Safe shutdown of SIRIUS 3RA6 compact starters with IO-Link interface. SIRIUS Industrial Controls, Safety Integrated, IO-Link FAQ 05.

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1 FAQ Safe shutdown of SIRIUS 3RA6 compact starters with IO-Link interface SIRIUS Industrial Controls, Safety Integrated, IO-Link

2 Siemens AG 2016 All rights reserved This entry originates from Siemens Industry Online Support. The terms of use specified there apply ( Security informati on Siemens provides products and solutions with industrial security functions that support the secure operation of plants, solutions, machines, equipment and/or networks. They are important components in a holistic industrial security concept. With this in mind, Siemens products and solutions undergo continuous development. Siemens recommends strongly that you regularly check for product updates. For the secure operation of Siemens products and solutions, it is necessary to take suitable preventive action (e.g. cell protection concept) and integrate each component into a holistic, state-of-the-art industrial security concept. Third-party products that may be in use should also be considered. For more information about industrial security, visit To stay informed about product updates as they occur, sign up for our productspecific newsletter. For more information, visit Table of contents 1 Introduction Safe shutdown by a safety relay Safe shutdown in a single channel up to SIL 1 or PL c RA64 direct starter RA65 reversing starter Safe shutdown in a single channel up to SIL 3 or PL e RA64 direct starter RA65 reversing starter Safe group shutdown of several compact starters up to SIL3 or PLe Safe shutdown by a failsafe controller Safe shutdown in a single channel up to SIL 1 or PL c RA64 direct starter RA65 reversing starter Safe shutdown in a single channel up to SIL 3 or PL e RA64 direct starter RA65 reversing starter Safe group shutdown of several compact starters up to SIL3 or PLe See also Contact/Support Anbindung; Entry ID: , V3.0,

3 1 Introduction 1 Introduction Question Answer How is it possible to switch the SIRIUS 3RA6 compact starter in normal operation using IO-Link while also ensuring safe shutdown? The 3RA6 compact starter is shut down safely by means of a safe evaluation unit that monitors, for example, an emergency stop command device. This safe evaluation unit interrupts the A1/A2 power supply at the 3RA6. When the emergency stop command device is actuated, the safe evaluation unit interrupts the power supply and the compact starter is shut down in accordance with stop category 0 as defined by EN The feedback circuit for monitoring the compact starter is implemented on the 3RA6 by installing auxiliary switch blocks 3RA6913-1A. The positively-driven contacts are wired back to the safe evaluation unit. Implementation of this arrangement is explained in the following chapters using the example of a SIRIUS 3SK1 safety relay and a SIMATIC S7 failsafe controller. Anbindung; Entry ID: , V3.0,

4 2 Safe shutdown by a safety relay 2 Safe shutdown by a safety relay A SIRIUS 3SK1 safety relay is used in the following example. Another safe evaluation unit (such as a SIRIUS 3RK3 modular safety system or a 3SK2 safety relay) could also be used to perform this function. In addition to the safety components shown, a controller and an IO-Link master are required for operational control of the 3RA6 compact starter. 2.1 Safe shutdown in a single channel up to SIL 1 or PL c The emergency stop command device is monitored in a single channel by the safety relay. When the emergency stop command device is actuated, the A1/A2 power supply of the 3RA6 compact starter is interrupted by the safety relay and the compact starter is thus safely shut down. Safety-related shutdown can be signaled to the controller via a signaling contact. After the emergency stop command device has been unlatched, the Reset button can be actuated to close the 3RA6 compact starter again per IO-Link. Proper functioning of the compact starter can be optionally monitored via an auxiliary contact in the feedback circuit of the safety relay. An additional 3RA6913-1A auxiliary switch block is required for this purpose. Because of the interruption of the power supply at the 3RA6x a failure message is sent to the PLC via the IO-Link communication. Anbindung; Entry ID: , V3.0,

5 2 Safe shutdown by a safety relay RA64 direct starter Fig. 2-1 A 3RA6913-1A auxiliary switch block is deployed in the circuit shown. The NC contact is wired back to INF/S of the 3SK1 safety relay to provide monitoring of the compact starter. It is not absolutely essential to install the feedback circuit in order to achieve SIL 1 or PL c. The feedback circuit has been optionally included in this example to illustrate the diagnostic capability of this arrangement. Anbindung; Entry ID: , V3.0,

6 2 Safe shutdown by a safety relay RA65 reversing starter The 3RA65 reversing starter is shut down safely when the A1 power supply is disconnected at the compact starter. Because of the interruption of the power supply at the 3RA6x a failure message is sent to the PLC via the IO-Link communication. Fig. 2-2 Two 3RA6913-1A auxiliary switch blocks are deployed in the circuit shown. One auxiliary switch block per direction of rotation. The NC contacts are wired back to INF/S of the 3SK1 safety relay to provide monitoring of the compact starter. It is not absolutely essential to install the feedback circuit in order to achieve SIL 1 or PL c. The feedback circuit has been optionally included in this example to illustrate the diagnostic capability of this arrangement. Anbindung; Entry ID: , V3.0,

7 2 Safe shutdown by a safety relay 2.2 Safe shutdown in a single channel up to SIL 3 or PL e A redundant arrangement is required for applications up to SIL 3 or PL e. For this reason, the emergency stop command device is monitored in two channels for discrepancy and cross circuits and a power contactor (Q1) is connected upstream of the compact starter (e.g. SIRIUS 3RT2.). When the emergency stop command device is actuated, the contactor and the compact starter are shut down safely. Safety-related shutdown is signaled to the controller via a signaling contact. After the emergency stop command device has been unlatched, the Reset button can be actuated to close the compact starter again per IO-Link. This action immediately closes the power contactor. Proper functioning of the contactor and the compact starter is monitored via auxiliary contacts in the the feedback circuit of the safety relay. In this case, an additional 3RA6913-1A auxiliary switch block must be provided for the compact starter. This is absolutely essential in order to ensure sufficiently high diagnostic coverage. Because of the interruption of the power supply at the 3RA6x a failure message is sent to the PLC via the IO-Link communication. Anbindung; Entry ID: , V3.0,

8 2 Safe shutdown by a safety relay RA64 direct starter Fig. 2-3 A 3RA6913-1A auxiliary switch block is deployed in the circuit shown. The NC contact is wired back to INF/S of the 3SK1 safety relay to provide monitoring of the compact starter. The auxiliary contact at contactor Q1 is also incorporated into the feedback circuit. NOTICE In order to achieve SIL 3 as defined by IEC 62061, or PL e as defined by ISO , it is absolutely essential to incorporate the mirror contacts (NC contacts) of the contactor and the compact starter into the feedback circuit of the safety relay. Anbindung; Entry ID: , V3.0,

9 2 Safe shutdown by a safety relay RA65 reversing starter The 3RA65 reversing starter is shut down safely when the A1 power supply is disconnected at the compact starter. Because of the interruption of the power supply at the 3RA6x a failure message is sent to the PLC via the IO-Link communication. Fig. 2-4 Two 3RA6913-1A auxiliary switch blocks are deployed in the circuit shown. One auxiliary switch block per direction of rotation. The NC contacts are wired back to INF/S of the 3SK1 safety relay to provide monitoring of the compact starter. The auxiliary contact at contactor Q1 is also incorporated into the feedback circuit. NOTICE In order to achieve SIL 3 as defined by IEC 62061, or PL e as defined by ISO , it is absolutely essential to incorporate the mirror contacts (NC contacts) of the contactor and the compact starter into the feedback circuit of the safety relay. Anbindung; Entry ID: , V3.0,

2 Safe shutdown by a safety relay 2.3 Safe group shutdown of several compact starters up to SIL 3 or PL e With IO-Link it is possible to group up to four load feeders as a single IO-Link device.

The first starter in the group uses 14-pole module connectors to distribute the data exchange with the IO-Link master and the power supply for the logic to the rest of the group.

10 2 Safe shutdown by a safety relay 2.3 Safe group shutdown of several compact starters up to SIL 3 or PL e With IO-Link it is possible to group up to four load feeders as a single IO-Link device. Direct and reversing starters can be freely combined within a group of four. The first starter in the group uses 14-pole module connectors to distribute the data exchange with the IO-Link master and the power supply for the logic to the rest of the group. A redundant arrangement is required for applications up to SIL 3 or PL e. For this reason, the emergency stop command device is monitored in two channels for discrepancy and cross circuits and a power contactor (Q1) is connected upstream of the compact starter (e.g. SIRIUS 3RT2.). In the event of an emergency, the safety relay interrupts the power supply to the power contactor and performs a group shutdown of the compact starters. The actuator is then shut down safely. Fig. 2-5 L1 L2 L3 3RT20 3SK1 Q1 3RA64 3RA64 3RA65 3RA64 Q2 Q3 Q4 Q4.1 Q5 IO-Link M M M M Anbindung; Entry ID: , V3.0,

11 2 Safe shutdown by a safety relay Fig RA6913-1A auxiliary switch blocks are deployed in the circuit shown. One auxiliary switch block is provided for the direct starter, and 2 auxiliary switch blocks (one per direction of rotation) for the reversing starter. The NC contacts are wired back to INF/S of the 3SK1 safety relay to provide monitoring of the compact starter. The auxiliary contact at contactor Q1 is also incorporated into the feedback circuit. Please compare to Chapter for an example of the arrangement of the feedback circuit for a reversing starter. NOTICE In order to achieve SIL 3 as defined by IEC 62061, or PL e as defined by ISO , it is absolutely essential to incorporate the mirror contacts (NC contacts) of the contactor and all of the compact starters into the feedback circuit of the safety relay. Anbindung; Entry ID: , V3.0,

12 3 Safe shutdown by a failsafe controller 3 Safe shutdown by a failsafe controller A SIMATIC S7 failsafe controller is used to shut down the 3RA6 compact starter in the following examples. 3.1 Safe shutdown in a single channel up to SIL 1 or PL c As with the safety relays, a failsafe controller safely shuts down the 3RA6 by disconnecting the A1 power supply at the compact starter. An F-PM-E module or an F-DQ module (e.g. ET 200SP) can be used to achieve a SIL1 shutdown. An F-PM-E module has been chosen for this purpose in the following example. Proper functioning of the compact starter can be optionally monitored by an additional 3RA6913-1A auxiliary switch block. A standard input of the ET 200SP can be used for this purpose. It is not essential to provide this monitoring function for applications up to SIL 1 or PL c. Because of the interruption of the power supply at the 3RA6x a failure message is sent to the PLC via the IO-Link communication. Anbindung; Entry ID: , V3.0,

13 3 Safe shutdown by a failsafe controller RA64 direct starter Fig. 3-1 A 3RA6913-1A auxiliary switch block is deployed in the circuit shown. The NC contact is wired back to a digital input module (DI) to provide monitoring of the compact starter. It is not absolutely essential to install the feedback circuit in order to achieve SIL 1 or PL c. The feedback circuit has been optionally included in this example to illustrate the diagnostic capability of this arrangement. Anbindung; Entry ID: , V3.0,

14 3 Safe shutdown by a failsafe controller Emergency stopping is monitored by the E-Stop block. The Q signal (S_E- Stop_OK) of the E-Stop block is read in again via the ON input of the FDBACK block. Fig. 3-2 Fig. 3-3 The feedback circuit signal (I_FDBACK_3RA6) of the 3RA6 is also connected via the FEEDBACK input at the FDBACK block. The read-back time of the FDBACK block should be set to around 500 ms. Operational switching is implemented outside the safety program via IO-Link. Fig. 3-4 The feedback enable signal (S_FDBACK_OK) is connected to the output of the 3RA6 and thus implements a safe shutdown. An error in the feedback circuit prevents closure of the 3RA6 compact starter. The enable signal is issued only if the emergency stop command device is unlatched and there are no faults in the feedback circuit. Anbindung; Entry ID: , V3.0,

15 3 Safe shutdown by a failsafe controller RA65 reversing starter In order to safely shut down a 3RA65 reversing starter up to SIL 1 or PL c, a jumper must be additionally inserted between the limit switch for clockwise rotation Y2 and the limit switch for counterclockwise rotation Y4. This will ensure that the compact starter is safely shut down in the event of an emergency irrespective of the current direction of rotation. The safety program for this example is identical to that for the direct starter on the previous pages. Fig. 3-5 Two 3RA6913-1A auxiliary switch blocks are deployed in the circuit shown. One auxiliary switch block per direction of rotation. The NC contacts are wired back to a digital input module (DI) to provide monitoring of the compact starter. It is not absolutely essential to install the feedback circuit in order to achieve SIL 1 or PL c. The feedback circuit has been optionally included in this example to illustrate the diagnostic capability of this arrangement. Anbindung; Entry ID: , V3.0,

16 3 Safe shutdown by a failsafe controller 3.2 Safe shutdown in a single channel up to SIL 3 or PL e RA64 direct starter Applications up to SIL 3 or PL e always require a redundant switch-off signal path (e.g. 3RA6 plus a power contactor). A pm-switching 4 F-DQ module of the ET 200SP is used in the example shown. The power supply of the 3RA6 is controlled via the p-switching output. The m- switching output disconnects the A2 power supply of the contactor Q1. This arrangement is thus a 2-channel structure. An additional 3RA6913-1A auxiliary switch block is required to monitor the proper functioning of the compact starter. To achieve a high diagnostic coverage, the contacts of the auxiliary switch block and the mirror contacts of the contactor are monitored via standard inputs. It is essential to provide this monitoring function for applications up to SIL 3 or PL e. Because of the interruption of the power supply at the 3RA6x a failure message is sent to the PLC via the IO-Link communication. Anbindung; Entry ID: , V3.0,

17 3 Safe shutdown by a failsafe controller Fig. 3-6 A 3RA6913-1A auxiliary switch block is deployed in the circuit shown. The NC contact is wired back to a digital input module (DI) to provide monitoring of the compact starter. The auxiliary contact at contactor Q1 is also incorporated into the feedback circuit. NOTICE In order to achieve SIL 3 as defined by IEC 62061, or PL e as defined by ISO , it is absolutely essential to wire the mirror contacts (NC contacts) of the contactor and the compact starter back to the controller as a feedback circuit. Emergency stopping is monitored by the E-Stop block. The Q signal (S_E- Stop_OK) of the E-Stop block is read in again via the ON input of the FDBACK block. Fig. 3-7 Anbindung; Entry ID: , V3.0,

3 Safe shutdown by a failsafe controller The feedback circuit signal (I_FDBACK_3RA6) of the 3RA6 is also connected via the FEEDBACK input at the FDBACK block.

18 3 Safe shutdown by a failsafe controller The feedback circuit signal (I_FDBACK_3RA6) of the 3RA6 is also connected via the FEEDBACK input at the FDBACK block. The read-back time of the FDBACK block should be set to around 500 ms. Operational switching is implemented outside the safety program via IO-Link. Fig. 3-8 The feedback enable signal (S_FDBACK_OK) is connected to the output of the 3RA6 and also to the output of the power contactor (Q1) and thus implements a safe shutdown. Fig. 3-9 An error in the feedback circuit prevents closure of the 3RA6 compact starter. The enable signal is issued only if the emergency stop command device is unlatched and there are no faults in the feedback circuit. Anbindung; Entry ID: , V3.0,

19 3 Safe shutdown by a failsafe controller RA65 reversing starter In order to safely shut down a 3RA65 reversing starter up to SIL 3 or PL e, a jumper must be additionally inserted between the limit switch for clockwise rotation Y2 and the limit switch for counterclockwise rotation Y4. This will ensure that the compact starter is safely shut down in the event of an emergency irrespective of the current direction of rotation. The safety program for this example is identical to that for the direct starter on the previous pages. Because of the interruption of the power supply at the 3RA6x a failure message is sent to the PLC via the IO-Link communication. Fig Two 3RA6913-1A auxiliary switch blocks are deployed in the circuit shown. One auxiliary switch block per direction of rotation. The NC contacts are wired back to a digital input module (DI) to provide monitoring of the compact starter. The auxiliary contact at contactor Q1 is also incorporated into the feedback circuit. NOTICE In order to achieve SIL 3 as defined by IEC 62061, or PL e as defined by ISO , it is absolutely essential to wire the mirror contacts (NC contacts) of the contactor and the compact starter back to the controller as a feedback circuit. Anbindung; Entry ID: , V3.0,

Direct and reversing starters can be freely combined within a group of four.

20 3 Safe shutdown by a failsafe controller 3.3 Safe group shutdown of several compact starters up to SIL 3 or PL e With IO-Link it is possible to group up to four load feeders as a single IO-Link device. Direct and reversing starters can be freely combined within a group of four. The first starter in the group uses 14-pole module connectors to distribute the data exchange with the IO-Link master and the power supply for the logic to the rest of the group. A redundant arrangement is required for applications up to SIL 3 or PL e. For this reason, the emergency stop command device is monitored in two channels for discrepancy and cross circuits and a power contactor (Q1) is connected upstream of the compact starter (e.g. SIRIUS 3RT2.). In the event of an emergency, the safety relay interrupts the power supply to the power contactor and performs a group shutdown of the compact starters. The actuator is then shut down safely. The safety program for this example is identical to the example in Chapter Fig Because of the interruption of the power supply at the 3RA6x a failure message is sent to the PLC via the IO-Link communication. L1 L 2 L3 3RT20 Q1 3RA64 3RA64 3RA65 3RA64 IO- Link Q2 Q3 Q4 Q4.1 Q5 M M M M Anbindung; Entry ID: , V3.0,

21 3 Safe shutdown by a failsafe controller Fig RA6913-1A auxiliary switch blocks are deployed in the circuit shown. One auxiliary switch block is provided for the direct starter, and 2 auxiliary switch blocks (one per direction of rotation) for the reversing starter. The NC contacts are wired back to a digital input module (DI) to provide monitoring of the compact starter. The auxiliary contact at contactor Q1 is also incorporated into the feedback circuit. Please compare to Chapter for an example of the arrangement of the feedback circuit for a reversing starter. NOTICE In order to achieve SIL 3 as defined by IEC 62061, or PL e as defined by ISO , it is absolutely essential to wire the mirror contacts (NC contacts) of the contactor and the compact starter back to the controller as a feedback circuit. Anbindung; Entry ID: , V3.0,

22 4 See also 4 See also Table 4-1 Title Entry ID FAQ "Connection of a 3RA6 compact starter to SIMATIC S7 F-DO" FAQ "Safe shutdown of SIRIUS 3RA27 function modules with IO-Link interface" Anbindung; Entry ID: , V3.0,

23 5 Contact/Support 5 Contact/Support Siemens AG Technical Assistance Phone: +49 (911) Fax : +49 (911) technical-assistance@siemens.com Internet: Anbindung; Entry ID: , V3.0,

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