-xx
7 Operating Manual PSEN op4F/H-s-.../1 1001 422-EN-xx
8 Operating instructions PIT si2.1 21 531-3FR-xx
9 Instruction manual PSEN op1.1, PSEN op1.2, PSEN op1.3 826002350-00
10 System Description Programmable safety and control system PSS 4000 1001 467-EN-xx
11 Safety Manual Programmable safety and control system PSS 4000 1001 468-EN-xx
12 PAS4000 online help -
1.2. Documentation from other sources of information
No. Description Item No.
1
2
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Application Note – No. 1002664_EN_01
PSS 4000 Timely limited automatic suspension of safety functions Structured Text
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 7/37 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: [email protected]
2. Hardware configuration
2.1. Pilz products
No. Description Order number Version Number
1 PSSu H PLC1 FS SN SD 312 070 001 1
2 PSSu E F 4DI 312 200 003 2
3 PSSu E F DI OZ 2 312 220 004 3
4 PSSu E S 4DI 312 400 004 2
5 PSSu E S 4DO 0.5 312 405 003 1
6 PSSu BP 1/8 C 312 601 1.1 8
7 PSEN op4F-s-14-090/1 630 745 - 1
8 PIT si2.1 620 015 - 1
9 PSEN op1.2 Emitter M12 630 322 - 4
10 PSEN op1.1 Receiver pnp no/nc M12 630 321 - 4
11 PAS4000 - v1.7.0 1
2.2. Hardware configuration
Fig. 1: Hardware configuration
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Application Note – No. 1002664_EN_01
PSS 4000 Timely limited automatic suspension of safety functions Structured Text
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 8/37 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: [email protected]
3. Application Task
3.1. Description
The example shows the implementation of a muting application with PSS 4000 PLC, a PSEN op4F-s-14-090/1 light curtain and PSEN op1.1/PSEN op1.2 muting sensors. The light curtain (A1, A2) protects against an unauthorized entering of the danger area. The muting sensors (MS1(_1)-MS4(_1)) can activate a timely limited suspension of the light curtain. A PIT si2.1 muting lamp (H1) is installed to indicate the active muting. "During muting, safe conditions shall be provided by other means" [EN ISO 13849-1] (e.g. the conveyed item blocking access to the danger zone). If an error occurs during muting, that stops the movement, the cargo can be moved out of the monitored area by the override switch (S3), as long as it is still inside the muting sensor area.
Fig. 2: Muting application
The safe control and evaluation of the signals is taken over by two Pilz function blocks (FS-FB) from the PAS4000 library. PAS4000 library - General FS blocks Check sum (CRC) Version
FS_LightCurtain 5963 1.1.0
FS_EnableSwitch 7C1A 1.1.0
FS_Muting 9E29 1.0.0
FS_OutputFBL B3A7 1.1.0
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Application Note – No. 1002664_EN_01
PSS 4000 Timely limited automatic suspension of safety functions Structured Text
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 9/37 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: [email protected]
3.1.1. Light curtain monitoring function
The control system monitors the light curtain (A1, A2) via the user program. An instance of the Pilz function block FS_LightCurtain is assigned to the light curtain. This FS-FB detects whether the assigned light curtain has been operated, as well as detecting incorrect input signals and whether the contact synchronization time has been exceeded, etc. If the light curtain is interrupted or an error occurs, the enable output Enable on the FS-FB will immediately be reset. The enable output Enable is also reset when the PSS is stopped and when the PSS is switched on. The signal from the enable output Enable must be evaluated by the user program and trigger an appropriate reaction (see muting monitoring function 3.1.3). Based on the diagnostic outputs (DiagSwitchError, DiagInputNotValid) it can be determined why Enable was reset. The outputs DiagOperated, DiagReadyForReset and DiagReadyForTest are used as status messages. (The analysis of the diagnose messages and status messages is not shown in this example. It can be identified in the diagnostic log or print on a display (e.g. PMI)). A valid bit is formed by the system for the respective hardware input to determine whether a process value received from a sensor is valid. The valid bit is queried in the function block and indicates whether an error has occurred in the signal transmission between hardware input and processor (such as test clock error, module overheats, etc.). If the valid bit is FALSE, the process value is invalid and the Pilz function block provides an appropriate diagnostic message. The error signal reset enable. (For more information, see “Validity process data” in PAS4000 online help) The way in which the error is reset will depend on the operating mode set on the FS-FB. In this application example, parameters for FS-FB have been set in such a way that when:
- PSS is cold started (PSS switched from off to on), - PSS is warm started (PSS transferring from STOP to RUN) or - when the light curtain are released
no confirmation is necessary. The output parameter Enable is set (high) automatically as soon as the light curtain detects no failure. The duty of acknowledge after a light curtain interruption by unauthorized access (muting not active) will be realized by the function block FS_Muting (see 3.1.3. Muting monitoring function). Although the light curtain and the light curtain function are configured to reset themselves, a PSS cold start or the release of the light curtain may not directly enable a machine to start up without further conditions being met.
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Application Note – No. 1002664_EN_01
PSS 4000 Timely limited automatic suspension of safety functions Structured Text
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 10/37 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: [email protected]
Safety assessment light curtain monitoring � A short between 24 VDC and an input circuit on the PSSu module will be detected as an error
by the AOPD; the AOPD outputs are shut down. � A short between the input circuits on the PSSu module will be detected as an error by the
AOPD; the AOPD outputs are shut down. � If an operator completely (or even maybe partly) is able to access the dangerous area, a risk
analysis should clarify whether an additional, separate manual reset function is required.
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Application Note – No. 1002664_EN_01
PSS 4000 Timely limited automatic suspension of safety functions Structured Text
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 11/37 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: [email protected]
3.1.2. Mute dependent override
The control system monitors the override switch S3 (key-operated push button) via the user program. An instance of the Pilz function block FS_EnableSwitch is assigned to the switch. This FS-FB detects whether the assigned switch has been operated, as well as detecting incorrect input signals and whether the contact synchronization time has been exceeded, etc. If the contacts of the override switch are interrupted or an error occurs, the enable output Enable on the FS-FB will immediately be reset. The enable output Enable is also reset when the PSS is stopped and when the PSS is switched on. The signal from the enable output Enable must be evaluated by the user program and trigger an appropriate reaction (see muting monitoring function 3.1.3). Based on the diagnostic outputs (DiagSwitchError, DiagInputNotValid) it can be determined why Enable was reset. The outputs DiagOperated, DiagReadyForReset and DiagReadyForTest are used as status messages. (The analysis of the diagnose messages and status messages is not shown in this example. It can be identified in the diagnostic log or print on a display (e.g. PMI)). A valid bit is formed by the system for the respective hardware input to determine whether a process value received from override switch (S3) is valid. The valid bit is queried in the function block and indicates whether an error has occurred in the signal transmission between hardware input and processor (such as test clock error, module overheats, etc.). If the valid bit is FALSE, the process value is invalid and the Pilz function block provides an appropriate diagnostic message. The error signal reset enable. (For more information, see “Validity process data” in PAS4000 online help) The way in which the error is reset will depend on the operating mode set on the FS-FB. In this application example, parameters for FS-FB have been set in such a way that when:
- PSS is cold started (PSS switched from off to on), - PSS is warm started (PSS transferring from STOP to RUN) or - the switch contacts have been closed
no confirmation is necessary. The output parameter Enable is set (high) automatically as soon as the switch contacts are set to TRUE. The duty of acknowledge after a mute depend override function will be realized by the function block FS_Muting (see 3.1.3. Muting monitoring function).
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Application Note – No. 1002664_EN_01
PSS 4000 Timely limited automatic suspension of safety functions Structured Text
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 12/37 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: [email protected]
Safety assessment override � A short between 24 VDC and an input circuit on the PSSu module will be detected as an error
by the programmable control system; the Enable output of the FS-FB is shut down. � A short between the input circuits on the PSSu module will be detected as an error by the
programmable control system; the Enable output of the FS-FB is shut down. � The override switch must be operated in adequate time interval for fault detection purposes. � The highest safety level can only be achieved when:
- The contacts on the enable switch are supplied with test pulses - The enable switch has dual-channel wiring.
� The override switch must be lockable and must have hold-to-run control. � The override switch must be installed in a fixed position outside the danger zone. � The danger zone and the muting station must be visible from the override switch position. � A separate operating mode must be provided for the bridging using Override = TRUE. This
operating mode will not permit automatic operation.
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Application Note – No. 1002664_EN_01
PSS 4000 Timely limited automatic suspension of safety functions Structured Text
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 13/37 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: [email protected]
3.1.3. Muting monitoring function
The control system monitors the muting sensors (MS1-MS4) via the user program. An instance of the Pilz function block FS_Muting is assigned to them. This FS-FB detects the Enable output of the function FS_LightCurtain. It recognises, when a valid suspension of the assigned light curtain was triggered by the muting sensors. The instance of FS_Muting is inserted between the instances of the function blocks FS_LightCurtain and FS_OutputFBL. If the muting function is not active, the instance transfers the Enable signal of the function block FS_LightCurtain directly to the function block FS_OutputFBL. If muting is activated (MS1-MS4 are activated in the correct operation- and time behaviour of the selected muting operating mode), enable of the function block remains active independently from the Enable signal of FS_LightCurtain in this time period. The light curtain then can be interrupted without triggering a shut-off of the machine. This situation must not produce a hazard. While muting is active, safe conditions must be provided by other means (e.g. the conveyed item blocking access to the danger zone). To execute muting without interruption of the automatic process, the function AutoReset of the function block FS_LightCurtain must be activated. Thus, the light curtain can resume its safety function without manual intervention once the muting is finished. If the light curtain is interrupted when muting is not active or when an error has occurred, the enable output Enable of the FS-FB FS_Muting is reset immediately. The enable output Enable is also reset when the PSS is stopped and when the PSS is switched on. The signal from the enable output Enable must be evaluated by the user program and trigger an appropriate reaction (see feedback loop monitoring function 3.1.4). Based on the diagnostic outputs (DiagTimingErrorMS1MS2, DiagMS1NotOperated, …) it can be determined why Enable was reset. The outputs DiagReadyForReset and MutingActive are used as status messages. (The analysis of the diagnose messages and status messages is not shown in this example. It can be identified in the diagnostic log or print on a display (e.g. PMI)). A valid bit is formed by the system for the respective hardware input to determine whether a process value received from muting sensors (MS1-MS4) is valid. The valid bit is queried in the function block and indicates whether an error has occurred in the signal transmission between hardware input and processor (such as test clock error, module overheats, etc.). If the valid bit is FALSE, the process value is invalid and the Pilz function block provides an appropriate diagnostic message. The error signal reset enable. (For more information, see “Validity process data” in PAS4000 online help)
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Application Note – No. 1002664_EN_01
PSS 4000 Timely limited automatic suspension of safety functions Structured Text
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 14/37 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: [email protected]
The way in which the error is reset will depend on the operating mode set on the FS-FB. In this application example, parameters for FS-FB have been set in such a way that when:
- PSS is cold started (PSS switched from off to on), - PSS is warm started (PSS transferring from STOP to RUN), - the signal process of the muting sensors is faulty or - the light curtain is interrupted without active muting
a confirmation with MyMuting1.Reset (S9) is necessary to set the output parameter Enable. The function block FS_Muting supports the following operating modes: � Sequential muting � Parallel muting � Cross muting The decision to select one of these operating modes is dependent on the application (material, sensors, tolerable drive direction, etc.). (You find more detailed information about the muting operating modes and detailed descriptions to the arrangement of the muting sensors and the switching conditions in the PAS4000 online help under “General FS control blocks/FS_Muting”) Info The existing Application Note shows exemplarily the variant sequential muting.
Fig. 3: Sequential muting application
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Application Note – No. 1002664_EN_01
PSS 4000 Timely limited automatic suspension of safety functions Structured Text
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 15/37 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: [email protected]
Safety assessment muting � A short between 24 VDC and an input circuit on the PSSu module will be detected as an error
by the logical sequence of the signals; the Enable output of the FS-FB is shut down. � A short between the input circuits on the PSSu module will be detected as an error by the
logical sequence of the signals; the Enable output of the FS-FB is shut down. � Standard sensors are used as muting sensors. Anyway they are read in the example from
safe inputs. The reason is that the hardware inputs are mapped to safe FS-I PI variables of the function block FS_Muting. Thus, the safety of muting evaluation is not determined by the sensors but by the logical sequence of the muting signals in the FS_FB.
� The connection cables to the muting sensors must be laid in a way that is protected against shorts (i.e. separate).
� The muting sensors must be aligned so that they detect the goods to be conveyed and not the transport equipment (e.g. pallet). So it must not be possible for the operator to undiscovered access through, pass through, or ride along in any way the transport system.
� The muting sensors (MS1-MS4) must be operated periodically for fault detection purposes. � “During muting, safe conditions shall be provided by other means” [EN ISO 13849-1 (chapter
5.2.5 Muting function)]. � “The performance level of safety-related parts providing the muting function shall be selected
so that the inclusion of the muting function does not diminish the safety required of the relevant safety function” [EN ISO 13849-1 (chapter 5.2.5 Muting function)].
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Application Note – No. 1002664_EN_01
PSS 4000 Timely limited automatic suspension of safety functions Structured Text
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 16/37 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: [email protected]
3.1.4. Feedback loop monitoring function
The control system monitors the feedback circuits (NC contacts) of the motor contactors KM1 and KM2 via the user program. An instance of the Pilz function block FS_OutputFBL is assigned to them. A second instance is used to monitor and control the conveyor belt (motor contactors KM3, KM4). The FS_FB drives the contactors as well as monitoring the feedback loop. A 1-signal at input parameter Input (Enable from light curtain/muting) of the FS-FB sets the outputs that drive the contactors, Output1 (and Output2), to “1”; a 0-signal sets it to “0”. If an error occurs, the outputs Output1 (and Output2) that drive the contactors on FS-FB will immediately be reset. Both outputs are also reset when the PSS is stopped and when the PSS is switched on. Based on the diagnostic outputs (DiagFeedbackLoopError, DiagFeedbackLoopNotValid) it can be determined why the outputs were reset. (The analysis of the diagnose messages is not shown in this example. It can be identified in the diagnostic log or print on a display (e.g. PMI).) A valid bit is formed by the system for the respective hardware input to determine whether a process value received from the feedback circuit is valid. The valid bit is queried in the function block and indicates whether an error has occurred in the signal transmission between hardware input and processor (such as test clock error, module overheats, etc.). If the valid bit is FALSE, the process value is invalid and the Pilz function block provides an appropriate diagnostic message. The error signal reset enable. (For more information, see “Validity process data” in PAS4000 online help) If an error occurs, a new activity has to take place at the input “Input” of the FS-FB once the error has been rectified, so that the outputs Output1 and Output2 will be set again. Feedback loop monitoring safety assessment � A short between 24 VDC and a safety output or a feedback loop input will be detected as an
error by the programmable safety system. The load can be switched off via the second shutdown route.
� The feedback loop contacts must be installed in a single mounting area (control cabinet). � To achieve a higher level of safety, 2 actuators must be used.
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Application Note – No. 1002664_EN_01
PSS 4000 Timely limited automatic suspension of safety functions Structured Text
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 17/37 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: [email protected]
3.2. Functional safety
3.2.1. Safety-related characteristics in accordance with EN ISO 13849-1
No. Safety function PL Safety-related parts of the control
system
1 Machine shut down when the safety light
curtain is interrupted.
(Motor 1 – Dangerous machine)
PL e Sensor (PSEN op4F-s…/1 A1, A2)
Input (PSSu E F 4DI)
Logic (PSSu H PLC1 FS SN)
Output (PSSu E F DI OZ 2)
Actuator (contactors KM1, KM2)
2 Machine shut down when the safety light
curtain is interrupted.
(Motor 2 - Conveyor belt)
PL e Sensor (PSEN op4F-s…/1 A1, A2)
Input (PSSu E F 4DI)
Logic (PSSu H PLC1 FS SN)
Output (PSSu E F DI OZ 2)
Actuator (contactors KM3, KM4)
3 Timely limited automatic suspension of a
safety device.
(Muting)
PL e Sensor (PSEN op1.1/op1.2 MS1-MS4
[Safety of sensor values
by FS-FB FS_Muting])
Input (PSSu E F 4DI)
Logic (PSSu H PLC1 FS SN)
4 Mute dependent override. PL e Sensor (key-operated push button S3)
Input (PSSu E F 4DI)
Logic (PSSu H PLC1 FS SN)
Output (PSSu E F DI OZ 2)
Actuator (contactors KM3, KM4)
Prerequisites No. Description Identification
1 Common cause failure (CCF) Requirements are considered to be met
(must be tested on implementation)
2 Mission time 20 years
3 Operating interval (electromechanical
components)
Sensor S3 one operation per week
Actuator KM1/KM2 one operation per week
Actuator KM3/KM4 two operations per week
4 Characteristic data of override key switch S3 B10d 100,000
5 Characteristic data of contactors KM1-KM4 B10d 2,000,000
Please note the further requirements of EN ISO 13849-1, e.g. requirements for avoiding systematic faults.
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Application Note – No. 1002664_EN_01
PSS 4000 Timely limited automatic suspension of safety functions Structured Text
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 18/37 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: [email protected]
3.2.2. Safety-related characteristics in accordance with EN 62061
No. Safety-related control function (SFCF) Safety Integrity
Level
Subsystems
1 Machine shut down when the safety light
curtain is interrupted.
(Motor 1 – Dangerous machine)
SIL 3 Sensor (PSEN op4F-s…/1 A1, A2)
Input (PSSu E F 4DI)
Logic (PSSu H PLC1 FS SN)
Output (PSSu E F DI OZ 2)
Actuator (contactors KM1, KM2)
2 Machine shut down when the safety light
curtain is interrupted.
(Motor 2 - Conveyor belt)
SIL 3 Sensor (PSEN op4F-s…/1 A1, A2)
Input (PSSu E F 4DI)
Logic (PSSu H PLC1 FS SN)
Output (PSSu E F DI OZ 2)
Actuator (contactors KM3, KM4)
3 Timely limited automatic suspension of a
safety device.
(Muting)
SIL 3 Sensor (PSEN op1.1/op1.2 MS1-MS4
[Safety of sensor values
by FS-FB FS_Muting])
Input (PSSu E F 4DI)
Logic (PSSu H PLC1 FS SN)
4 Mute dependent override. SIL 3 Sensor (key-operated push button S3)
Input (PSSu E F 4DI)
Logic (PSSu H PLC1 FS SN)
Output (PSSu E F DI OZ 2)
Actuator (contactors KM3, KM4)
Prerequisites No. Description Identification
1 Common cause failure (CCF) ß = 2% (must be tested on
implementation)
2 Proof test interval 20 years
3 Operating interval (electromechanical
components)
Sensor S3 one operation per week
Actuator KM1/KM2 one operation per week
Actuator KM3/KM4 two operations per week
4 Characteristic data of override key switch S3 B10d 100,000
Dangerous
failure rate
50%
5 Characteristic data of contactors KM1-KM4 B10d 2,000,000
Dangerous
failure rate
65%
Please note the further requirements of EN 62061, e.g. requirements for systematic safety integrity.
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Application Note – No. 1002664_EN_01
PSS 4000 Timely limited automatic suspension of safety functions Structured Text
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 19/37 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: [email protected]
3.3. PAS-Project
To operate a plant with one or more programmable control systems PSS 4000, a project must be created in PAS4000. A project consists of the hardware configuration and the user program.
3.3.1. IEC 61131 Programming
When programming in accordance with IEC 61131, the user program is structured by three types of program organisation units (POUs): � Programs (PRG) � Function blocks (FB) � Functions (FUN) The program forms the higher structural level. Functions and function blocks may be called up within a program. Function blocks and functions undertake specific individual tasks within the program. Each POU consists of a declaration part and an instruction part. The variables and type declarations are made in the declaration part, which is shown in text format, irrespective of the programming language. The instruction part contains the instructions. The instructions can be formulated in one of the IEC 61131 programming languages. (For more information about programming with PAS4000, look at PAS4000 online help)
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Application Note – No. 1002664_EN_01
PSS 4000 Timely limited automatic suspension of safety functions Structured Text
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 20/37 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: [email protected]
3.3.1.1. STL-Editor
The program for the cyclic process is created in a POU of the type Program. The Pilz function blocks for light curtain, enabling (override), muting and feedback loop were added from the library. (Right-click in the declaration part of the POU “Add library element”).
Fig. 4: Add library element
Fig. 5: Selection library element
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Application Note – No. 1002664_EN_01
PSS 4000 Timely limited automatic suspension of safety functions Structured Text
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 21/37 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: [email protected]
Failsafe program Declaration part 001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 017 018 019 020 021 022 023 024 025 026 027 028 029 030 031 032 033 034 035 036 037 038 039 040 041 042 043 044 045 046 047 048 049 050 051 052 053 054 055 056 057 058 059 060 061 062
PROGRAM Main_FS VAR // My Light Curtain 1 MyLightCurtain1 : FS_LightCurtain; MyLCurt1_Enable : SAFEBOOL; MyLCurt1_DiagOperated : SAFEBOOL; MyLCurt1_DiagReadyForReset : SAFEBOOL; MyLCurt1_DiagReadyForTest : SAFEBOOL; MyLCurt1_DiagSwitchError : SAFEBOOL; MyLCurt1_DiagInputNotValid : SAFEBOOL; // My Oveerride Switch 1 MyEnableSwitch1 : FS_EnableSwitch; MyEnab1_Enable : SAFEBOOL; MyEnab1_DiagOperated : SAFEBOOL; MyEnab1_DiagReadyForReset : SAFEBOOL; MyEnab1_DiagReadyForTest : SAFEBOOL; MyEnab1_DiagSwitchError : SAFEBOOL; MyEnab1_DiagInputNotValid : SAFEBOOL; // My Muting 1 MyMuting1 : FS_Muting; MyMut1_NoMovement AT %I* : SAFEBOOL; MyMut1_Enable AT %Q* : SAFEBOOL; MyMut1_MutingActive AT %Q* : SAFEBOOL; MyMut1_DiagTimingErrorMS1MS2 : SAFEBOOL; MyMut1_DiagMS1NotOperated : SAFEBOOL; MyMut1_DiagMS2NotOperated : SAFEBOOL; MyMut1_DiagTimingErrorMS3MS4 : SAFEBOOL; MyMut1_DiagMS3NotOperated : SAFEBOOL; MyMut1_DiagMS4NotOperated : SAFEBOOL; MyMut1_DiagSequenceError : SAFEBOOL; MyMut1_DiagMutingLampError : SAFEBOOL; MyMut1_DiagOverrideOperatedWithoutError : SAFEBOOL; MyMut1_DiagResetError : SAFEBOOL; MyMut1_DiagObjectDetectedAtStartTime : SAFEBOOL; MyMut1_DiagInputNotValid : SAFEBOOL; MyMut1_DiagParameterError : SAFEBOOL; MyMut1_DiagMutingTimeExceeded : SAFEBOOL; MyMut1_DiagMovementError : SAFEBOOL; MyMut1_DiagLightCurtainInterruptedNoMuting : SAFEBOOL; MyMut1_DiagReadyForReset : SAFEBOOL; // My FBL Motor 1 MyFeedBackLoop1 : FS_OutputFBL; MyFBL1_DiagFblError : SAFEBOOL; MyFBL1_DiagFblNotValid : SAFEBOOL; // My FBL Motor 2 MyFeedBackLoop2 : FS_OutputFBL; MyFBL2_DiagFblError : SAFEBOOL; MyFBL2_DiagFblNotValid : SAFEBOOL; END_VAR VAR CONSTANT // Declaration SwitchType 3 (NCNC) MyLCURT1_DOUBLE_CH : USINT := USINT#3; // Declaration SwitchType 3 (NCNC) MyEnable1_DOUBLE_CH : USINT := USINT#3; // Declaration MutingMode 1 MyMuting1_DOUBLE_CH : USINT := USINT#1; END_VAR
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Application Note – No. 1002664_EN_01
PSS 4000 Timely limited automatic suspension of safety functions Structured Text
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 22/37 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: [email protected]
Instruction part 063 064 065 067 068 069 070 071 072 073 074 075 076 077 078 079 080 081 082 083 084 085 086 087 088 089 090 091 092 093 094 095 096 097 098 099 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123
// Safety-Block Light Curtain 1 MyLightCurtain1( SwitchType := MyLCURT1_DOUBLE_CH, AutoStart := TRUE, AutoReset := TRUE, MonitoredReset := TRUE, StartupTest := FALSE, SimultaneityTime := T#100ms, DelayTime := T#40ms, Enable => MyLCurt1_Enable, DiagOperated => MyLCurt1_DiagOperated, DiagReadyForReset => MyLCurt1_DiagReadyForReset, DiagReadyForTest => MyLCurt1_DiagReadyForTest, DiagSwitchError => MyLCurt1_DiagSwitchError, DiagInputNotValid => MyLCurt1_DiagInputNotValid ); // Safety-Block Override 1 (Enable Switch) MyEnableSwitch1( SwitchType := MyEnable1_DOUBLE_CH, AutoStart := TRUE, AutoReset := TRUE, MonitoredReset := TRUE, StartupTest := FALSE, SimultaneityTime := T#100ms, DelayTime := T#40ms, Enable => MyEnab1_Enable, DiagOperated => MyEnab1_DiagOperated, DiagReadyForReset => MyEnab1_DiagReadyForReset, DiagReadyForTest => MyEnab1_DiagReadyForTest, DiagSwitchError => MyEnab1_DiagSwitchError, DiagInputNotValid => MyEnab1_DiagInputNotValid ); // Safety-Block Muting 1 MyMuting1( MutingMode := MyMuting1_DOUBLE_CH, LightCurtain := MyLCurt1_Enable, Override := MyEnab1_Enable AND MyOM_SetupMode, // Override from MyEnableSwitch1 (only in setup mode) NoMovement := MyMut1_NoMovement, // FALSE: Conveyor ON; TRUE: Conveyor OFF MutingLamp := FALSE, MutingLampCheck := FALSE, MutingEndMode := TRUE, SimultaneityTime := TIME#1500ms, InterruptionTime := TIME#50ms, MutingTime := TIME#60000ms, // Max. muting time Enable => MyMut1_Enable, MutingActive => MyMut1_MutingActive, // For activation a Muting-Lamp DiagTimingErrorMS1MS2 => MyMut1_DiagTimingErrorMS1MS2, DiagMS1NotOperated => MyMut1_DiagMS1NotOperated, DiagMS2NotOperated => MyMut1_DiagMS2NotOperated, DiagTimingErrorMS3MS4 => MyMut1_DiagTimingErrorMS3MS4, DiagMS3NotOperated => MyMut1_DiagMS3NotOperated, DiagMS4NotOperated => MyMut1_DiagMS4NotOperated, DiagSequenceError => MyMut1_DiagSequenceError, DiagMutingLampError => MyMut1_DiagMutingLampError, DiagOverrideOperatedWithoutError => MyMut1_DiagOverrideOperatedWithoutError, DiagResetError => MyMut1_DiagResetError, DiagObjectDetectedAtStartTime => MyMut1_DiagObjectDetectedAtStartTime, DiagInputNotValid => MyMut1_DiagInputNotValid,
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826 pt
Application Note – No. 1002664_EN_01
PSS 4000 Timely limited automatic suspension of safety functions Structured Text
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 23/37 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: [email protected]
124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147
DiagParameterError => MyMut1_DiagParameterError, DiagMutingTimeExceeded => MyMut1_DiagMutingTimeExceeded, DiagMovementError => MyMut1_DiagMovementError, DiagLightCurtainInterruptedNoMuting => MyMut1_DiagLightCurtainInterruptedNoMuting, DiagReadyForReset => MyMut1_DiagReadyForReset ); // Safety-Block monitoring FBL1 and release motor1 MyFeedBackLoop1( Input := MyMut1_Enable AND MyOM_AutoMode,// interlock with auto mode FeedbackLoopTime := T#200ms, DiagFeedbackLoopError => MyFBL1_DiagFblError, DiagFeedbackLoopNotValid => MyFBL1_DiagFblNotValid ); // Safety-Block monitoring FBL2 and release motor2 MyFeedBackLoop2( Input := MyMut1_Enable AND (MyOM_AutoMode OR MyOM_SetupMode), FeedbackLoopTime := T#200ms, DiagFeedbackLoopError => MyFBL2_DiagFblError, DiagFeedbackLoopNotValid => MyFBL2_DiagFblNotValid ); END_PROGRAM
Extract from DIN CLC/TS 62046 (VDE V 0113-211):2009-02: "The mute dependent override function shall only enable those movements that are necessary to permit blockages to be removed from the detection zone of the protective equipment." That means, only the conveyor belt M2 may be activated by the override key switch S3 but not the dangerous machine M1. Therefore an interlock (AND MyOM_AutoMode) is implemented, that only tolerates the enabling of output MyFeedBackLoop1.Output1, when a valid operating mode is activate. Info � The operation mode selection (MyOM_AutoMode / MyOM_SetupMode) will not be shown in
this Application Note. The implementation of this functionality can be taken for example of the Pilz function block FS_OperatingModeSelectorSwitch.
� The FS-I-variable NoMovement of the function block FS_Muting administrates the condition information (motion/standstill) from the conveyor belt (M2). In the example, the information is read from an external source through a safety input. The implementation of this functionality can also be taken from a safe control signal of the conveyor belt or as direct recording with the Pilz function block FS_CounterDual.
� Near the override switch an emergency stop device1 must be firmly mounted. The implementation of an emergency stop function can be taken for example with the Pilz function block FS_EmergencyStop.
(The description of this functionalities is not part of this Application Note).
1 Directive 2006/42/EC – 1.2.4.3 (Emergency stop)
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Application Note – No. 1002664_EN_01
PSS 4000 Timely limited automatic suspension of safety functions Structured Text
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 24/37 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: [email protected]
Standard program The signals from the start- and stop switches are read in from a standard module PSSu E S 4DI (1A3). These signals belong to the motor control and thus to the standard control functions of the machine. The program code for the evaluation and processing of these signals is not processed within the FS resource (safety-related part) of the control, but in a ST resource in a separate task as an independent application (additional POU of type program). Declaration part 001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 017 018 019 020 021 022 023 024
PROGRAM Main_ST VAR ST_Value_MyOM_AutoMode_from_FS AT %I* : BOOL; // From FS-Part "MyOM_AutoMode" ST_Value_MyOM_SetupMode_from_FS AT %I* : BOOL; // From FS-Part "MyOM_SetupMode" ST_Value_MyMut1_Enable_from_FS AT %I* : BOOL; // From FS-Part "MyMut1_Enable" MyRisingEdge_Start_M1 : R_TRIG; Start_Motor1 AT %I* : BOOL; Stop_Motor1 AT %I* : BOOL; Start_FLR_Motor1 : BOOL; Set_Motor1 : BOOL; Reset_Motor1 : BOOL; Motor1_On AT %q* : BOOL; FF_Motor1On : RS; MyRisingEdge_Start_M2 : R_TRIG; Start_Motor2 AT %I* : BOOL; Stop_Motor2 AT %I* : BOOL; Start_FLR_Motor2 : BOOL; Set_Motor2 : BOOL; Reset_Motor2 : BOOL; Motor2_On AT %q* : BOOL; FF_Motor2On : RS; END_VAR
The functional controlling of the motors (M1, M2) will be executed in the instruction part of the standard control. � The danger machine (M1) can be started by the switch Start_Motor1 (S5), if the appropriate
enable signal from the safety program is given (see FS-part). � The danger machine (M1) can be stopped by the switch Stop_Motor1 (S6), if the muting
enable (ST_Value_MyMut1_Enable_from_FS) is lost or by the activation of the override enable (ST_Value_MyEnab1_Enable_from_FS).
� The conveyor belt (M2) can be started by the switch Start_Motor2 (S7), if the appropriate enable signal from the safety program is given (see FS-part).
� The conveyor belt (M2) can be stopped by the switch Stop_Motor2 (S8) or when the muting enable (ST_Value_MyMut1_Enable_from_FS) is lost.
Note For real application it may be needed to take into consideration additional requirements.
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Application Note – No. 1002664_EN_01
PSS 4000 Timely limited automatic suspension of safety functions Structured Text
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 25/37 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: [email protected]
Instruction part 025 026 027 028 029 030 031 032 033 034 035 036 037 038 039 040 041 042 043 044 045 046 047 048 049 050 051 052 053 054 055 056 057 058 059 060 061 062 063 064 065 066 067 068 069 070
//***** Motor 1 - Dangerous Machine ***** // Rising Edge 1 - Motor1 Start MyRisingEdge_Start_M1( clk := Start_Motor1, q => Start_FLR_Motor1 ); // Start Motor1 Set_Motor1 := Start_FLR_Motor1; // Stop Motor1 Reset_Motor1 := NOT Stop_Motor1 OR NOT ST_Value_MyMut1_Enable_from_FS OR NOT ST_Value_MyOM_AutoMode_from_FS OR OperatingMode_Change; // Flip-Flop Motor1 On FF_Motor1On( set := Set_Motor1, reset1 := Reset_Motor1, q1 => Motor1_On ); //***** Motor 2 - Conveyor Belt ***** // Rising Edge 2 - Motor2 Start MyRisingEdge_Start_M2( clk := Start_Motor2, q => Start_FLR_Motor2 ); // Start Motor2 Set_Motor2 := Start_FLR_Motor2; // Stop Motor2 Reset_Motor2 := NOT Stop_Motor2 OR NOT ST_Value_MyMut1_Enable_from_FS OR OperatingMode_Change; // Flip-Flop Motor2 On FF_Motor2On( set := Set_Motor2, reset1 := Reset_Motor2, q1 => Motor2_On ); END_PROGRAM
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Application Note – No. 1002664_EN_01
PSS 4000 Timely limited automatic suspension of safety functions Structured Text
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 26/37 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: [email protected]
3.3.2. I/O Mapping
In PAS4000, variables can be created and the user program can be programmed without the need of the mapping to the hardware being present at the beginning of the project. After identification of the used I/O from the variable declaration, the required hardware can be determined. The I/O mapping editor forms the connecting between the user program and the hardware and coordinates the available I/O and existing PI-variables.
3.3.2.1. I/O Mapping Editor
The PI variables declared in the user-program can be assigned in the I/O mapping editor to the hardware configuration.
Fig. 6: Mapping Editor – STL-program
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Application Note – No. 1002664_EN_01
PSS 4000 Timely limited automatic suspension of safety functions Structured Text
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 27/37 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: [email protected]
3.3.3. Process PAS Project
� Step 1: In the STL editor, PI variables and the logical sequence will be generated as a
program.
Fig. 7: PI variables
� Step 2: The design of the hardware (control, I/O, sensor, actor) will created as a circuit diagram. (parallel possible to Step 1)
Fig. 8: Circuit diagram (extract)
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Application Note – No. 1002664_EN_01
PSS 4000 Timely limited automatic suspension of safety functions Structured Text
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 28/37 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: [email protected]
� Step 3: Based on the PI variables (I/O), the required power of control (PLC, Multi) is selected. The implementation of the I/O modules in the PAS system occurs in the PSSu module editor.
Fig. 9: PSSu Module Editor
� Step 4: Assignment of the PI variables in the I/O Mapping Editor.
Fig. 10: I/O Mapping Editor
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Application Note – No. 1002664_EN_01
PSS 4000 Timely limited automatic suspension of safety functions Structured Text
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 29/37 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: [email protected]
� Overview process PAS Project (Steps 1-4)
Fig. 11: Process PAS Project
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Application Note – No. 1002664_EN_01
PSS 4000 Timely limited automatic suspension of safety functions Structured Text
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 36/37 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: [email protected]
Table of figures
Fig. 1: Hardware configuration ...................................................................................................... 7 Fig. 2: Muting application .............................................................................................................. 8 Fig. 3: Sequential muting application .......................................................................................... 14 Fig. 4: Add library element .......................................................................................................... 20 Fig. 5: Selection library element .................................................................................................. 20 Fig. 6: Mapping Editor – STL-program ........................................................................................ 26 Fig. 7: PI variables ...................................................................................................................... 27 Fig. 8: Circuit diagram (extract) ................................................................................................... 27 Fig. 9: PSSu Module Editor ......................................................................................................... 28 Fig. 10: I/O Mapping Editor ......................................................................................................... 28 Fig. 11: Process PAS Project ...................................................................................................... 29
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Application Note – No. 1002664_EN_01
PSS 4000 Timely limited automatic suspension of safety functions Structured Text
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 37/37 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: [email protected]
