Applications & Tools. Controlling Safety Integrated Extended Functions and transferring the F-DIs of the CU310-2 PN via PROFIsafe with PROFINET

Transcription

1 lcover sheet Controlling Safety Integrated Extended Functions and transferring the F-DIs of the CU310-2 PN via PROFIsafe with PROFINET SINAMICS S120 Application example February 2014 Applications & Tools Answers for industry.

2 Siemens Industry Online Support This article is taken from Siemens Industry Online Support. The following link takes you directly to the download page for this document: Caution: The functions and solutions described in this article are limited primarily to the implementation of the automation task. Please also note that in case of networking your plant area with other parts of the plant, the company network or the Internet, appropriate protective measures within the framework of industrial security must be adopted. For more information, see the entry ID

3 s Task 1 Solution 2 Basic principles 3 SIMATICS S120 Safety Integrated Configuration and project engineering 4 Installation 5 Controlling Safety Integrated Extended Functions + transferring the F-DIs of the CU310-2 PN via PROFIsafe with PROFINET Commissioning the application 6 Operating the application 7 References 8 Contact persons 9 History 10 3

4 Warranty and liability Warranty and liability Note The application examples in this document are not binding and do not claim to be complete regarding the configuration, equipping, and any eventuality. The application examples do not represent specific customer solutions, but are only intended to provide support for typical applications. You are responsible for the proper operation of the described products. These application examples do not relieve you of your responsibility regarding the safe handling when using, installing, operating, and maintaining the equipment. By using these application examples, you agree that Siemens cannot be made liable for possible damage beyond the mentioned liability clause. We reserve the right to make changes to these application examples at any time and without prior notice. If there are any differences between the suggestions made in these application examples and other Siemens publications such as catalogs, the contents of the other document(s) have priority. We give no guarantee for the information contained in this document. We accept no liability for any damage or loss caused by the examples, information, programs, planning data or performance data described in these application examples, irrespective of the legal basis for claims arising from such damage or loss, unless liability is mandatory. For example, according to the product liability law, in cases of malfeasance, gross negligence, due to endangerment of life, the body or health, due to assumption of a guarantee for a product's characteristics of state, due to malicious concealment of a defect or due to violation of basic contractual obligations. However, claims for indemnification based on breach of contract shall be limited to liability for damages to the contract-specific, foreseeable damages, provided there is no mandatory liability for intent, acts of gross negligence, harm to the life, body and health of human beings. Any change to the burden of proof to your disadvantage is not covered hereby. Any form of duplication of these application examples or excerpts hereof is not permitted without the express consent of Siemens Industry Sector. 4

5 Table of contents Table of contents Warranty and liability Task Overview Solution Overview of the overall solution Description of the core functionality Hardware and software components used Basic principles PROFINET communication PROFIsafe communication Configuration and project engineering Passwords Preparation Hardware configuration Configuring the basic drive functions PROFIsafe configuration to control the safety functions integrated in the drive Parameterizing the safety functions integrated in the drive Configuring the F-CPU Acceptance test Installation Commissioning the application Preconditions Preparation Commissioning Operating the application Overview Description of function Summary of input signals References Related documents Internet links Contact persons History

6 1 Task 1.1 Overview 1 Task 1.1 Overview Introduction The following safety functions according to DIN EN are currently integrated in SINAMICS S120 drives: Table 1-1: SINAMICS S120 safety functions according to DIN EN Name Function Description STO Safe Torque Off SS1 Safe Stop 1 SBC Safe Brake Control SS2 Safe Stop 2 SOS SLS SSM SDI SLP Safe Operating Stop Safely Limited Speed Safe Speed Monitor Safe Direction Safely Limited Position Safe disconnection of the torque-generating power supply to the motor. The switching on inhibited function prevents the drive unit from being switched on again. (Category 0 stop function according to EN ) The drive is quickly stopped along the OFF3 ramp and is safely monitored. After a delay time has elapsed or the shutdown speed has been reached, a transition is made to STO. (Category 1 stop function according to EN ) SBC is only used when there is a motor brake and the motor brake is connected to the power connector via the outputs. SBC always responds in conjunction with STO or when internal safety monitoring functions respond with safe pulse cancellation. The drive is quickly and safely stopped along the OFF3 ramp and is safely monitored. Transition to SOS after a delay time has expired; the drive remains in closed-loop control. (Category 2 stop function according to EN ) Not available for safety functions without encoder. This function serves to safely monitor the standstill position of a drive; the drive remains in closed-loop control. Not available for safety functions without encoder. The drive speed is safely monitored. Parameterizable shutdown response when the limit value is violated. Safely displays when the speed falls below a speed limit (n < nx). The direction of motion (positive and negative directions) is safely monitored. Parameterizable shutdown response when moving in the direction that has not been enabled. The positioning range of a drive is safely monitored; corresponds to safety-relevant software limit switches. Parameterizable shutdown response when position limits are violated. Not available for safety functions without encoder. 6

7 1 Task 1.1 Overview In addition to the functions defined in standard DIN EN , the following safety functions are also available in SINAMICS S120. Table 1-2: SINAMICS S120 safety functions not specified by DIN EN Name Function Description SP SBT Safe Position Safe Brake Test The safety-relevant position values of the SINAMICS S120 are transferred to a higher-level fail-safe control system (F-CPU) using a PROFIsafe telegram. For safety functions without encoder, these are only available with some restrictions. Using this function, the holding torque of up to 2 (holding) brakes can be tested. In conjunction with the SBC function, a safety-relevant brake can be implemented. Not available for safety functions without encoder. The implementation of safety concepts is facilitated significantly through the use of safety technology integrated in the drive, and its use also simplifies the verification of the required safety category for a machine. The user is also supported by the Safety Evaluation Tool. In the following application example, the drive-integrated safety functions are controlled via PROFIsafe with PROFINET. 7

8 1 Task 1.1 Overview Overview of the automation task The following diagram provides an overview of the automation task. Figure 1-1: Concept of the safety functions The following safety functions are used as basis for further consideration. Table 1-3: Safety functions of the application example Safety function Description Response SF1 SF2 Actuating the Emergency Stop pushbutton -S5. Actuating the Emergency Stop pushbutton -S1. SS1 local (only effective for this drive) via terminal: Fast stopping of the drive with subsequent pulse cancellation. SS1 global (effective for all drives of a system/machine): Fast stopping of the drive with subsequent pulse cancellation. 8

9 1 Task 1.1 Overview Safety function Description Response SF3 SF4 When protective door 1 is open (-S6), it is not permissible that the drive exceeds the velocity/speed configured by the user. When protective door 2 is open (-S2), it is not permissible that the drive exceeds the velocity/speed configured by the user. SLS local (only effective for this drive) via terminal: Monitoring of the drive speed. SLS global (effective for all drives of a system/machine): Monitoring of the drive speed. Description of the automation task A modular safety concept is to be presented in this example. Sensors locally connected at the F-DIs of the drive only control safety functions SS1 and SLS for this particular drive. Sensors directly connected to the F-DI modules of the F-CPU, control the SS1 and SLS safety functions for all drives of a machine. PROFIsafe via PROFINET is always used for the control. To do this, the signals of the sensors connected to the F-DIs of the SINAMICS S120 are transferred to the F-CPU using PROFIsafe, where they are subsequently evaluated. In this particular example, there is only one drive; however the principle can be employed to globally and locally control safety functions of a modular machine. 9

10 2 Solution 2.1 Overview of the overall solution 2 Solution 2.1 Overview of the overall solution Schematic The following schematic diagram shows the most important components of the solution: Fig. 2-1: Relative components of the safety functions Controlling safety functions SS1 and SLS via PROFIsafe with PROFINET for a SINAMICS S120 drive line-up is demonstrated using this application example. The S120 drive line-up used comprises a Control Unit CU310-2 PN, a Power Module PM340 and a 1FK7 servomotor with incremental Drive-CLiQ encoder. In order to be able to implement a modular safety concept, in this particular example, the safety functions are locally controlled (only effective for this drive) and globally controlled (effective for all drives of a system/machine). The local safety functions are controlled using sensors at the F-DIs of the drive. These sensors only control the SS1 and SLS safety functions for this particular drive. The local, safety- 10

11 2 Solution 2.1 Overview of the overall solution relevant signals are transferred from the fail-safe onboard terminals of the SINAMICS S120 via PROFIsafe with PROFINET to the F-CPU. The other global safety functions are controlled using the sensors of the SAFETY training case. These global signals are sensed using the fail-safe inputs of the F-CPU. They control the SS1 and SLS safety functions for all of the drives of a machine. All of the signals detected and transferred at the F-CPU are evaluated in the F- CPU, and logically interlocked in the safety program to allow the integrated SS1 and SLS safety functions to be controlled. The safety functions integrated in the SINAMICS S120 drive being used are controlled using fail-safe PROFIsafe communication. The F-CPU is the F host as well as also the PROFINET controller. Design This application example is based on the SINAMICS S120 CU310-2 PN training case (6A AA17-0AA0) and the SAFETY training case. Advantages Limitations The application described here offers you the following advantages: Simple control of the safety functions integrated in the drive. Simple design using standard technology. The existing system can be quickly and simply expanded. Space-saving and favorably-priced design using integrated safety functions additional hardware is not required. Complex safety concepts can be implemented on this basis. This application does not contain a description of the safety functions of the SINAMICS S120, the general drive functions of the SINAMICS S120 and the hardware interfaces of the CU310-2 It is assumed that readers have basic knowledge of these topics. Information on these topics can be found in the documents in the references. Knowledge required It is assumed that readers have basic knowledge about engineering SINAMICS S120 drives with the STARTER or SIMOTION SCOUT engineering software. 11

12 2 Solution 2.2 Description of the core functionality 2.2 Description of the core functionality Overview and description of the core functionality Copyright Siemens AG Copyright-2013 All rights reserved Figure 2-2: SAFETY + SINAMICS S120 CU310-2 PN training case Note For this application example, the standard wiring of the S120 CU310-2 PN training case was adapted. The changes are presented in detail in Chapter 5. Sequence of the core functionality Switches -S1 to -S4 are located on a switchbox that belongs to the SAFETY training case. The global SS1 safety function is initiated using -S1. Global safety function SLS is selected or deselected using switch -S2. Pushbutton -S4 is used for fail-safe acknowledgment. A lamp integrated in this pushbutton indicates whether safety fault messages are active in the drive. In this particular application example, switch -S3 is not used. Switches -S5 to -S11 are located on the enclosure of the SINAMICS training case. The local SS1 safety function is initiated using switch -S5 (switch pair -S5.1 and S5.2). The local SLS function is selected using switch -S6 (switch pair -S6.1 and S6.2). Switch -S7 is used to switch on and switch off the drive. Switch -S8 is used to switch between two speed levels. Switch -S9 is used to initiate a test stop of the safety functions. In this particular application example, switches -S10 and -S11 are not used. 12

13 2 Solution 2.3 Hardware and software components used 2.3 Hardware and software components used The application was created with the following components: Hardware components Table 2 1: Hardware used Component Type MLFB/ ordering data Qty Manufacturer SINAMICS training case S120 CU310 6A AA17-0AA0 1 Siemens Compact Flash Card 6SL3054-0EG00-1BA0 1 Siemens Control Unit CU310-2 PN 6SL3040-1LA01-0AA0 1 Siemens Safety training case 1 Siemens Table 2-2: SAFETY training case (essential components) Component Type MLFB/ ordering data Qty Manufacturer SITOP power supply SITOP SMART 120W 6EP AA01 1 Siemens SIMATIC S7-300 CPU SIMATIC S7 fail-safe input module SIMATIC S7 fail-safe output module SINAMICS fail-safe Terminal Module Drive-CLiQ Toggle switches -S2 and -S3 Emergency Stop button -S1 Pushbutton -S4 Load resistors R1 R8 CPU 315F-2 PN/DP 6ES FH13-0AB0 1 Siemens SIMATIC MMC, 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 TM54F 6SL3055-0AA00-3BA0 1 Siemens Cable, gray metal connector Toggle switch 0-I, latching, 16 mm, black Holder with solder pins Mushroom pushbutton, red, 16 mm Holder with solder pins Pushbutton, flat, 16 mm, white Holder with lamp socket and lamp 1kOhm 1W 6FX2002-1DC00-1AC0 1 Siemens 3SB2000-2AB01 2 Siemens 3SB2908-0AB 2 Siemens 3SB2000-1AC01 1 Siemens 3SB2908-0AB 1 Siemens 3SB2000-0AG01 1 Siemens 3SB2455-1B 1 Siemens Type PO595-0 style 0207 Power metal oxide film resistors 1 Yageo Europe 13

14 2 Solution 2.3 Hardware and software components used Component Type MLFB/ ordering data Qty Manufacturer Terminals for the load resistors (R1 R8) Load resistor R9 Terminals for load resistor (R9) ST 2.5-QUATTRO- TG P-CO component connector SMA0207 1K2 1% TK TERMINALS_ACCES SORY_EMPTY_CON NECTOR_TYPE1_G RAY TERMINAL_4- WIRE_GRAY RES_MET_FLM_1K2_+ - 1%_600mW_+50ppm_0 207 Phoenix Contact Phoenix Contact 1 Beyschlag WAGO WAGO Note The application example was tested with the hardware components listed here. Alternatively, other components with the same function may be used. In such a case, a different parameter assignment and different wiring of the components may be required. Components marked yellow are not relevant for this application example. Standard software components Table 2-3: Software used Component Qty. MLFB/ ordering data Version STEP 7 1 6ES7810-4CC10-0YA7 V5.5 SP2 HF1 S7 Distributed Safety Programming 1 6ES7833-1FC02-0YA5 V5.4 SP5 S7 F configuration pack 1 V5.5 SP10 STARTER 1 6SL3072-0AA00-0AG0 V Sample files and projects The list below contains all the files and projects used in this example. Table 2-4: Documents and files MC_FE_I_018_V10.zip Component _MC_FE_I_018_V10_en.pdf Note This zipped file contains the project. This document 14

15 3 Basic principles 3.1 PROFINET communication 3 Basic principles 3.1 PROFINET communication In addition to the MAC and IP address, PROFINET also uses a device name to identify PROFINET devices. This device name must be unique across the PROFINET network. During the commissioning phase, each PROFINET device is assigned a device name once using the configuration tool, and this is stored retentively in the PROFINET device (a process known as node initialization). If a device is replaced, e.g. because of a defect, the new device has a different MAC address. If it is initialized with the same device name as the replaced device (e.g. by reconnecting an interchangeable medium that stores the device name retentively), it can take over the function of the replaced device without any changes in the configuration. Rules for assigning names Letters a-z and digits 0-9 may be used. Special characters are not permitted! " $ % & / ( ) =? * ' _ : ; > <, # + ~ \ } ] [ { No spaces The total maximum length for a name is 240 characters. Reserved names "port-xyz" or "port-xyz-abcde a,b,c,d,e, x, y, z = The file name must only comprise lower case letters. The engineering system replaces upper case letters by lower case letters. The minus character must not be used for a SIMOTION control system. 3.2 PROFIsafe communication Every drive with configured PROFIsafe slot in the drive device represents an F device with a fail-safe communication to the F host via PROFINET. A suitable PROFIsafe telegram (PROFIsafe slot) is created for each drive. SIEMENS telegram 31 is used in this example. Telegram 31 transfers safety control word 2 (S_STW2) and safety status word 2 (S_ZSW2) as user data. Using safety status word 2, it is also possible to transfer the status of the F-DIs of the CU310-2 to the F-CPU where it is processed. The structure of control word 2 and status word 2 is described in more detail in the following tables. 15

16 3 Basic principles 3.2 PROFIsafe communication Table 3-1: Description of safety control word 2 (S_STW2) Byte Bit Meaning Remark 0 0 STO 1 Deselect STO 0 Select STO 1 SS1 1 Deselect SS1 0 Select SS1 2 SS2 1 Deselect SS2 0 Select SS2 3 SOS 1 Deselect SOS 0 Select SOS 4 SLS 1 Deselect SLS 5 Reserved Select SLS 6 SLP 1 Deselect SLP 0 Select SLP 7 Internal event ACK 1/0 Acknowledgment 1 0 Reserved No acknowledgment 1 Select SLS bit 0 - Selection of the speed limit for SLS 2 Select SLS bit 1 - (2 bits) 3 Reserved SDI positive 1 Deselect SDI positive 0 Select SDI positive 5 SDI negative 1 Deselect SDI negative 6,7 Reserved Select SLP position range 4 7 Reserved Select SDI negative 1 Select SLP area 2 (SLP2) 0 Select SLP area 1 (SLP1) Reserved

17 3 Basic principles 3.2 PROFIsafe communication Table 3-2: Description of safety status word 2 (S_ZSW2) Byte Bit Meaning Remark 0 0 STO active 1 STO active 0 STO not active 1 SS1 active 1 SS1 active 0 SS1 not active 2 SS2 active 1 SS2 active 0 SS2 not active 3 SOS active 1 SOS active 0 SOS not active 4 SLS active 1 SLS active 0 SLS not active 5 Reserved SLP active 1 SLP active 0 SLP not active - The status signal "SLP active" is not the same as the diagnostic signal "SLP active" (r9722.6), but is the AND logic operation of "SLP active" (r9722.6) and "safely referenced" (r ). 7 Internal event 1 Internal event 1 0 Reserved No internal event 1 Active SLS level bit 0 - Display of the speed limit for SLS (2 bits) 2 Active SLS level bit 1-3 Reserved SDI positive active 1 SDI positive active 0 SDI positive not active 5 SDI negative active 1 SDI negative active 6 Reserved SDI negative not active SSM (speed) 1 Speed below the limit value 3 SLP active position range 0 Speed higher than or equal to limit value 1 SLP range 2 (SLP2) active 0 SLP range 1 (SLP1) active - The status signal "SLP active position range" always corresponds to the diagnostics signal "SLP active position range" (r ). 4,5 Reserved Safe position valid 1 Safe position valid 0 Safe position invalid 7 Safely referenced 1 Safe position is applicable as "safely referenced" 0 Safe position is not applicable as "safely 17

18 3 Basic principles 3.2 PROFIsafe communication Byte Bit Meaning Remark referenced" 3 0 F-DI 0 1) 1 F-DI 0 inactive 0 F-DI 0 active 1 F-DI 1 1) 1 F-DI 1 inactive 0 F-DI 1 active 2 F-DI 2 1) 1 F-DI 2 inactive 3,4 Reserved F-DI 2 active 5 SOS selected 1 SOS selected 6 SLP upper limit maintained 7 SLP lower limit maintained 1) Only valid for CU SOS deselected 1 SLP: Upper limit maintained 0 SLP: Upper limit not maintained - The status signal "SLP upper limit maintained" always corresponds to the diagnostics signal "SLP upper limit maintained" (r ). 1 SLP: Lower limit maintained 0 SLP: Lower limit not maintained - The status signal "SLP lower limit maintained" always corresponds to the diagnostics signal "SLP lower limit maintained" (r ). 18

19 4 Configuration and project engineering In this chapter, you get to know how the individual components must be parameterized. STARTER is used as the engineering software for SINAMICS S Passwords How the software project belonging to this application example was set-up is described step-by-step in the following sections. Note The screenshots were generated with the "English" language setting. Display differences can occur for other language settings. 4.1 Passwords For reasons of simplicity, a common safety password is used for the program and hardware on the SIMATIC components in the project. Safety password for F-CPU: 0 Safety password for SINAMICS: 1 NOTICE Such simple passwords must not be used in a real application as they do not provide adequate protection against authorized personnel accessing the configuration. 19

20 4.2 Preparation 4.2 Preparation Table 4-1: Setting the PG/PC interface 1. To start, please open the SIMATIC Manager. 2. Then create a new project by pressing the "New" button. 3. You can now enter an arbitrary project name. Please acknowledge with "OK". 20

21 4.2 Preparation The PG/PC interface is now set up. 4. To do this, please press the "Set PG/PC button in the "Options" menu. Here, select the hardware which you wish to use to establish an online connection. 5. In this example, it involves the USB Ethernet adapter "ASIX AX88179 USB 3.0". Open the properties window using the "Properties" button. 21

22 4.2 Preparation 6. In the subsequent window, please click on the "Network properties" button. 7. Select the network connection being used and open the status window by double-clicking on the corresponding network. 22

23 4.2 Preparation 8. Now click the "Properties" button. 9. Now select the menu item "Internet Protocol (TCP/IP)" and press the "Properties" button. 23

24 4.2 Preparation Now set a fixed IP address. 10. The following setting is used in this example: IP address: Subnet mask: Acknowledge your entry with "OK" and then close all of the open windows. 11. In order to assign the devices the required IP addresses and device names, under "PLC", select the "Edit Ethernet Node" item. 24

25 4.2 Preparation 12. Then click the "Browse" button. 13. All of the nodes/participants that can be reached are listed. Initially, select "S7-300" station. 25

26 4.2 Preparation In this example, the S7-300 station was assigned the following configuration: IP address: Subnet mask: Now acknowledge the entries that you have made with "Assign IP Configuration", and close the window with "Close". 15. Note: The "Assign Name" button can be used to assign a specific name to a node/participant. The "pn-io" default value is kept unchanged for this particular example. The CU310-2 PN is assigned an IP address in the following. To do this, select the Control Unit from the nodes/participants that can be reached. 26

27 4.2 Preparation In this example, the CU310-2 PN was assigned the following configuration: IP address: Subnet mask: Now acknowledge the entries that you have made with "Assign IP Configuration", and close the window with "Close". Note: The "Assign Name" button can be used to assign a specific name to a node/participant. The "s120xcu310x2xpn" default value is kept unchanged for this particular example. 27

28 4.3 Hardware configuration 4.3 Hardware configuration Table 4-2: Hardware configuration In the next step, now insert a SIMATIC 300 station into the project. 1. To do this, click on the "Insert" menu item. In the following submenu select the entry "Station" followed by "2 SIMATIC 300 station" Now open the window to configure the hardware being used. This is realized by doubleclicking on the "Hardware" entry, for example. First insert a rack in the "HW Config" window. Then please select the F-CPU being used and insert this. To do this you can drag the corresponding F-CPU and drop it into the rack (profile rail). In this example the following F- CPU is used: "CPU 315F-2 PN/DP". Once this has been done, then the adjacent window is displayed. Here, please check that the IP address of the CPU lies within the address range of the PC/PG interface, and press the "New" button to create a new subnet (PROFINET). 28

29 4.3 Hardware configuration 4. Press the "OK" button to acknowledge that a new subnet is created. 5. Then select the subnet that has been created and exit the mask with "OK". 6. Now make the basic settings, with which the safety mode of the F-CPU being used is activated. To do this, open the properties window (by doubleclicking on the F-CPU). 29

30 4.3 Hardware configuration Here, go to the "Protection" tab. Activate the safety mode by setting a checkmark for "CPU contains safety program". 7. As protection level, select level 1, and activate passwordprotected access. Assign a password for the safety program. 0 is used as password in this particular example. Click "OK" to confirm the data that have been entered. 8. Now insert the F-DI module of the safety demonstration case by dragging and dropping. In this example an "FDI24xDC24V" module is used. Then open the properties of the module by double-clicking on the module. 9. Check the address settings for the input and output range of the data. In this example, the following applies: Input address: 0..9 Output address:

31 4.3 Hardware configuration 10. In the property window of the FDI module, make the following adaptations under the "Parameters" tab. Select "Safety mode". Select "Passivate the channel". Set the checkmark for "Diagnostic interrupt". 11. Make the settings for the F-DIs, which are highlighted in the adjacent screenshot. Please note, that for all of the other channels, the checkmark is removed for "Activated", as only channels 0, 1 and 3 are to be used. 31

32 4.3 Hardware configuration Now insert the F-DO module of the safety demonstration case by dragging and dropping. 12. An "FDO8xDC24V/2A" module is used in this example. Then open the properties of the module by double-clicking on the module. 13. Check the address settings for the input and output range of the data. In this example, the following applies: Input address: Output address: Now make the selected changes as shown in the adjacent screenshot. To do this, go to the "Parameters" tab. 14. It should be noted that only channel 7 is activated. The checkmark for "Activated" should be removed for all other channels. For channel 7, also remove the checkmark for "Diagnostics: wire break". 32

33 4.3 Hardware configuration Now insert SINAMICS S120 into the hardware configuration. 15. In the catalog select a SINAMICS S120 with CU310-2 PN and drag the component with version V4.6 and drop at the PROFINET connection that has been created (Ethernet 1). The following window is opened after insertion. Here, please select the subnet on which the SINAMICS S120 is to be operated In this example, this is the "Ethernet 1" network. Also check the automatically created address. In the example, the CU320-2 PN is assigned address Close the screen form using the "OK" button. Here, save and compile the hardware configuration. Then please open "NetPro" to insert the PG/PC into the configuration. 18. From the catalog, select the PG/PC object, and drag it to the work area. Open it by double-clicking on the properties window symbol. 33

34 4.3 Hardware configuration Select the "Interfaces" tab, and press the "New" button to configure a network interface. 19. An "Industrial Ethernet" interface is required for the example. Click "OK" to confirm the selection. 20. Select the newly created interface, and press the "Properties" button to open the window that is displayed. Remove the checkmark for "Set MAC address / use ISO protocol" and set the same network address and subnet mask that you assigned when setting the PC/PG interface in Section 4.2. In the example, the following IP address and subnet mask are used: Click "OK" to confirm what has been entered. 21. Now change to the "Assignment" tab to assign the interface of the hardware being used. To do this, select the corresponding interface (in the example: TCP/IP -> ASIX AX88179 ) and press "Assign". 34

35 4.3 Hardware configuration 22. The assigned interface is now displayed in the "Assigned" window. Please ensure that the checkmark for "S7ONLINE Access" is set. Click "OK" to confirm what has been entered. The computer is now inserted with an active connection shown in yellow. 23. Please save and compile the changes that have been made. 24. Then close "NetPro" and return to HW Config. Save and compile the settings in HW Config again. Then load the configuration into the F-CPU. 35

36 4.4 Configuring the basic drive functions 4.4 Configuring the basic drive functions All of the SINAMICS S120 drive lineup settings required to move the axis are explained in this section. The configuration of the safety functions is described in a separate section. Table 4-3: Configuring the basic functions 1. Open STARTER from the existing S7 project. You can do this by doubleclicking on "Commissioning". 2. Now go online and start the automatic drive configuration. You can go online by pressing the "Connect to selected target devices" button. In the project navigator then select the entry "Automatic Configuration". 3. Then press the "Configure" button. The DRIVE-CLiQ nodes are then read out. 36

37 4.4 Configuring the basic drive functions 4. Select the "Servo" control mode. Then press the "Create" button Go offline after the automatic configuration has been completed. The drive has to be postconfigured in the next step. Open the drive configuration by double-clicking on the drive, in this particular case "SERVO_02". Then press the "Configure DDS" button. 37

38 4.4 Configuring the basic drive functions The extended setpoint channel is used to specify the speed of the drive. Therefore, enable the "Extended setpoint channel" function. 7. Complete your entries by pressing "Next". Note: In the following, only those screen forms are described in which a change is required. 8. In a next step, select the PM340 "6SL3210-1SB14-0UA0" Power Module being used, and go to the next screen form by pressing "Next". 38

39 4.4 Configuring the basic drive functions Since a motor with DRIVE-CLiQ interface is used, this should be read out. To do this, activate the "Read out motor again" checkbox. 9. Press the "Next" button to acknowledge the entries that you have made. Continue with the post configuration until it has been completed. 10. After the post configuration has been completed, in the project navigator, select the menu item "Telegram configuration". 39

40 4.4 Configuring the basic drive functions 11. In the following screen form, please select "Standard Telegram 1" for the drive Then return to "Free telegram configuring with BICO ; as a consequence, the links of the "Standard Telegram 1" are kept. These can be subsequently adapted for the example. Now save the changes that have been made. Then go online and download the project to the target device. The speed controller should be set as follows, as in the following the "Safely Limited Speed" (SLS) is parameterized. A speed controller that has been sent too weak can result in alarm C01714/C30714 "Safely Limited Speed exceeded"! To do this, change to the "Speed controller" screen form, and set the following values: P gain: 0.05 Nms/rad Reset time: 20 ms 40

41 4.4 Configuring the basic drive functions In order to switch the drive on with switch -S7, the appropriate digital input is interconnected to the ON/OFF1 enable. 15. To do this, click "Control Logic" below the drive object. Digital input DI 8 (r722.8) is then connected to parameter p840. The required speed setpoint is specified in the following screen form. To do this, click on "Setpoint channel > Fixed setpoints". Binary logic (bit 0-3) can be implemented here which allows a switchover to various speed setpoints. 16. The following interconnections have been made: Bit0: 1 Bit1: Control Unit DI9 (r722.9), (switch -S8) The following fixed values were entered: Fixed value 1: 500 rpm Fixed value 3: 2000 rpm Fixed setpoint active p1024 still has to be interconnected with p1070[0] main setpoint. 17. From the project navigator, open the screen form "Ramp-function generator" to set the OFF3 ramp-down time. Then click on the button with the red frame. 41

42 4.4 Configuring the basic drive functions The "OFF3 ramp-down time is used for braking when SS1 is selected. 18. Set parameter (p1135) to 2.5 seconds. For this example, this means that when SS1 is selected the drive operating at maximum speed (p1082) comes to a standstill in 2.5 seconds Then save the configuration, copy from RAM to ROM and load the configuration into the PG/PC. Now go offline again to continue the configuration. 42

43 4.5 PROFIsafe configuration to control the safety functions integrated in the drive 4.5 PROFIsafe configuration to control the safety functions integrated in the drive Table 4-4: PROFIsafe configuration In the project navigator now change to the menu item "Telegram configuration". 1. Then add a PROFIsafe slot by pressing the "Add PROFIsafe" button. 2. Now change the telegram to "PROFIsafe standard telegram 31". Then transfer the telegram configuration to HW Config. You do this by pressing the "Set up addresses" button. Now change to the hardware configuration in SIMATIC Manager. 3. The telegram selected was entered automatically into HW Config. The allocated address can be changed here. Open the PROFIsafe properties by double-clicking on "PROFIsafe telegram 31". 43

44 4.5 PROFIsafe configuration to control the safety functions integrated in the drive Additional settings can be made under the "PROFIsafe tab. In STARTER, the value of "F_Dest_Add" should be entered in the hexadecimal format for the drive. 4. "C6hex" or "198dec" were used in this particular example. Note: The watchdog time ("F_WD_Time" = 150msec) should not be an integer multiple of the OB 35 cycle. In the example, the OB35 cycle is 100msec Close the screen form by pressing the "OK" button. Now save and compile the HW configuration. Then load the HW Config to the target system. 44

45 4.6 Parameterizing the safety functions integrated in the drive 4.6 Parameterizing the safety functions integrated in the drive Table 4-5: Parameterizing the safety functions integrated in the drive 1. Now go online with STARTER again. Download the project and copy RAM to ROM. 2. In the project navigator then change to the "Safety Integrated" safety functions. 3. Here, please press the "Change settings" button. Please select the extended safety functions via PROFIsafe. (Extended functions via PROFIsafe) 45

46 4.6 Parameterizing the safety functions integrated in the drive 4. Now enable the safety functions. To do this, set the "Safety functions" to "Enable". Then press the "Safety inputs" button. 5. In the following window, please enable the F-DIs, by selecting "Enable". In this particular example, only F-DI 0 and F-DI 1 are used; therefore, please close the particular connections as shown in the adjacent screenshot. Return to the previous screen form by pressing "Close". 6. Now click the "Configuration" button. 46

47 4.6 Parameterizing the safety functions integrated in the drive In the following screen form, activate the extended alarm acknowledgment by setting the check mark for "Ext. alarm acknowledgement". 7. Then select DI10 (r722.10) as signal source for the test stop of the safety functions. This means that the test stop can be controlled using switch -S9. Now press the "PROFIsafe configuration" button. In the PROFIsafe configuration, enter the PROFIsafe address that you defined in HW Config. 8. Address C6hex is used in this example. Then check that the PROFIsafe telegram of "Telegram configuration" matches the "Safety parameterization". Close the window by clicking "Close". 9. Please press the "Safe stop functions (SS1, SS2, SOS, SAM)" button to configure SS1 safety function. 47

48 4.6 Parameterizing the safety functions integrated in the drive 10. The delay time "Delay time SS1/STOP B -> STO active" is set to 500ms in screen form SS1. This means that 500ms after selecting SS1, the subsequent state STO is initiated, independent of the drive speed. 11. In screen form SS2, please also change the value of the delay time "Delay time SS2/STOP C -> SOS active" to 500ms. This stop response becomes active when the SLS limit is exceeded. 12. Close the screen form using "Close". To be able to parameterize the SLS safety function, please press the "Safely limited speed (SLS)" button in the "Safety Integrated" screen form. For SLS level 1, please set the value to 15000mm/min; in this example this corresponds to a speed of 1500 rpm. 13. Please select "STOP C" as stop response. Now change the value of the delay time "Delay time between sel. SLS -> SLS active" to 500ms and then close the screen form by pressing "Close". 48

49 4.6 Parameterizing the safety functions integrated in the drive 14. The parameters must now be copied. To do this, please press the "Copy parameters" button. Then click on the "Activate settings" button. 15. You are subsequently prompted to change the password. The default password is "0". Change the password to "1". 16. Data is copied from RAM to ROM when pressing the "Yes" button. 17. Then go offline Now please carry out a power on reset of the drive. Then go online again, load the project into the PG/PC and save it. POWER OFF/ON 49

50 4.7 Configuring the F-CPU 4.7 Configuring the F-CPU A standard program is not required for this application example, as the drives are exclusively controlled via BICO interconnections in SINAMICS. For most applications in practice, a program which is independent of the safety program is expected here, which is based on a standard telegram. In this example, in OB1 only the required enables are defined in the control word. In this example, the safety program in the F-CPU is processed in fail-safe function block FB1. A simplified program sequence has been selected to illustrate how the functions work. Complex safety logic and boundary conditions for creating the safety program are covered in the Distributed Safety manuals. NOTICE The safety program for this application example has been consciously made as simple as possible, and coordinated to run on the safety demonstration case. It is not permissible that the program is used in this form for a real application. You start with the F call block. This is required to call the safety program. For this purpose, a function (in this case, FC1) must be inserted in the block folder in the F call programming language. Cyclic interrupt OB35 is required to cyclically call the safety program. In this example, the actual safety program is executed in a function block (here, FB1), this means that only FB1 must now be inserted using the F-LAD or F-FBD programming language. 50

51 4.7 Configuring the F-CPU Table 4-6: Configuring the F-CPU OB1 1. Permanently writing all enables to the control word Now insert an additional function. 2. This function is called using what is known as the F call block with the safety program. This is simply created. No changes can be made in this block. Please assign the "FC1" name and as programming language, select "F-CALL". Click "OK" to confirm what has been entered. OB35 Subsequently insert an organization block. 3. Assign the "OB35" name, and select "STL" as programming language. Open the OB35 and insert a network, in which the safety program is called using the "CALL FC 1" command. Then save the block. 51

52 4.7 Configuring the F-CPU FB1 In this example, the actual safety program is created in an FB function block. 4. Please insert such a block into the block folder. Then assign the "FB1" name, and as programming language select "F-FDB" (=F-FUP). Click "OK" to confirm what has been entered. 5. You can now create the safety program. Network 1: The automatic acknowledgment is activated in this network. Network 2: The STO safety function is safely deselected. Network 3: Safety function SS1 is controlled using switches -S1 and/or -S5. Network 4: The SS2 safety function is safely deselected. 52

53 4.7 Configuring the F-CPU Network 5: The SOS safety function is safely deselected. Network 6: Safety function SLS is controlled using switches -S2 and/or -S6. 6. Network 7: The SLP safety function is safely deselected. Network 8: Pushbutton -S4 is used to control the acknowledgment bit of the PROFIsafe telegram in this network. Networks 9 and 10: In this network, SLS speed level 1 is permanently selected on the PROFIsafe STW. Network 11: The SDI+ safety function is safely deselected. Network 12: The SDI- safety function is safely deselected. 53

54 4.7 Configuring the F-CPU Network 13: Fixed selection of the SLP position range Network 14: Here, the signal lamp in -S4 is controlled via the PROFIsafe status word. The lamp is switched on if a safety drive fault message is active. Network 15: Pushbutton -S4 is used to reintegrate the drive. (acknowledge safety alarms) 8. FC1 Open the "FC1" function. In the adjacent screenshot, safety program (FB1) is assigned to the FC1 and the associated I-DB defined. Select "DB1" as I-DB. Then acknowledge with "OK". The safety program should then be generated and downloaded into the CPU. 9. To do this, please press the "Compile" button followed by "Download". In addition, the standard blocks must be loaded to the F-CPU. Note We recommend that blocks OB82 and OB86 are also integrated in order to tolerate the failure of the I/O (e.g. the drives for a power on reset) without the F- CPU going into the STOP operating state. 54

55 4.8 Acceptance test 4.8 Acceptance test To verify safety-relevant parameter assignments/configurations, when the machine is first commissioned, and also when safety-relevant parameters are changed, an acceptance test must be performed. The acceptance test must be appropriately documented. The acceptance reports must be appropriately stored and archived. This involves specifications laid down in the machinery directive. The acceptance test must be carried out after parameterization has been completed and a power on reset. You can find information about the acceptance test, the acceptance report and an example of a corresponding acceptance report in the "Function Manual SINAMICS S120 Safety Integrated" (FHS) /1/ in the Chapter Acceptance test and acceptance report. A script has been generated to simplify handling the acceptance test; this script is available at no charge in the PRODIS entry (link only available in the SIEMENS Intranet) that can be downloaded by authorized personnel. This script conveniently guides the user step by step through the acceptance test. 55

56 5 Installation 4.8 Acceptance test 5 Installation Hardware installation The following diagrams show the hardware configuration of the application. Fig. 5-1: Overview of the test setup (schematic) 56

57 5 Installation 4.8 Acceptance test Figure 5-2: Original wiring of the SINAMICS S120-CU310-2 PN training case 57

58 5 Installation 4.8 Acceptance test Figure 5-3: Adapted wiring of the SINAMICS S120-CU310-2 PN training case The fail-safe digital inputs are not used in the original wiring of the S120-CU310-2 PN training case. The original wiring can be taken from Fig The wiring must be modified as shown in Fig. 5-3 in order to be able to use the two safety functions (SS1 and SLS). The toggle switches (-S5.1 and -S5.2) are connected at the channels of the F-DI 0. An Emergency Stop switch -S5 is implemented using these two switches. Further, toggle switches (-S6.1 and -S6.2) are connected at the channels of the F-DI 1 in order to be able to implement switch -S6. Toggle switch -S11 was connected to input X121.0; however, it is not used in this application example. Now, only inputs X120.5 and X have to be connected to ground M. This means that two failsafe inputs are available for the application example. 58

59 5 Installation 4.8 Acceptance test Figure 5-4: Wiring the F-DIs/F-DOs SAFETY demonstration case 59

60 6 Commissioning the application 6.1 Preconditions 6 Commissioning the application Until now, the configuration of the application example has been described step by step. The following steps should now be followed if the sample project is to be directly downloaded to the hardware. First, all components (S7-F-CPU and SINAMICS S120) should be generally reset or reset to factory settings. 6.1 Preconditions Preconditions for operation The motor is connected to the PM340 Power Module and the Drive-CLiQ cable of the encoder is inserted in the Drive-CLiQ port of the CU The wiring of the F-DIs of the training case is modified according to Chapter 5. The components are supplied with 24V DC. The infeed is connected to the line supply. 6.2 Preparation (see Chapter 4.2 Preparation) 6.3 Commissioning Table 6-1: Commissioning the sample project 1. To start, please open the SIMATIC Manager. 2. Please unzip the project supplied into any directory and then open it. In the SIMATIC Manager, click on "File" followed by "Retrieve". 60

61 6 Commissioning the application 6.3 Commissioning 3. Once the project has been opened, please open the HW config, and carry out a download. 4. Please load the safety program as next step. Depending on the particular setting, the standard blocks are also loaded. If this is not the case, then manually load the blocks into the F-CPU. 5. Now open the integrated STARTER project. To do this, double-click on "Commissioning". 6. Then establish an online connection and carry out a download. 61

62 6 Commissioning the application 6.3 Commissioning 7. When using the extended safety functions, the hardware replacement must be acknowledged after the download. To do this, please press the "Acknowledge hardware replacement" button. 8. Then copy from RAM to ROM. Then go offline. 9. Now carry out a power-on reset. POWER OFF/ON 10. To complete the installation, go back online, load the configuration into the PG and save it. 62

63 7 Operating the application 7.1 Overview 7 Operating the application 7.1 Overview Siemens AG Copyright-2013 All rights reserved Figure 7-1: Overview diagram showing how to operate the application Switches -S1 to -S4 are located on a switchbox that belongs to the SAFETY training case. Copyright Switches -S5 to -S11 are located on the SINAMICS S120 CU310-2 PN training case housing. 7.2 Description of function Switching on/switching off The drive is switched on (OFF1) using switch -S7 and a speed setpoint of 500 rpm entered. Speed levels You can toggle between speed setpoints of 500 rpm and 2000 rpm using switch S8. Emergency Stop If, while the motor is rotating, switch -S1 or -S5 is actuated (low signal), then safety function SS1 is activated. The drive is braked along the OFF3 ramp and STO is subsequently activated. 63

64 7 Operating the application 7.3 Summary of input signals Protective doors Switches -S2 and -S6 simulate a protective door. As long as switches -S2 and -S6 are not actuated (high-level), both protective doors are closed. In this particular case, the drive can be operated at any speed. If switch -S2 or -S6 is actuated (low signal), then this corresponds to the protective door being opened. Safety function SLS is selected. After a configurable time has elapsed, the speed is safely monitored against a limit value (in this case, 1500 rpm). For an active SLS level, the corresponding stop response STOP C is initiated when this limit value is exceeded. This means that the drive is braked along the OFF3 ramp, and after a configurable delay time has elapsed, standstill (zero speed) is monitored using the SOS safety function. In this particular case, the drive remains in the closed-loop controlled mode. Safety messages C01714 and C30714 are output. Reintegrating/acknowledging safety faults The drives have to be reintegrated after power OFF/ON. All messages are acknowledged by pressing button -S4. Test stop A test stop can be carried out using button -S9. Signal lamp The signal lamp in switch -S4 lights up if a safety fault is present. 7.3 Summary of input signals Table 7-1: Overview of the SAFETY training case switch functions Switch Component Function -S1 Emergency Stop button SS1 -S2 Toggle switch SLS -S3 Toggle switch Not used -S4 Button Reintegration/acknowledgment Table 7-2: SINAMICS digital inputs Digital input Switch Description DI 8 -S7 Switch on/switch off drive (ON/OFF1) with speed setpoint = 500rpm DI 9 -S8 Switching over the speed setpoints DI 10 -S9 Test stop selection 64