Function Example No. MC-FE-I-011-V10-DE

Transcription

1 Function Example No. MC-FE-I-011-V10-DE SIMOTION with SINAMICS S120 Safety Integrated Extended Functions Failsafe Drives on SIMOTION D435 with PROFIsafe Control via PROFIBUS Data Exchange Broadcast

2 Preliminary remarks The Functional Examples dealing with Safety Integrated are fully functional and tested automation configurations based on I DT & IA standard products for simple, fast and inexpensive implementation of automation tasks in safety engineering. Each of these Functional Examples covers a frequently occurring subtask of a typical customer problem in safety engineering. Aside from a list of all required software and hardware components and a description of the way they are connected to each other, the Functional Examples include the tested and commented code. This ensures that the functionalities described here can be reset in a short period of time and thus also be used as a basis for individual expansions. Important note The Safety Functional Examples are not binding and do not claim to be complete regarding the circuits shown, equipping and any eventuality. The Safety Functional do not represent customer-specific solutions. They are only intended to provide support for typeical applications. You are responsible for ensuring that the described products are correctly used. These Safety Functional Examples do not relieve you of the responsibility in safely and professionally using, installing, operating and servicing equipment. When using these Safety Functional Examples, you recognize that Siemens cannot be made liable for any damage/claims beyond the liability clause described. We reserve the right to make changes to these Safety Functional Examples at any time without prior notice. If there are any deviations between the recommendations provided in these Safety Functional Examples and other Siemens publications - e.g. Catalogs - then the contents of the other documents have priority. I DT Safety Integrated Page 2/74 MC-FE-I-011-V10-DE

3 Contents 1 Warranty, Liability and Support Automation Function Function Example Advantages / Customer Benefits Components Required Hardware Components Software Components Engineering software Firmware Configuration and Wiring Overview of the Hardware Configuration Hardware Component Wiring Control voltage wiring DRIVE-CLiQ wiring Major Hardware Component Settings Bus interfaces Bus topology Overview and Operation Operating List of Input Signals Sample Project Passwords Basic Configurations Hardware configuration of the failsafe SIMATIC Controller Inserting SIMOTION in the existing SIMATIC project Basic commissioning of the SINAMICS drives (without safety) Telegram configuration Inserting F-CPU in the SIMOTION HW Config and connecting it Programming the Failsafe Controller Parameterizing the Safety Functions in SINAMICS Configuring the safety functions on the drives Configuring the safety data block on SINAMICS SIMOTION Creating SIMOTION axes SIMOTION programs Runtime system configuration SIMOTION messages Downloading the Sample Project Loading the S7-F-CPU configuration Loading the SIMOTION and SINAMICS configuration I DT Safety Integrated Page 3/74 MC-FE-I-011-V10-DE

4 6.7 Acceptance Test History I DT Safety Integrated Page 4/74 MC-FE-I-011-V10-DE

5 1 Warranty, Liability and Support We do not accept any liability for the information contained in this document. Any claims against us - based on whatever legal reason - resulting from the use of the examples, information, programs, engineering and performance data etc., described in this Safety Functional Example shall be excluded. Such an exclusion shall not apply in the case of mandatory liability, e.g. under the German Product Liability Act ( Produkthaftungsgesetz ), in case of intent, gross negligence, or injury of life, body or health, guarantee for the quality of a product, fraudulent concealment of a deficiency or breach of a condition which goes to the root of the contract ( wesentliche Vertragspflichten ). However, claims arising from a breach of a condition which goes to the root of the contract shall be limited to the foreseeable damage which is intrinsic to the contract, unless caused by intent or gross negligence or based on mandatory liability for injury of life, body or health. The above provisions do not imply a change in the burden of proof to your detriment Copyright 2009 Siemens I DT. It is not permissible to transfer or copy these standard applications or excerpts of them without first having prior authorization from Siemens I DT in writing. For questions regarding this article please contact us at the following address: applications.erlf.aud@siemens.com I DT Safety Integrated Page 5/74 MC-FE-I-011-V10-DE

6 2 Automation Function 2.1 Function Example The following safety functions have been integrated in SINAMICS S120 drives according to IEC : Name Function STO Safe Torque Off Failsafe disconnection of the torque-forming power supply from the motor. Restarting is blocked via the switch-on inhibit (stop function category 0 according to EN ). SBC Safe Brake Control SBC is only used with existing motor brake which is connected to the power connector via the outputs. SBC always responds in combination with STO or when the internal safety monitors respond with failsafe pulse suppression. SS1 Safe Stop 1 Fast and safely monitored drive standstill along the OFF3 ramp. Upon expiry of a delay time or reaching the cuttoff speed, transition to STO (stop function category 1 according to EN ). SS2 Safe Stop 2 Fast and safely monitored drive standstill along the OFF3 ramp. Upon expiry of a delay time, transition to SOS; the drive is controlled (stop function category 2 according to EN ). SOS SLS SSM Safe Operating Stop Safely-Limited Speed Safe Speed Monitor This function serves to safely monitor the standstill position of a drive; the drive is controlled. Safe drive speed monitoring. Parameterizable cutoff reaction in case of limit value violation. Safe display of speed limit violation (n < nx). These extended safety functions can be activated both via PROFIsafe with PROFIBUS and via a terminal extension module TM54F. In the present example, the safety functions are activated from a SIMATIC F-CPU using the PROFIsafe telegram. I DT Safety Integrated Page 6/74 MC-FE-I-011-V10-DE

7 Task A system equipped with SINAMICS S120 drives is controlled by a SIMOTION D435. Various safety functions must be used on this system. The SIMOTION does not comprise any safety functions and uses the extended safety functions integrated in SINAMICS S120 drives. These drive-integrated safety functions shall be activated from the F-CPU using the PROFIsafe telegram via PROFIBUS data exchange broadcast. The safety signals acquired via a failsafe digital input module are processed by the F-CPU and transferred to the drives using the above-stated telegram. In this case, the SIMOTION serves as PROFIBUS master and the F-CPU as I slave. The PROFIdrive communication is established between the SIMOTION and the SINAMICS, the PROFIsafe telegrams are exchanged between the F-CPU and the SINAMICS via PROFIBUS data exchange broadcast. This function example is based on the SIMOTION D435 training case (6ZB AE00), the SINAMICS training case (6ZB BA00) and the SAFETY training case. The following figure provides a sample overview of the assumed machine configuration. Further considerations are based on the following safety functions. I DT Safety Integrated Page 7/74 MC-FE-I-011-V10-DE

8 Safety function SF1 SF2 SF3 Solution Hardware overview Actuation of the emergency stop button The drive 1 must be quickly stopped when opening the protective door 1. The drive 1 must then be stopped with speed setpoint = 0 and the standstill position safely monitored. With open protective door 2, the drive 2 may not exeed a maximum speed Reaction Fast controlled stopping of drive 1 -> followed by pulse suppression (SS1) Stopping of drive 2 with immediate pulse suppression (STO) The SIMOTION decelerates the drive 1 with position control. Upon expiry of a waiting time, the standstill position is safely monitored (SOS) Speed monitoring on drive 2 (SLS) This function example shows the activation of the safety functions STO, SS1, SOS and SLS via the PROFIsafe telegram using the PROFIBUS data exchange broadcast on a SIMOTION D435 with SINAMICS S120 drive group. I DT Safety Integrated Page 8/74 MC-FE-I-011-V10-DE

9 The drive group in Booksize format comprises an infeed unit and a Double Motor Module. Motion Control is performed via a SIMOTION D435 and the motor control via a SINAMICS S120. The Double Motor Module controls the two mutually independent servo motors. A Smart Line Module is used as infeed unit. The safety-related signals are acquired via failsafe ET200M inputs and logically processed in the F-CPU. The F-CPU uses the failsafe data to create a PROFIsafe telegram for each drive. This is transferred via the PROFIBUS data exchange broadcast to the SINAMICS drives where it activates the safety functions. Upon emergency stop request, the drive 1 is stopped with the driveintegrated safety function SS1 and the drive 2 with STO. Two switches in the Safety training case simulate one protective door each for drive 1 and 2. When opening the protective door 1, the drive 1 is decelerated by the SIMOTION until it stops. Upon expiry of a configurable time period, the standstill position is safely monitored (activation of the SOS function). When the door is closed, the axis 1 is restarted (deactivation of the SOS function). When the protective door 2 is opened, the speed for drive 2 is monitored for a configurable maximum value (SLS function). The setpoint speed is limited to 80% of the selected SLS step. When closing the simulated door, the speed limitation is canceled without influencing the other drive. 2.2 Advantages / Customer Benefits Convenient activation of the safety functions integrated in the drive. Convenient setup through standardized technology. The existing system can be extended quickly and conveniently. Space-saving and cost-efficient setup through integrated safety functions no additional hardware required. The SIMOTION system provides convenient evaluation and diagnostic information Complex safety concepts can thus be realized. I DT Safety Integrated Page 9/74 MC-FE-I-011-V10-DE

10 3 Components Required This section describes the hardware components and software versions required to implement the function example. 3.1 Hardware Components SAFETY training case (major components) Component Type MLFB / Order Data No. Manufactu rer SITOP power supply SITOP SMART 120W 6EP AA01 1 Siemens SIMATIC S7-300 CPU SIMATIC S7 failsafe input module SIMATIC S7 failsafe output module CPU 315F-2 PN/DP 6ES FH13-0AB0 1 Siemens SIMATIC Micro Memory Card, 512KB 6ES LJ20-0AA0 1 Siemens SM 326 F-DI 24 6ES BK01-0AB0 1 Siemens SM 326 F-DO 8 6ES BF40-0AB0 1 Siemens SINAMICS failsafe Terminal Module TM54F 6SL3055-0AA00-3BA0 1 Siemens Drive-CLiQ Cable, gray, metallic plug 6FX2002-1DC00-1AC0 1 Siemens Protective door simulation switches Toggle switch 0-I, latching, 16mm, black 3SB2000-2AB01 2 Siemens S2 and S3 Holder with solder pins 3SB2908-0AB 2 Siemens Emergency stop control device Mushroom pushbutton, red, 16mm 3SB2000-1AC01 1 Siemens S1 Holder with solder pins 3SB2908-0AB 1 Siemens Reset button S4 Load resistors R1.. R8 Terminals for load resistors (R1..R8) Load resistor R9 Terminals for load resistor (R9) Pushbutton, flat pushbutton, 16mm, white Holder with lamp socket, lamp and solder pins 1kOhm 1W 3SB2000-0AG01 1 Siemens 3SB2455-1B 1 Siemens Type PO595-0 Style 0207 Power Metaloxide film resistors ST 2,5-QUATTRO-TG Component plug P-CO SMA0207 1K2 1% TK TERMINALS_ACCESS_DUMMY PLUG_TYPE1_GRAY WID_MET_SHT_1K2_+- 1%_600mW_+50ppm_ Yageo Europe Phoenix Contact Phoenix Contact 1 Beyschlag WAGO TERMINAL_4-WIRE_GRAY WAGO SIMOTION training case Component Type MLFB / Order Data No. Manufactu rer SIMOTION training case D435 6ZB AE00 1 SIEMENS I DT Safety Integrated Page 10/74 MC-FE-I-011-V10-DE

11 SINAMICS training case Component Type MLFB / Order Data No. Manufactu rer SINAMICS training case S120 CU320 6ZB BA00 1 SIEMENS Note The function example has been tested using the hardware components listed. Alternatively, you can use other, functionally equivalent components. In such cases, you may have to use another component parameterization resp. wiring. Components highlighted in yellow are not relevant for this function example. 3.2 Software Components Engineering software Component Type MLFB / Order Data No. Manufacturer STEP 7 V5.4 SP4 6ES7810-4CC08-0YA5 1 Siemens S7 Distributed Safety Programming V5.4 SP4 6ES7833-1FC+02-0YA5 1 Siemens S7 F Configuration Pack V5.5 SP5 1 Siemens SIMOTION SCOUT V4.1 SP4 6AU1810-1BA41-2XA0 1 Siemens Firmware The Firmware Version V2.6 SP2 (or later) must be installed on all SINAMICS components. The SIMOTION must be used with Firmware Version V4.1 SP4 HF 1 (or later). I DT Safety Integrated Page 11/74 MC-FE-I-011-V10-DE

12 4 Configuration and Wiring 4.1 Overview of the Hardware Configuration I DT Safety Integrated Page 12/74 MC-FE-I-011-V10-DE

13 4.2 Hardware Component Wiring Control voltage wiring I DT Safety Integrated Page 13/74 MC-FE-I-011-V10-DE

14 4.2.2 DRIVE-CLiQ wiring The SINAMICS devices must be connected using a DRIVE-CLiQ cable as displayed in the following figure. D435 DRIVE CLiQ X100 X101 X102 X103 PROFIBUS X126 X127 CU320 DRIVE CLiQ X100 X101 X102 X103 PROFIBUS X126 SLM DMM DRIVE CLiQ X200 X201 X202 X203 Ethernet X120 X130 Drive 2 Drive 1 DRIVE-CLiQ wiring I DT Safety Integrated Page 14/74 MC-FE-I-011-V10-DE

15 4.3 Major Hardware Component Settings In this example, the PROFIBUS is used to activate the safety functions in the drives. For this, control and status signals are exchanged between the drives and the F-CPU via the PROFIsafe telegram. The drives are controlled by the SIMOTION via the PROFIBUS. Further, the PROFIBUS is used to configure the F-CPU, SINAMICS and SIMOTION Bus interfaces Programming device / PC PROFIBUS address = 0 Since the SIMOTION used is the bus master, the PROFIBUS interface of the programming device may not be the only master that is configured on the bus (the field PG/PC is the only master on the bus may not be ticked). After increasing the transfer speed in the HW Config to 12Mbit/s and downloading this, the transfer speed must also be increased on the PG interface. I DT Safety Integrated Page 15/74 MC-FE-I-011-V10-DE

16 SIMOTION D435 PROFIBUS address = 2 The PROFIBUS address is set via the HW Config. SINAMICS S120 CU320 PROFIBUS address = 4 The PROFIBUS address is set via the HW Config and must coincide with the setting of the DIP switch on the CU 320. I DT Safety Integrated Page 16/74 MC-FE-I-011-V10-DE

17 SIMATIC 315F-2 PN/DP CPU PROFIBUS address = 3 The PROFIBUS address is set via the HW Config. I DT Safety Integrated Page 17/74 MC-FE-I-011-V10-DE

18 4.3.2 Bus topology View in NetPro Prerequisites for operation The SIMATIC components have been installed and interconnected. The PROFIsafe addresses of the failsafe input and output modules must be set via the DIL switch; see section Hardware configuration of the failsafe SIMATIC controller. All components are connected according to section 4.2 Hardware Component Wiring. The DRIVE-CliQ topology of the SINAMICS components is complied with. The motors are connected to the Motor Module via power and encoder cable. The Motor Module has been properly connected to the infeed unit (dc link and control voltage DC 24 V). The infeed unit is connected to the power supply. The components are supplied with DC 24 V. I DT Safety Integrated Page 18/74 MC-FE-I-011-V10-DE

19 5 Overview and Operation 5.1 Operating Hardware overview Before you can move the drives, you have to switch the SIMOTION to the RUN state. In the example, this is done via the SCOUT. For this, mark the object D435 and press the right mouse button. Make the following selection: Target device -> operating status. A screen is displayed where you can set the operating status of the SIMOTION. Set the toggle switch to the RUN position. I DT Safety Integrated Page 19/74 MC-FE-I-011-V10-DE

20 The switches -S1 to -S4 are located on a switchbox included in the Safety training case which is used to activate the different safety functions. The switches -S5 to -S10 are located on a switchbox included in the SINAMICS training case. These switches are used to switch axis enables, start traversing programs, trigger the test function of safety functions and acknowledge pending errors. In this example, the switches on the SIMOTION training case are not used. Unlock the emergency stop button -S1 to traverse the drives. The switch -S5 activates the axis enable for drive 1 (upper motor). -S6 starts and stops the related traversing program. The axis 2 (lower motor) is enabled via -S7 and the traversing program activated resp. deactivated with -S8. Pending alarms on the SIMOTION and drive alarms can be acknowledged with -S9. This does not apply to safety alarms which must be acknowledged failsafe via -S4. The test stop of the safety functions in the drives which must be performed cyclically is activated via -S10. When pressing the emergency stop button -S1, the safety function SS1 is activated for drive 1 (upper motor); that means the drive is decelerated along the OFF3 ramp and STO activated. STO is directly triggered with drive 2 (lower motor), that means the drive coasts down. When triggering the emergency stop, the drive 1 stops earlier than the drive 2. The drive 1 can be traversed with closed protective door 1 (toggle switch - S2). The safety function SOS is activated when opening -S2; that means the drive is decelerated by the SIMOTION until it stops. Upon expiry of a configurable time period, the standstill position is safely monitored by the drive. The traversing program is restarted when closing the simulated protective door -S2. An ON command is not required. With closed protective door 2 (toggle switch -S3), the drive 2 can be traversed at an arbitrary speed. When opening -S3, the traversing speed is limited by the SIMOTION to 80% of the speed limit value of step 1 of the safety function SLS. Upon expiry of a defined time period, this limit value is monitored by the safety function SLS. When closing -S3, the SLS is deactivated and the speed limitation canceled on the SIMOTION. The drive can now be traversed at the configured speed. I DT Safety Integrated Page 20/74 MC-FE-I-011-V10-DE

21 5.2 List of Input Signals Digital inputs of the SINAMICS at the SIMOTION D435 DI0 -S5 Drive 1 Set / remove axis enables DI1 -S6 Drive 1 Start / stop traversing program DI2 -S7 Drive 2 Set / remove axis enables DI3 -S8 Drive 2 DI6 -S9 Drive 1 / Drive 2 / SIMOTION Start / stop traversing program Acknowledge alarms DI7 -S10 Drive 1 / Drive 2 Trigger test stop Failsafe inputs on the F-DI module F-DI0 -S1 Emergency stop button F-DI1 -S2 F-DI2 -S3 Protective door 1 (for drive 1) Protective door 2 (for drive 2) F-DI3 -S4 Acknowledgement button Drive 1: SS1 Drive 2: STO SOS SLS Failsafe acknowledgement (drive 1 & 2) and depassivation (all F slaves) I DT Safety Integrated Page 21/74 MC-FE-I-011-V10-DE

22 6 Sample Project This section describes how to parameterize the individual components. SIMOTION SCOUT is used as engineering software for the SIMOTION and SINAMICS S120. Distributed safety is required to program the F-CPU. The following section describes how the software project belonging to this function example has been set up. 6.1 Passwords To simplify matters, we have used a common safety password for program and hardware regarding the SIMATIC components used in the project. A password is also used for the safety configuration of the SINAMICS components (drives). Safety password for F-CPU: "0" Safety password for SINAMICS components: "1" Change these passwords in real applications! I DT Safety Integrated Page 22/74 MC-FE-I-011-V10-DE

23 6.2 Basic Configurations Hardware configuration of the failsafe SIMATIC Controller In the SIMATIC Manager, insert a SIMATIC 300 station in the project. In the HW Config, create and parameterize the complete station. For this, move the modules included in the parts list from Chap. 3.1 Hardware Components via Drag&Drop from the catalog screen to the configuration screen. Make address settings for the DP interface as described in Chap I DT Safety Integrated Page 23/74 MC-FE-I-011-V10-DE

24 Configuring the F-CPU In the Properties screen of the F-CPU in the Protection tab, activate the access protection for the F- CPU and protect it by a password. Activate safety program ("CPU contains safety program.") Configuring the F-DI module. Configuring the PROFIsafe address according to the DIL switches. Configuring the F-DI module. Configuring F-DI 0 (Channel 0, 12) I DT Safety Integrated Page 24/74 MC-FE-I-011-V10-DE

25 Configuring the F-DI module. Configuring F-DI 1 (Channel 1, 13) Configuring F-DI 2 (Channel 2, 14) Configuring F-DI 3 (Channel 3, 15) Configuring F-DI 5 (Channel 5, 17) Configuring the F-DO module. Configuring the PROFIsafe address according to the DIL switches. I DT Safety Integrated Page 25/74 MC-FE-I-011-V10-DE

26 Configuring the F-DO module. Configuring F-DO 7 Save and compile HW Config Configuring the DP interface as slave (step 1) I DT Safety Integrated Page 26/74 MC-FE-I-011-V10-DE

27 Configure the DP interface as slave (step 2). Press the button New to open a second screen. Press the button OK to accept the default setting. Note: This link is automatically inserted here by the system to allow a proper compilation of the HW Config. This link is not required for the example and can be deleted afterwards (after creating the F-link). I DT Safety Integrated Page 27/74 MC-FE-I-011-V10-DE

28 6.2.2 Inserting SIMOTION in the existing SIMATIC project Insert another SIMATIC 300 station in the existing object. Then rename (if required) the station; e.g. into SIMOTION D I DT Safety Integrated Page 28/74 MC-FE-I-011-V10-DE

29 Select the corresponding SIMOTION component from the catalog and enter it in the working area (Drag&Drop). Configure and network the DP interface of the SIMOTION. DP2 is used in the example (see also section Bus topology) Save and compile. Then load the HW Config into the SIMOTION. You can now close the HW Config. I DT Safety Integrated Page 29/74 MC-FE-I-011-V10-DE

30 Save and compile the HW Config. Load the HW Config into the SIMOTION. Insert the PC in NetPro to generate the routing information required to access the SINAMICS online. From the folder Stations, move the object PC/PG into the working area. Double click the Properties screen. I DT Safety Integrated Page 30/74 MC-FE-I-011-V10-DE

31 Select the tab Interfaces and press the button New. In the following screen, select PROFIBUS and confirm with OK. Set the PG PROFIBUS address to the value 0 and establish the connection using the already configured PROFIBUS (selection PROFIBUS(1) ) Confirm settings with OK. I DT Safety Integrated Page 31/74 MC-FE-I-011-V10-DE

32 Assign the interface on the PC/PG. In the example, the computer is equipped with the CP5512 interface which shall be connected to the PROFIBUS(1). Press the button Assign to set up the connection. Check whether the interface has been set to active. Press OK to close the screen. The PG now comprises the active interface. Store and compile the project and load it into the CPU (place focus on the SIMATIC CPU). I DT Safety Integrated Page 32/74 MC-FE-I-011-V10-DE

33 The SIMOTION is now integrated in the existing project. I DT Safety Integrated Page 33/74 MC-FE-I-011-V10-DE

34 6.2.3 Basic commissioning of the SINAMICS drives (without safety) Open the SCOUT / STARTER from the SIMATIC project (-> Double-click Commissioning ) Go online. Start automatic drive configuration. Select Servo mode for both drives. Go offline and Store and compile I DT Safety Integrated Page 34/74 MC-FE-I-011-V10-DE

35 Reconfiguring Drive 1 In the project navigator, open the configuration screen for drive 1 (SERVO_02). Configure DDS starts the guided reconfiguration. Note: The following section only describes the screens to be changed. Reconfiguring both drives Configure a signal for Infeed in progress (p0864). The fixed binector 1 is used in the example. Note: In real applications, you should not use the fixed binector 1 as the signal for Infeed in progress (p0864). I DT Safety Integrated Page 35/74 MC-FE-I-011-V10-DE

36 Reconfiguring Drive 2 The second drive has no Drive-CLiQ encoder; the motor must be selected manually. The motor used in the example has type 1FK7022-5AK71-1AG0. Reconfiguring Drive 2 Analogously to the motor, you must manually select the encoder. For this, also use the type number (MLFB). Save configuration, go online and load the modified project into the SINAMICS. I DT Safety Integrated Page 36/74 MC-FE-I-011-V10-DE

37 Via the Project Navigator, open the Speed controller screen with the object SERVO_02. For both drives, the speed controller has been set as follows in the example: P gain = 0.1 Nms/rad Reset time = 10ms On both drives, adapt some parameters in the expert list. Adaptation to the 230V operation. Configuring the OFF3 ramp. Interconnect alarm acknowledgement with -S9 (= DI 6). p2101 = r722.6 in the CU expert list Copy RAM to ROM (on SINAMICS), load configuration onto the PG and save. I DT Safety Integrated Page 37/74 MC-FE-I-011-V10-DE

38 6.2.4 Telegram configuration In the SCOUT (offline!), open the screen for configuring the PROFIdrive telegram. Select telegram type 105 for both drives. Create PROFIsafe slot for both drives via the button Insert line and PROFIsafe. Select telegram type 390 for CU. I DT Safety Integrated Page 38/74 MC-FE-I-011-V10-DE

39 Insert telegram extension for the socalled safety data block. Three words are required to transfer data from the drive to the SIMOTION (input data). The SIMOTION does not transfer data to the drive (output data) Insert this telegram extension for both drives. Enter changes in the HW Config. The telegram configuration should look as displayed here (same address assignment assumed). Save, go online and load the configuration. I DT Safety Integrated Page 39/74 MC-FE-I-011-V10-DE

40 6.2.5 Inserting F-CPU in the SIMOTION HW Config and connecting it Open the HW Config of the SIMOTION and enter the F-CPU. For this, enter the object CPU 31X from the folder already configured stations in the working area. The screen displayed is automatically opened. Press the Connect button. After closing and reopening the Properties screen of the DP slave, it should look as displayed here. The default connection can be deleted. Another tab F configuration is displayed. Select this tab and press the button New. I DT Safety Integrated Page 40/74 MC-FE-I-011-V10-DE

41 Create the F- connection for the first drive. Settings in the example: Address (LADDR) = 15 Input address= 76 Exit the screen with OK and create the second F-connection via the button New in the Properties screen. Note: The drive 1 has the PROFIsafe address 76. The F-program, however, accesses the drive via the address 15. The address 76 is only required for data exchange broadcast. Create the F- connection for the second drive. Settings in the example: Address (LADDR) = 21 Input address= 82 Exit the screen with OK and create the second F-connection via the button New in the Properties screen. Note: The drive 2 has the PROFIsafe address 82. The F program, however, accesses the drive via the address 21. The address 82 is only required for data exchange broadcast. I DT Safety Integrated Page 41/74 MC-FE-I-011-V10-DE

42 Save and compile the HW Config and load it onto the SIMOTION. To check the correct configuration of the PROFIsafe setting of the drives, open the screen DP Slave properties of the SINAMICS. The tab Data Exchange Broadcast - overview shows the data exchange broadcast setting. In the tab Configuration, press the button Activate. I DT Safety Integrated Page 42/74 MC-FE-I-011-V10-DE

43 Place focus on object 1 resp. 2 (first resp. second line) and press the button PROFIsafe. The following screens are opened for the F parameters of the two drives. This screen shows the PROFIsafe settings of the first drive. No changes are required. F_Dest_Add designates the PROFIsafe address of the first drive. This is later required for the safety configuration of the drives. The value is 3FEhex (= 1022 dez). Note: The watchdog time (F_WD_Time = 150msec) must match the OB35 cycle. In the example, this is 100msec. I DT Safety Integrated Page 43/74 MC-FE-I-011-V10-DE

44 This screen displays the PROFIsafe settings of the second drive. No changes are required. F_Dest_Add designates the PROFIsafe address of the second drive. This is later required for the safety configuration of the drives. The value is 3FDhex (= 1021 dez). Note: The watchdog time (F_WD_Time = 150msec) must match the OB35 cycle. In the example, this is 100msec. Set the clock synchronization in the tab clock synchronization. For this, checkmark Synchronize drive to equidistant DP cycle, set the DP cycle to 3ms and confirm with the button Align. I DT Safety Integrated Page 44/74 MC-FE-I-011-V10-DE

45 Then open the HW Config of the F-CPU öffnen. The Properties screen of the MPI/DP interface should also display the connection. The setting made in the tab Configuration is displayed. No changes are required. The settings made in the tab F configuration are displayed. No changes are required. Save, compile and load the HW Config of the F-CPU. 6.3 Programming the Failsafe Controller We have intentionally selected a very easy safety program. In the present case, it is the main task of the safety program to compose the PROFIsafe control words for the drives using the signals to the F-DIs. These are transferred via the PROFIsafe telegram to the drives where they activate the I DT Safety Integrated Page 45/74 MC-FE-I-011-V10-DE

46 safety functions. First, you have to create the blocks required for the safety program. Notice: This program may not be used for real applications. Start with the F-Call block. This is required to call up the safety program. For this, insert a function (here FC1) in the block folder using the generation language F-Call. The cyclic interrupt OB35 is required to cyclically call up the safety program. In this example, the safety program is processed in a function block (here FB1); that means the FB 1 must be inserted with the generation language F-KOP (F-LAD) or F-FUP (F-FBD). Programming OB35 Calling up the safety program I DT Safety Integrated Page 46/74 MC-FE-I-011-V10-DE

47 Programming FB1 Network 1: Activate automatic acknowledgement Network 2: -S4 is used for acknowledgement (for errors which cannot be acknowledged automatically) Programming FB1 PROFIsafe control word for drive 1; A15 and A16 (LOW/HIGH byte) Network 3: A15.0 (STO) is permanently deactivated with VKE1. Network 4: -S1 is connected to A15.1 (SS1). I DT Safety Integrated Page 47/74 MC-FE-I-011-V10-DE

48 Programming FB1 PROFIsafe control word for drive 1; A15 and A16 (LOW-/HIGH byte) Network 5: A15.2 (SS2) is permanently deactivated with VKE1. Network 6: -S2 is connected to A15.3 (SOS). Inversion required because -S2 is wired as NO contact/nc contact. Network 7: A15.4 (SLS) is permanently deactivated with VKE1. Network 8: - S4 is connected to A15.7 (failsafe acknowledgement). Networks 9 and 10: The VKE0 is connected to A16.1 and A16.2 and the SLS step 1 permanently activated. I DT Safety Integrated Page 48/74 MC-FE-I-011-V10-DE

49 Programming FB1 PROFIsafe control word for drive 2; A21 and A22 (LOW-/HIGH byte) Network 11: -S1 is connected to A21.0 (STO). Network 12: A21.1 (SS1) is permanently deactivated with VKE1. Network 13: A21.2 (SS2) is permanently deactivated with VKE1. Network 14: A21.3 (SOS) is permanently deactivated with VKE1. Network 15: -S3 is connected to A21.4 (SLS). Network 16: - S4 is connected to A21.7 (failsafe acknowledgement). Networks 17 and 18: The VKE0 is connected to A22.1 and A22.2 and the SLS step 1 permanently activated. I DT Safety Integrated Page 49/74 MC-FE-I-011-V10-DE

50 The checkback signal SSM from the safety status word of both drives is AND-ed and connected to the lamp in S4 via DO7. Creating new F runtime group Here, the safety program (FB1) is assigned to the FC1 and the related I-DB defined. Then generate the safety program and load it into the CPU. In addition, load the standard blocks into the F-CPU. Note: We recommend that you also integrate the blocks OB82 and OB86 to tolerate I/O failure (e.g. of the drives upon Power On reset) without causing the F-CPU to change to the operating status STOP. I DT Safety Integrated Page 50/74 MC-FE-I-011-V10-DE

51 6.4 Parameterizing the Safety Functions in SINAMICS Configuring the safety functions on the drives Note: The safety functions must be configured online on the drives. We have only described the screens that are subject to parameter changes. On both drives, the safety functions STO, SS1, SS2, SOS, SLS and SSM are commissioned such that they can be activated. This example only describes the activation of SS1 and SOS for the drive 1. For the drive 2, STO and SLS are activated. The safety functions are configured in the same way on both drives. There is only one exception regarding the PROFIsafe address (input in the configuration screen). For drive 1 (SERVO_02), the value is 3FEhex and for drive 2 (SERVO_03), the value is 3FDhex. Open the Safety integrated screen of the drive 1/2 (SERVO_02 / SERVO_03) and activate commissioning mode with Change settings. The password for first commissioning is 0. I DT Safety Integrated Page 51/74 MC-FE-I-011-V10-DE

52 Safety integrated screen The following must be configured in the example: Select control with Motion Monitoring via PROFIsafe Set enables to Enable. Configuration screen The following must be configured in the example: PROFIsafe address with 3FEhex (for drive 1) resp. 3FDhex (for drive 2) Speed limit (SSM) with 100 mm/min Test stop signal source with DI7 of the SINAMICS I DT Safety Integrated Page 52/74 MC-FE-I-011-V10-DE

53 Safe Stops screen The following must be configured in the example: Delay time SS1 -> Pulse suppression = 500msec Delay time selection SOS -> SOS active = 500msec Delay time SS2 -> SOS active = 500msec Acceleration monitoring = 500mm/min Shutdown speed SS1 = 100mm/min Standstill tolerance SOS = 2.5mm Safely reduced speed screen The following must be configured in the example: n_max for step 1 = 625mm/min Copy parameters and open dialog to change the password. I DT Safety Integrated Page 53/74 MC-FE-I-011-V10-DE

54 Assign new password. The example uses the value 1. Activate settings. Copy RAM to ROM, save. Axis backup is sufficient (start with Axis parameters ). Note: Restart only upon completion of the configuration. With Version V2.5 (SINAMICS), the two drives need to be adapted to the clocksynchronized PROFIBUS. Copy RAM to ROM (on SINAMICS). Perform Power On reset. Go online, load configuration onto the PG and save. 1. p10 = p9510 = 1 3. p10 = 0 I DT Safety Integrated Page 54/74 MC-FE-I-011-V10-DE

55 The use of drive-integrated safety functions is selected, these functions can be activated resp. deactivated via the F-CPU operator elements. Only the following messages shall be visible. These messages do not affect the functionality described above. They only state that the safety functions test stop must be performed in the drives (A1697). These are warnings, that means the drives can be activated and traversed as soon as the SIMOTION configuration has been completed Configuring the safety data block on SINAMICS The telegram extension for the so-called safety data block was created in section Telegram configuration. This data block shall be supplied by SINAMCS Integrated with the necessary data. Six bytes / three words are required. The data are transferred from the drive to the SIMOTION. No safety signals are transferred from the SIMOTION to the drive. The operator connects the process data via the SINAMICS BiCo wiring. The sequence of the individual signals in the safety data block may not be changed. The feed back bits of the drive safety functions are transferred in the first word. I DT Safety Integrated Page 55/74 MC-FE-I-011-V10-DE

56 Perform the following BiCo wiring for each drive: The status word is then provided in parameter r2089[3]. The effective setpoint speed limitation when selecting SLS (r9733) as a floating point number is transferred in the second and third word. The safety data block wiring at the drive end has the following assignment: Safety status word r2089[3] effective setpoint speed limiting r9733 [0] = p9531 [x] * p9533 / p9520 (x: active SLS stage) The SINAMICS safety status signals are displayed in the SIMOTION system variable D435.Axis_1.drivedata.drivesafetyextendedfunctionsinfodata.state. The setpoint speed limitation value is displayed in D435.Axis_1.drivedata.drivesafetyextendedfunctionsinfodata.safespeedlimit. I DT Safety Integrated Page 56/74 MC-FE-I-011-V10-DE

57 6.5 SIMOTION Creating SIMOTION axes On the SIMOTION, the axes must be created as follows using the Commissioning Wizard. SERVO_02 is assigned to Axis_1, SERVO_03 is connected accordingly to Axis_2. This example shows the procedure for an axis (Axis_1). Before loading the project into the SIMOTION, you must configure both axes. Start Commissioning Wizard by doubleclicking Insert axis in the Project Navigator. In the example, the first axis is called Axis_1. Speed control and Positioning are activated. The preset values are kept. They refer to a linear axis with electrical drive. I DT Safety Integrated Page 57/74 MC-FE-I-011-V10-DE

58 In the example, the values preset in the Units screen are kept. Modulo correction is not activated in the example. I DT Safety Integrated Page 58/74 MC-FE-I-011-V10-DE

59 The assignment between the SIMOTION object (Axis_1) and the SINAMICS axis (SERVO_02) is made in this screen. Perform data adjustment with the drive (normalization speed and maximum speed). Check whether the PROFIdrive telegram 105 is selected. Press the button Change PROFIdrive message frame to open the following screen. Since the configuration of the SINAMICS drives has been completed, you must only check whether the values have been correctly transferred. In general, no changes must be made. Check particularly the message frame extension by three words at the input end, because this is required to transfer the safety data from the drive to the SIMOTION. I DT Safety Integrated Page 59/74 MC-FE-I-011-V10-DE

60 The encoder is assigned here. Press the button Data transfer from the drive to transfer the encoder data to the Wizard. Further encoder data are displayed here. No changes are required if the data have been correctly transferred from the drive. I DT Safety Integrated Page 60/74 MC-FE-I-011-V10-DE

61 Terminate Wizard for the creation of the object axis on the SIMOTION. Upon completion of the Commissioning Wizard, some parameters must still be changed in the example. These are displayed in the following screens. Dynamic response screen The speed is set to the value mm/s (corresponds to 500rev/min). The value mm/s 2 is entered for acceleration and delay. I DT Safety Integrated Page 61/74 MC-FE-I-011-V10-DE

62 Limits screen Set the maximum speed to 500mm/s. Closed-loop control screen In the example, the servo gain factor is set to 12 1/s. With the second axis, differences arise in the Drive assignment screen. The logical hardware addresses according to Servo_03 are entered here. I DT Safety Integrated Page 62/74 MC-FE-I-011-V10-DE

63 With the second axis, differences also arise in the Encoder assignment screen. The encoder data can be entered in the Wizard by pressing the button Data transfer from the drive. With the second axis, differences also arise in the Encoder data screen. Further encoder data are displayed here. Changes are not required if the data have been properly transferred from the drive. I DT Safety Integrated Page 63/74 MC-FE-I-011-V10-DE

64 Since the Safety alarms of the SIMOTION do not yet completely correspond to the specification, we recommend that you hidde these alarms for both axes. Open the screen by selecting the TechFault Task in the runtime system, then press the button Alarm configuration. The axis-specific reactions in this example do not use these alarms either. Note: As from Version 4.1.4, the alarm function is correct. However, we recommend that you refrain from using the alarms for programming axisspecific reactions. Upon completion of commissioning both axis on the SIMOTION, save the project and load it onto the SIMOTION (in the Project Navigator, place focus on D435). If the commissioning was performed as shown here, all settings for the safety data block are correct. You should only check if the start address was correctly entered (276 for Axis_1 and 302 for Axis_2) Axis_1 Axis_2 I DT Safety Integrated Page 64/74 MC-FE-I-011-V10-DE

65 6.5.2 SIMOTION programs This section briefly presents the programs used in the function example. We have refrained from providing the program code resp. a detailed description because the programs include comments. ST programs include comments directly in the code. With MMC programs, commented blocks are marked with a green triangle in the upper right corner. You can open the comment by marking the block and pressing the right mouse button to open a menu. Here, select the entry Enter comment IO_ReadWrite (read in resp. write digital I/Os) The digital inputs of the SINAMICS are used to control the axis movements. These inputs are read in on the SIMOTION via the I/O variable io_cu320_inword. The variable io_cu320_outword is used to control the SINAMICS outputs (this variable is not used in this example). The inputs are used, for example, to activate the drives, start traversing program, acknowledge faults and start test stop resp. forced dynamization. These two variables are created in the Project Navigator under I/O as described in the following. In this example, the DIs are provided by the SINAMICS at the address 310 (corresponding to PZD 2 of the Control Unit send direction). Use the Address 298 (corresponding to PZD 2 of the Control Unit receive direction) for the outputs. The program IO_ReadWrite was transferred from the FAQ with the number Program sections which are not required have been removed subsequently. A detailed documentation and the program code can be downloaded at the following link: The program is processed in the Background Task and provides the signals at the digital inputs of the SINAMICS using the above-stated variables for the SIMOTION program sequence Axis_01.mmc_bg_task1 (runtime controller for Axis_1) This program is used to actuate the upper training case drive (Axis_1; resp. SERVO_02). The program is cyclically processed in the BackgroundTask and is responsible for activating/deactivating the axis enable, error acknowledgement and for starting and stopping the traversing program mt_axis_1. Program functions: -S5 (DI 0) Set / remove enables for Axis_1 -S6 (DI 1) Start resp. stop traversing program mt_axis_1. -S9 (DI 6) Acknowledge alarms I DT Safety Integrated Page 65/74 MC-FE-I-011-V10-DE

66 Axis_02.mmc_bg_task2 (runtime controller for Axis_2) This program is used to actuate the lower training case drive (Axis_2; resp. SERVO_03). The program is cyclically processed in the BackgroundTask and is responsible for activating/deactivating the axis enable, error acknowledgement and for starting and stopping the traversing program mt_axis_2. Program functions: -S7 (DI 2) Set / remove enables for Axis_2 -S8 (DI 3) Start resp. stop traversing program mt_axis_2. -S9 (DI 6) Acknowledge alarms Axis_01.mt_axis_1 (traversing program for Axis_1) The traversing program comprises three traversing commands which are cyclically called by mmc_bg_task1 while a HIGH level is pending at -S1. That means, after starting the traversing program once, the axis performs an endless movement until this is aborted by activating a safety function or through a LOW level at -S1. This program is processed in the Motion- Task_3. This task is cyclically started by the program Axis_01.mmc_gb_task Axis_02.mt_axis_2 (traversing program for Axis_2) The traversing program comprises three traversing commands which are cyclically called by mmc_bg_task2 while a HIGH level is pending at -S3. That means, after starting the traversing program once, the axis performs an endless movement until this is aborted by activating a safety function or through a LOW level at -S3. This program is processed in the Motion- Task_4. This task is cyclically started by the program Axis_02.mmc_bg_task Axis_01.mt_safety_axis_1 This program is used to perform the axis-specific reactions to the activation / deactivation of safety functions. Since several safety functions can be active at the same time, you must first determine the priority before you can perform the axis-specific reaction. For this, determine the value of a variable which is used to select the reaction (via CASE instruction). In the example, the reactions described below are initiated for the individual functions. When they have been performed, the variables for the status of the individual safety functions (determined in ST_Main.extsafety) and for prioritization (determined in Axis_01.mt_safety_1) are reset. The program is processed in MotionTask_6. STO No special reaction is required when activating STO because the pulses are immediately deleted. No reaction is required when deactivating STO because a new ON command must be set after deactivating STO. SS1 When activating SS1, the axis must be switched to follow-up mode and the I DT Safety Integrated Page 66/74 MC-FE-I-011-V10-DE

67 movement program Axis_01.mt_axis_1 aborted. For this, the Motion- Task_3 and the current traversing command are aborted. When deactivating SS1, the MotionTask_3 is reset in order to restart it again. Since SS1 directly leads to an STO, a new ON command must be entered to start the axis movement. SS2 When activating SS2, the axis must be switched to follow-up mode and the movement program Axis_01.mt_axis_1 aborted. For this, the Motion- Task_3 and the current traversing command are aborted. When deactivating SS2, the MotionTask_3 is resumed. The movement automatically continues upon deactivation. No further command is required. SOS When activating SOS, the axis movement is decelerated via a STOP command in position control until it stops. Afterwards, the MotionTask_3 is aborted to prevent traversing by the following positioning command. When activating SOS, the MotionTask_3 is resumed and the next pending positioning command processed. That means, no command need be entered in order to restart the axis movement. SLS When activating SLS, the permissible maximum positioning speed (SIMOTION variable: pluslimitsofdynamics.velocity) is reduced to the value transferred by the SINAMICS (via the so-called safety data block) to the SIMOTION. The movement is performed at the reduced speed. When deactivating SLS, this limit value is reset to the original value Axis_02.mt_safety_axis_2 See where this program is processed in MotionTask_7 and the axis movement of Axis_2 is controlled via MotionTask_ ST_VarGlobal ST_Main The variables required for evaluating the safety status word are defined in this ST program. This program comprises three subprograms: startup, extsafety and techfault. Note: As from Version 4.1.4, the function of the safety messages of SIMOTION to is correct. In earlier versions, these did not yet completely correspond to the specification. In general, we recommend that you cyclically evaluate the safety status word and refrain from using the alarms for axis-specific reactions. startup This program assigns the axis instances, that means it determines which axis corresponds to which variable. Further, the speed limit value of the SIMOTION configuration is stored in a variable. When activating SLS, this I DT Safety Integrated Page 67/74 MC-FE-I-011-V10-DE

68 value is overwritten and must be provided upon deactivation. The program is processed in the StartupTask. extsafety This program evaluates the safety status word to obtain information about the status of safety functions. A differentiation is made between the statuses activated / selected (incoming event), active, deactivated / deselected (outgoing event) and inactive. Depending on this information, the motion task is started which comprises the program initiating the axisspecific reaction to the safety functions (MotionTask_6 for Axis_1 and MotionTask_7 for Axis_2). In the example, the program is processed in the IPO task, which is only necessary when using the functions SS2 or SS1. Without these two functions, processing in the BackgroundTask is sufficient. When activating the safety functions SS1 resp. SS2, the drive is immediately separated from the higher-level set point of the SIMOTION upon activation of the function and you must prevent following errors leading to pulse suppression (with standard setting). In such a case, processing must therefore be performed as quickly as possible. The functions SOS and SLS include a configured timer between selection and activation; for this reason, more time is available for the reaction of the SIMOTION. techfault This is an empty program (dummy) which must be integrated in the TechnologicalFaultTask. If this program is missing, the operating status of the SIMOTION changes to the operating status STOP in case of a TechnologicalFault alarm other_mmcs.peripheralfault This is an empty program (dummy) which must be integrated in the PeripheralFaultTask. If this program is missing, the operating status of the SIMOTION changes to the operating status STOP in case of a PeripheralFault alarm other_mmcs.executionfault This is an empty program (dummy) which must be integrated in the ExecutionFaultTask. If this program is missing, the operating status of the SIMOTION changes to the operating status STOP in case of a ExecutionFault alarm Runtime system configuration The different SIMOTION programs must be assigned to the different tasks. The function example is based on the following configuration. I DT Safety Integrated Page 68/74 MC-FE-I-011-V10-DE

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70 6.5.4 SIMOTION messages Safety messages The SIMOTION outputs three messages for the extended safety functions : Safety alarm in the drive 50202: Drive starts Safety Integrated Extended Function 50203: Drive terminates Safety Integrated Extended Function These messages shall not be used to configure the axis-specific reactions of the SIMOTION Other messages When activating the different safety functions, further messages are displayed. These are to be expected and do not display an incorrect behavior : Device type: X, log. address: Y faulty. This error occurs among others when activating STO and SS1 and states that the drive has been deactivated : Command aborted (reason: X, command type: Y) This message is also output upon the activation of STO and SS1 and stop of positioning through deactivation of -S6 resp. S8. The reason for this is that the current positioning command was aborted prior to or during processing : The programmed speed is limited This error occurs when activating SLS if the configured speed is above the limit for SLS : Missing enable(s) (Parameter1: X) and/or incorrect mode (Parameter2: Y) This error occurs when activating STO and indicates missing axis enables with a pending movement command. 6.6 Downloading the Sample Project So far, we have described step by step the configuration setup of the function example. If you wish to load the sample project directly onto the hardware, please note the following steps. First, perform a general reset of all components (S7-F-CPU, SIMOTION and SINAMICS) resp. reset them to the factory setting Loading the S7-F-CPU configuration First download the hardware configuration of the S7-F-CPU. Double-click Hardware to open the hardware configuration. I DT Safety Integrated Page 70/74 MC-FE-I-011-V10-DE

71 Depending on the preset values resp. the previous F-CPU configuration, you may have to adapt the baudrate of the PC/PG interface for downloading the F-CPU hardware configuration. If the SIMOTION and the F-CPU have the same PROFIBUS address (the default for both is 2), then first connect the F-CPU to the PC/PG to download the hardware configuration thus changing the bus address and baud rate to the values stated in section Then you can connect the SIMOTION to the PROFIBUS network. Before you can go online, change the baud rate according to section Note: If a safety program was installed on the CPU before, this is protected by a password. You must know this to perform the download. If you do not know the password, you have to destroy the memory card using a suitable device (e.g. SIEMENS PG). Deletion resp. formatting using a card reader will destroy the card. After downloading the hardware configuration, load the program blocks onto the F-CPU. I DT Safety Integrated Page 71/74 MC-FE-I-011-V10-DE

72 1 2 First open the screen for loading the safety function via the yellow button in the function bar. Then press the button Load to start the download from this screen. The remaining (unsafe) blocks are loaded as usual Loading the SIMOTION and SINAMICS configuration First, load the hardware configuration of the SIMOTION. In general, no online connection is set up to the SINAMICS without performing this step. Double-click Hardware to open the hardware configuration. After performing the download, open the SCOUT from the SIMATIC project (double-click Commissioning ). I DT Safety Integrated Page 72/74 MC-FE-I-011-V10-DE

73 Here you can load the complete SIMOTION and SINAMICS configuration. Since the series numbers of the encoder modules do not coincide with the devices used to create the sample project. Various safety faults are pending after the download. Analogously to series commissioning, you have to transfer the new series numbers to the safety configurations. This is done via Confirm hardware replacement. The easiest method is to open the safety screen on both drives and press the button Confirm hardware replacement. Then start the backup process from RAM to ROM for the SINAMICS and perform a restart (Power On reset). I DT Safety Integrated Page 73/74 MC-FE-I-011-V10-DE