Using PROFIsafe modules in combination with PROFIBUS-DP and PROFINET Application note

Transcription

1 Using PROFIsafe modules in combination with PROFIBUS-DP and PROFINET, English Version

2 2 General Copyright 2010 by WAGO Kontakttechnik GmbH & Co. KG All rights reserved. WAGO Kontakttechnik GmbH & Co. KG Hansastraße 27 D Minden Phone: +49 (0) 571/ Fax: +49 (0) 571/ info@wago.com Web: Technical Support Phone: +49 (0) 571/ Fax: +49 (0) 571/ support@wago.com Every conceivable measure has been taken to ensure the accuracy and completeness of this documentation. However, as errors can never be fully excluded, we always appreciate any information or suggestions for improving the documentation. We wish to point out that the software and hardware terms, as well as the trademarks of companies used and/or mentioned in the present manual, are generally protected by trademark or patent.

3 Contents 3 TABLE OF CONTENTS 1 Important Notes Legal Principles Copyright Personnel Qualification Intended Use Scope of Validity Symbols General Terms of Use WAGO-I/O-SYSTEM Basics General Using the WAGO-I/O-SYSTEM with PROFIBUS-DP General GSD File Download Internet Using the WAGO-I/O-SYSTEM with PROFINET General GSDML file Download Internet Using the WAGO-I/O-SYSTEM with PROFIsafe Siemens Safety Controls (Distributed Safety) General Required Software Tools Operating Principles Safety Program "Edit safety program" Function Fail-safe I/O DB PASS_ON ACK_NEC ACK_REI IPAR_EN PASS_OUT QBAD ACK_REQ IPAR_OK DIAG Assignment of the Hardware Configuration to F periphery DB Using PROFIBUS Using PROFINET Note about assigned F periphery DBs Data Transfer and Data Access Standard Program to the Safety Program Safety Program to the Standard Program Sinumerik 840D from Siemens General... 27

4 4 Contents A Example with Safety Controller from Siemens Terms of Use System Configuration Hardware Configuration Safety Control PROFIBUS-DP Slave with PROFIBUS-DP address Slave with PROFIBUS-DP address PROFINET "WAGO " Device "WAGO " Device Software Structure Program Structure Cyclic Program Calls OB Program Calls via Watchdog Alarm OB Runtime Group Assignments Defined Interfaces Cyclic Program to the Safety Program Safety Program to the Cyclic Program Runtime Group Communication Note about Assignment of the Safety Module to Runtime Group Program Functions Cyclic Application Program Organization Blocks Used Watchdog Alarm OB Watchdog Alarm OB Watchdog Alarm OB Watchdog Alarm OB Watchdog Alarm OB Watchdog Alarm OB Watchdog Alarm OB Safety Program Function Basis Data Transfer from Standard Program User Acknowledgement / Reintegration Evaluation E-Stop Active Relay Control Status Displays of the Safety Program Function Activation Using ipar Server General ipar Server FB Example Application Note General Required Block Calls Function Call for PROFIBUS in FC Function Call for PROFINET FC

5 Contents Information about Using FB Parameterization FB Initialization FB Status Indication FB Information about Using FB System Configuration with ipar Server Creating the System Configuration Adjusting the System Configuration Source Directory Version information... 74

6 6 Important Notes 1 Important Notes 1.1 Legal Principles Copyright To ensure quick installation and start-up of the units, please carefully read and adhere to the following information and explanations. This document, including all figures and illustrations contained therein, is subject to copyright protection. Any use of this document that infringes upon the copyright provisions stipulated herein is prohibited. Reproduction, translation, electronic and phototechnical filing/archiving (e.g., photocopying), as well as any amendments require the written consent of WAGO Kontakttechnik GmbH & Co. KG, Minden, Germany. Non-observance will involve the right to assert damage claims. WAGO Kontakttechnik GmbH & Co. KG reserves the right to make any alterations or modifications that serve to increase the efficiency of technical progress. WAGO Kontakttechnik GmbH & Co. KG owns all rights arising from granting patents or from the legal protection of utility patents. Third-party products are always mentioned without any reference to patent rights. Thus, the existence of such rights cannot be excluded Personnel Qualification Intended Use The use of the product detailed in this document is geared exclusively to specialists having qualifications in PLC programming, electrical specialists or persons instructed by electrical specialists who are also familiar with the valid standards. WAGO Kontakttechnik GmbH & Co. KG assumes no liability resulting from improper action and damage to WAGO products and third-party products due to non-observance of the information contained in this document. For each individual application, the components are supplied from the factory with a dedicated hardware and software configuration. Modifications are only admitted within the framework of the possibilities documented in this document. All other changes to the hardware and/or software and the non-conforming use of the components entail the exclusion of liability on part of WAGO Kontakttechnik GmbH & Co. KG. Please send your requests for modified and new hardware or software configurations directly to WAGO Kontakttechnik GmbH & Co. KG.

7 Important Notes Scope of Validity This application note is based on the stated hardware and software from the specific manufacturer, as well as the associated documentation. This application note is therefore only valid for the described installation. New hardware and software versions may need to be handled differently. Please note the detailed description in the specific manuals.

8 8 Important Notes 1.3 Symbols DANGER Personal Injury Warning Indicates a high-risk, imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING Personal Injury Warning Indicates a moderate-risk, potentially hazardous situation which, if not avoided, could result in death or (serious) injury. CAUTION Personal Injury Warning Indicates a low-risk, potentially hazardous situation which, if not avoided, could result in slight to moderate injury. NOTICE Material Damage Warning Indicates a potentially hazardous situation which, if not avoided, may result in damage to property. ESD Warning of Material Damage Due to Electrostatic Charging Indicates a potentially hazardous situation which, if not avoided, may result in damage to property. Note Information Important Note Indicates routines or suggestions for efficient use of equipment and possible software optimizations. The respective device manuals of the components used are to be observed. Note about Additional Information Indicates other information, which is not an integral part of this documentation, such as manual, data sheet, Internet, etc.

9 General 9 2 General 2.1 Terms of Use DANGER The examples listed are based exclusively on a test configuration with no reference to any machine or system. To use the PROFIsafe module in a system, the applicable regulations, standards and safety requirements of the machine are to be observed and implamented. DANGER The application note provides additional information about the current manuals of the PROFIsafe modules. In addition, the information contained in the system description for the WAGO-I/O-SYSTEM is to be observed. Fig. 1 Screenshot of the WAGO-I/O-SYSTEM design notes Fig. 2 Screenshot of the PROFIsafe Module V2 manual

10 10 General Fig. 3 Screenshot of the PROFIsafe Module V2 ipar manuals and quickstart guide

11 WAGO-I/O-SYSTEM Basics 11 3 WAGO-I/O-SYSTEM Basics 3.1 General The modular and fieldbus-independent I/O system WAGO I/O 750/753 supports numerous fieldbus systems. The I/O modules are connected by so-called bus interfaces available in various rating classes depending on the bus system used. To use the PROFIsafe technology, the PROFIBUS-DP or PROFINET industrial bus systems can be used. 3.2 Using the WAGO-I/O-SYSTEM with PROFIBUS-DP General GSD File Download Internet To connect the PROFIBUS-DP bus system to the modular WAGO I/O 750/753 I/O system, various bus interfaces are available that differ in their range of performance. To use PROFIsafe on the PROFIBUS-DP, the PROFIBUS- DP/V1 bus interface must be used for system implementations. To configure the modular WAGO-I/O-SYSTEM 750/753, GSD files are used that are available to download from the WAGO homepage in Service area. Fig. 4 Screenshot of the WAGO homepage Source 1: WAGO homepage as of 11/29/10

12 12 WAGO-I/O-SYSTEM Basics Go to "Quicklinks \ Downloads" to display the following selection: Fig. 5 Screenshot of the WAGO homepage, Downloads Source 1: WAGO homepage as of 11/29/10 The required GSD file is available under the "WAGO-I/O-SYSTEM 750/753" selection: Fig. 6 Screenshot of the WAGO homepage, Downloads AUTOMATION Source 1: WAGO homepage as of 11/29/10

13 WAGO-I/O-SYSTEM Basics 13 Fig. 7 Screenshot of the WAGO homepage, WAGO-I/O-SYSTEM 750/753 Source 1: WAGO homepage as of 11/29/10 The GSD files are available from an installation program. Note When installing, all Step 7 programs should be closed on the PC to enable troublefree transfer of data. When using the PROFIsafe Module V2 ipar, the "Professional" installation should be selected. The entries contain the "PRO" extension in the hardware catalog. After the "Professional" installation, the GSD files appears as follows within the hardware catalog of the Step 7 hardware configuration: Fig. 8 Screenshot of the hardware catalog, WAGO-GSD PRO selection

14 14 WAGO-I/O-SYSTEM Basics 3.3 Using the WAGO-I/O-SYSTEM with PROFINET General GSDML file Download Internet To connect the PROFINET bus system to the modular WAGO I/O 750/753 I/O system, various bus interfaces are available that differ in their range of performance. To use PROFIsafe on the PROFINET, the PROFINET I/O bus interface must be used for system implementations. To configure the modular WAGO-I/O-SYSTEM 750/753 on the PROFINET, GSDML files are used that are available to download from the WAGO homepage in Service area. Fig. 9 Screenshot of the WAGO homepage Source 1: WAGO homepage as of 11/29/10

15 WAGO-I/O-SYSTEM Basics 15 Go to "Quicklinks \ Downloads" to display the following selection: Fig. 10 Screenshot of the WAGO homepage, Downloads Source 1: WAGO homepage as of 11/29/10 The required GSDML file is available under the "WAGO-I/O-SYSTEM 750/753" selection: Fig. 11 Screenshot of the WAGO homepage, Downloads AUTOMATION Source 1: WAGO homepage as of 11/29/10

16 16 WAGO-I/O-SYSTEM Basics Fig. 12 Screenshot of the WAGO homepage, WAGO-I/O-SYSTEM 750/753 Source 1: WAGO homepage as of 11/29/10 Note The GSDML files are "installed" in the hardware configuration of Step 7 "Tools \ Install GSD Files". To install the GSDM files, please follow the instructions in the Step 7 interface.

17 WAGO-I/O-SYSTEM Basics Using the WAGO-I/O-SYSTEM with PROFIsafe Due to the requirements of the PROFIsafe specification and the respective implementations of the manufacturer, a brief overview of the most important information about using the PROFIsafe modules from WAGO in conjunction with various PROFIsafe masters follows Siemens Safety Controls (Distributed Safety) General The PROFIsafe technology is offered as an option for safety controls of the S7 series (Distributed Safety) identified by an "F" in the name of the control Required Software Tools The following software tools are required to use the current technologies of PROFIsafe in conjunction with S7 controls: - Basic Package Step 7 V 5.4 SP5 - Extension Distributed Safety V 5.4 SP 5 Information The software tools listed here only represent the base requirement for using the WAGO PROFIsafe modules. Additional tools may be required based on the control components used. The corresponding information in the device manuals must be observed Operating Principles Safety Program Some important information has been compiled to give you a simple introduction to the topic. In addition, you should always read the manual of the safety control used. The safety program is created in a safety editor, which is similar to the usual program editor, but subject to functional limitations. After creating the safety program, the call path must be implemented based on the CPU requirements. The "Edit safety program" function must be used within the Step 7 interface "Edit safety program" Function This function must be used in the Step 7 interface to define the system call in conjunction with the F-runtime group and to generate the required collective signature for acceptance and thus operation of the safety program.

18 18 WAGO-I/O-SYSTEM Basics Fail-safe I/O DB The following individual steps are required for basic implementation of a safety program: - Add or adapt the F-runtime group(s) - Add F-CALL in the application program of the CPU (typically in OB35) - Check the fail-safe I/O data block and F-runtime group assignments by "Generate" function - Test and document the implemented functions When using PROFIsafe modules in the S7 world, an F periphery DB is created after creating an F module within the hardware configuration. This secure data block contains all required information to execute the required base functions (passivation and depassivation) and to receive diagnostic messages. : Fig. 13 Screenshot of the PROFIsafe periphery DB module Source 2 Representation of the periphery DB in Step 7 for PROFIsafe modules (Step 7 V5.4 SP5)

19 WAGO-I/O-SYSTEM Basics PASS_ON ACK_NEC Manual passivation of the PROFIsafe module by selecting VKE 1 in periphery DB (e.g. via safety program) Do not forget to reset to VKE 0 via the safety program. As long as PASS_ON = 1, the corresponding periphery will be passivated. This passivation cannot be disabled using the ACK_NEC and ACK_REI reintegration variables. Using this periphery DB variable, the behavior of the periphery can be defined after a channel error. ACK_NEC = 0 automatic reintegration after a channel error. ACK_NEC =1 Reintegration is only possible via acknowledgement by the user (ACK_REI must be set to VKE 1) DANGER Information The parameterization ACK_NEC = 0 means automatic reintegration of the affected F periphery, i.e., automatic error acknowledgement and thus automatic machine start-up. When starting up the controller, ACK_NEC is automatically set to 1, i.e., the automatic reintegration of the modules must be consciously realized by corresponding programming within the safety program ACK_REI User acknowledgement via positive edge at ACK_REI for reintegration of the F periphery after an error. Note Acknowledgement is only possible if a reintegration acknowledgement by the user is requested by the affected module via ACK_REQ = 1.

20 20 WAGO-I/O-SYSTEM Basics IPAR_EN PASS_OUT QBAD Release to accept so-called i parameters from DP standard slaves. This function is not available for the WAGO I/O modules at the moment. For detailed information, see PROFIBUS standard. Indication that substitute values are sent by the PLC, at least 1 channel was passivated. If passivated via PASS_ON = 1, no indication will be made via PASS_OUT (only QBAD is set). Indication that substitute values are sent by the PLC, at least 1 channel was passivated. Passivation can either be performed independently by the CPU or be activated by the user by setting PASS_ON = 1 in the periphery DB In any case, indication is done via QBAD. Note The modules currently work with a module related passivation ACK_REQ System indication that the user acknowledgement for the integration of the affected F periphery is required Indication is set by the system as soon as the error has been corrected and acknowledgement by the user is possible. DANGER By evaluating the information ACK_REQ and QBAD, reintegration can be implemented again by setting the user acknowledgement ACK_REI, i.e., possible automatic machine start-up in case of error IPAR_OK Indication that new i parameters have been taken over via IPAR_EN = 1. As soon as the IPAR_OK indication is displayed, the IPAR_EN request must be reset so that reintegration of the affected fail-safe DP standard slave can be performed. This function is not available for the WAGO I/O modules at the moment.

21 WAGO-I/O-SYSTEM Basics DIAG Cyclic diagnostic indication of each PROFIsafe module within the F periphery DBs. The information can be used within the normal cyclic application program. Bit Meaning 0 Timeout F periphery is identified 1 F periphery / channel error of F periphery is identified 2 CRC / Sequence number error of F periphery is identified 3 Reserve 4 Timeout of F system is identified 5 Sequence number error of F system is identified 6 CRC error of F system is identified 7 Reserve Fig. 14 Configuration of diagnostic periphery DB

22 22 WAGO-I/O-SYSTEM Basics Assignment of the Hardware Configuration to F periphery DB Using PROFIBUS Due to automatic creation of the F-periphery-DBs for PROFIsafe modules, we have to take a look at the relationship between information within the hardware configuration, naming within the project and symbolic program access to the safety information. The symbol name of the IOs for the safety program is created via the first byte address of the module in the hardware configuration and the DP identification of the device. Example: F00010_196 results from I/O byte 10 and DP ID 196: Fig. 15 Screenshot showing the hardware configuration of the application note (focus PROFIBUS) Source 3: Screenshot of Step 7 Project V5.4 SP5 Fig. 16 Screenshot of the safety program after creating the hardware configuration Source 3: Screenshot of Step 7 Project V5.4 SP5 When accessing information from the F-periphery-DBs within the application program, usually the symbolic name is used only, e.g., "F00010_196". QBAD are sent for evaluating substitute values.

23 WAGO-I/O-SYSTEM Basics Using PROFINET The symbol name of the IOs for the safety program is created by the first byte address of the module in the hardware configuration and the symbol name of the device. Example: F00060_753_667_4FDI_4FDO results from I/O byte 60 and module name FDI / 4 FDO of the hardware configuration: Fig. 17 Screenshot showing the hardware configuration of the application note (focus PROFINET) Source 3: Screenshot of Step 7 Project V5.4 SP5 Fig. 18 Screenshot of the safety program after creating the hardware configuration Source 3: Screenshot of Step 7 Project V5.4 SP5 When accessing information from the F periphery DBs within the application program, usually the symbolic name is used only, e.g., "F00060_753_667_4FDI_4FDO". QBAD are sent for evaluating substitute values.

24 24 WAGO-I/O-SYSTEM Basics Note about assigned F periphery DBs In principle, each PROFIsafe module can only be evaluated by one runtime group, i.e., the corresponding F-periphery-DB of a safety module is assigned fixed to one runtime group. Note From Distributed Safety V 5.4 SP3 or higher, only F-periphery-DBs are assigned to a runtime group, whose modules are also used. In other words, at least one read or write access to information of the safety module has to occur (input, output, status in the F-periphery-DB). After creating the safety program, the current assignment of the F-periphery-DBs to the F-runtime group within the editor can be checked: Fig. 19 Screenshot of the editor showing "Processing of safety program" Source 3: Screenshot of Step 7 Project V5.4 SP5 Note Fig. 20 Screenshot of the editor showing "Processing of safety program" Source 3: Screenshot of Step 7 Project V5.4 SP5 All assigned F periphery DBs of the safety module of a runtime group can be reintegrated via the FB 219 "F_ACK_GL" centrally for this runtime group.

25 WAGO-I/O-SYSTEM Basics Data Transfer and Data Access By using common hardware for the standard application and safety program, various data access paths are required to realize a user program. Consequently, the most important information is briefly summarized to provide a certain basis for the following example Standard Program to the Safety Program Fig. 21 Excerpt from the online help "Transfer from the Standard to the Safety Program" Source 4 Online help Step 7 V5.4 SP 5 and Distributed Safety V 5.4 SP5

26 26 WAGO-I/O-SYSTEM Basics Safety Program to the Standard Program The following information is available in the online help of Step 7 on this topic: Fig. 22 Excerpt from the online help "Transfer from the Safety to the Standard User Program" Source 4 Online help Step 7 V5.4 SP 5 and Distributed Safety V 5.4 SP5

27 WAGO-I/O-SYSTEM Basics Sinumerik 840D from Siemens General For connecting distributed periphery, the PROFIBUS-DP with PROFIsafe V1 is available when using the Sinumerik 840D A To use the PROFIsafe modules from WAG in conjunction with a Sinumerik 840D, there is a separate application note available on the Internet to download in the Documentation area. Fig. 23 Screenshot of the Sinumerik 840D application note Fig. 24 Screenshot of the application note download page

28 28 Example with Safety Controller from Siemens 4 Example with Safety Controller from Siemens 4.1 Terms of Use NOTICE The examples and implementations listed are based exclusively on a test configuration with no reference to any machine or system. To use the PROFIsafe modules in a system, the applicable regulations, standards and safety requirements of the machine are to be observed and implamented. The general use of safety components does not automatically lead to a safe machine or system! Note This application note does not replace the device descriptions of the individual components used. In addition, all required boundary conditions in the device manuals and program guidelines from Siemens Safety CPUs are to be observed. Note The FB24 required for this application note is generally available under entry ID in the Support area of the Siemens website. (link

29 Example with Safety Controller from Siemens System Configuration To use the application note, a safety CPU from Siemens on the one hand and the following listed components on the other must be provided Hardware Configuration The following hardware configuration is realized in the Step 7 project: Safety Control Fig. 25 Screenshot of the hardware configuration of the Step 7 project A CPU 319F-3 PN/DP was used for the example: Fig. 26 Screenshot of the properties of the CPU319F hardware configuration for Step 7

30 30 Example with Safety Controller from Siemens PROFIBUS-DP Slave with PROFIBUS-DP address 6 In this slave, the PROFIsafe modules / FDI and / FDI/ 4 FDO are used. Fig. 27 Configuration of the PROFIBUS-DP slave with PROFIsafe modules / Fig. 28 Screenshot of the hardware configuration of the PROFIBUS-DP Slave with PROFIsafe / Module / Type I Add. O Add. PROFIsafe Address Symbol F Periphery DB CPU 319F 8 F-DI 24V DC F00005_196 DB / F-DO 0.5A / 4 F-DI 24V DC F00010_196 DB 3278 Fig. 29 Safety definitions for PROFIsafe / with PROFIBUS-DP

31 Example with Safety Controller from Siemens 31 The following hardware wiring is implemented for this slave. Module I Address O Address Use 75x-432 4DI 0.0 Reset button (normally open contact) 0.1 Switch 1 (normally open contact) -> Function Activation Switch 2 (normally open contact) -> Function Activation Switch 3 (normally open contact) -> Function Activation 3 75x-530 8DO 0.0 Status: Safety program active 0.1 Status: EStop active 0.2 Status: Output of substitute values active 0.3 Status: User acknowledgment of safety modules expected 0.4 Status: Reserved 0.5 Status: Feedback loop error 0.6 Status: Warning, safety program active 0.7 Status: Error, safety program active / FDI 5.0 Emergency Stop Contact 1 (normally closed contact) 5.1 Emergency Stop Contact 2 (normally closed contact) 5.2 Reserved / no function 5.3 Reserved / no function 5.4 Feedback relay control (normally open contact) 5.5 Feedback relay control (normally open contact) 5.6 Feedback relay control (normally open contact) 5.7 Feedback relay control (normally open contact) / FDI/4FDO 10.0 Relay control Relay control Relay control Relay control Feedback relay control (normally closed contact) 10.1 Feedback relay control (normally closed contact) 10.2 Feedback relay control (normally closed contact) 10.3 Feedback relay control (normally closed contact) Fig. 30 Hardware wiring for PROFIBUS Slave Add. 6

32 32 Example with Safety Controller from Siemens Slave with PROFIBUS-DP address 9 Fig. 31 Configuration of the PROFIBUS-DP slave with PROFIsafe modules / Fig. 32 Screenshot of the hardware configuration of the PROFIBUS-DP Slave with PROFIsafe / Module 75x-662/ Type I Add. O Add. PROFIsafe Address Symbol F Periphery DB CPU 319F 8 F-DI 24V DC F00025_196 DB x-667/ F-DO 0.5A / 4 F-DI 24V DC F00030_196 DB 3280 Fig. 33 Safety definitions for PROFIsafe / with PROFIBUS-DP

33 Example with Safety Controller from Siemens 33 The following hardware wiring is implemented for this slave. Module I Address O Address Use 75x-430 8DI x-530 8DO 20.0 Status: Safety program active 20.1 Status: EStop active 20.2 Status: Output of substitute values active 20.3 Status: User acknowledgment of safety modules expected 20.4 Status: Reserved 20.5 Status: Feedback loop error 20.6 Status: Warning, safety program active 20.7 Status: Error, safety program active / FDI Emergency Stop Contact 1 (normally closed contact) 25.1 Emergency Stop Contact 2 (normally open contact) / FDI/4FDO 30.0 Relay control Relay control Relay control Relay control Feedback relay control (normally closed contact) 30.1 Feedback relay control (normally closed contact) 30.2 Feedback relay control (normally closed contact) 30.3 Feedback relay control (normally closed contact) Fig. 34 Hardware wiring for PROFIBUS Slave Add. 9

34 34 Example with Safety Controller from Siemens The following parameter settings are carried out for the PROFIsafe modules: / FDI (DP 9, Slot 3) / FDI/ 4 FDO (DP 9, Slot 4)

35 Example with Safety Controller from Siemens PROFINET "WAGO " Device The PROFINET device is configured as follows: Fig. 35 Configuration of the PROFINET device with PROFIsafe modules / Fig. 36 Screenshot of the hardware configuration of the PROFINET device with PROFIsafe / Module Type I Add. O Add. PROFIsafe Address Symbol F Periphery DB CPU 319F 75x-662/ F-DI 24V DC F00105_753_ 662_8_F_DE DB x-667/ F-DO 0.5A / 4 F-DI 24V DC F00110_753_ 667_4_F_DE_DA DB 3282 Fig. 37 Safety definitions for PROFIsafe / with PROFINET

36 36 Example with Safety Controller from Siemens The following hardware wiring is implemented for this slave. Module I Address O Address Use 75x-430 8DI x-530 8DO Status: Safety program active / FDI Status: EStop active Status: Output of substitute values active Status: User acknowledgment of safety modules expected Status: Reserved Status: Feedback loop error Status: Warning, safety program active Status: Error, safety program active / FDI/4FDO Relay control Relay control Relay control Relay control Feedback relay control (normally closed contact) Feedback relay control (normally closed contact) Feedback relay control (normally closed contact) Feedback relay control (normally closed contact) Fig. 38 Hardware wiring for PROFINET device 1

37 Example with Safety Controller from Siemens 37 The following parameter settings are carried out for the PROFIsafe modules: / FDI (PN 1, Slot 3) / FDI/ 4 FDO (PN 1, Slot 4)

38 38 Example with Safety Controller from Siemens "WAGO " Device The PROFINET device is configured as follows: Fig. 39 Configuration of the PROFINET device with PROFIsafe modules / Fig. 40 Screenshot of the hardware configuration of the PROFINET device with PROFIsafe / Module Type I Add. O Add. PROFIsafe Address Symbol F Periphery DB CPU 319F 75x-662/ F-DI 24V DC F00052_753_ 662_8_F_DE DB x-667/ F-DO 0.5A / 4 F-DI 24V DC F00060_753_ 667_4_F_DE_DA DB 3320 Fig. 41 Safety definitions for PROFIsafe / with PROFINET

39 Example with Safety Controller from Siemens 39 The following hardware wiring is implemented for this slave. Module I Address O Address Use 75x-430 8DI x-530 8DO 50.0 Status: Safety program active / FDI Status: EStop active 50.2 Status: Output of substitute values active 50.3 Status: User acknowledgment of safety modules expected 50.4 Status: Reserved 50.5 Status: Feedback loop error 50.6 Status: Warning, safety program active 50.7 Status: Error, safety program active / FDI/4FDO 60.0 Relay control Feedback relay control (normally closed contact) Fig. 42 Hardware wiring for PROFINET device 1

40 40 Example with Safety Controller from Siemens The following parameter settings are carried out for the PROFIsafe modules: / FDI (PN 2, Slot 3) / FDI/ 4 FDO (PN 2, Slot 4)

41 Example with Safety Controller from Siemens Software Structure Program Structure The following software structure is implemented in both examples. The only differences are the F-DB number for the F_GLOBDB and the automatically created F-periphery-DBs of the PROFIsafe modules. The following software structure is implemented in the program examples Cyclic Program Calls OB Program Calls via Watchdog Alarm OB35 Fig. 43 Graphic of block calls via cyclic program calls OB1 Fig. 44 Graphic of block calls via watchdog alarm OB35

42 42 Example with Safety Controller from Siemens Runtime Group Assignments For a better overview of the possibilities, the program example was divided into 2 runtime groups to show all possibilities. For runtime group 1, the PROFIBUS DB slave address 6 and the PROFINET device are assigned "WAGO ". Fig. 45 Graphic of assignment of PROFIsafe modules to runtime group 1 For runtime group 2, the PROFIBUS DB slave address 9 and the PROFINET device are assigned "WAGO ". Fig. 46 Graphic of assignment of PROFIsafe modules to runtime group 2

43 Example with Safety Controller from Siemens Defined Interfaces Cyclic Program to the Safety Program Data transfer between the standard PLC program and the safety program is to be carried out as follows based on the device manual of the safety CPU via flags: Cycle Comment Safety Transfer into MB 2 CPU timing flag MB502 OB35 E 0.0 / M 1.0 Reset safety program M OB Safety Program to the Cyclic Program Fig. 47 Overview of defined flag interface to the safety program Data transfer between the safety program and the cyclic S7 program has to be realized as a secure data block (F-DB) based on the device manual of the S7 CPU. The DBs contain the following information: - Indication of the current status of the safety program - User acknowledgement feedback loop monitoring required - Output of substitute values, PROFIsafe module active Fig. 48 Screenshot, excerpt structure F-DB499 Communication Safety -> cyclic program Note The respective status information in DB499 is created in the associated runtime group and stored in DB499. Within FC10, parts of the status information of DB499 are transferred to digital outputs as a status display.

44 44 Example with Safety Controller from Siemens Runtime Group Communication For direct data exchange between both runtime groups within the safety program, so-called F-runtime group communication is available as a system function. To use the interface, call up the "Edit F-runtime groups" sub-function under "Edit safety program" in the Step 7 interface and enter the required data block (designation family "RTG_DB" in the block header). Fig. 49 Screenshot of the designation F-DB as "Cross-communication DB F program" Fig. 50 Screenshot of runtime group communication

45 Example with Safety Controller from Siemens Note about Assignment of the Safety Module to Runtime Group In the S7 tool chain, safety modules are always assigned to a runtime group. A safety module is automatically assigned by a write or read command within the application program to the respective input or output address of the safety module. In principle, only one safety module can be accessed from one runtime group, i.e., so-called runtime group communication has to be used for preparing module information for other runtime groups. The "Edit safety program" function can be used to read the current status of the assignment. Note Fig. 51 Screenshot showing the assignment of the safety module to the runtime group If not all PROFIsafe modules of the runtime group do not appear in the F periphery DBs, no access within the safety program to the PROFIsafe module is realized. In this program status, the missing PROFIsafe modules are also not reintegrated via the function block FB219 "F_ACK_GL". Possible remedy Read access to the information QBAD within the F periphery DBs of the PROFIsafe module in the safety program.

46 46 Example with Safety Controller from Siemens 4.4 Program Functions Cyclic Application Program The standard application program is called up cyclically via the OB1 and processed according to the program calls. The individual function details are apparent from the respective network comments of the program Organization Blocks Used Watchdog Alarm OB Watchdog Alarm OB Watchdog Alarm OB Watchdog Alarm OB Watchdog Alarm OB Watchdog Alarm OB Watchdog Alarm OB87 The safety program is called up time-controlled via organization block OB35. Update alarm for DPV1 required to use ipar Server FB24 in conjunction with PROFINET. Organization block for diagnostic alarms no evaluation of the diagnostic information provided in this example. Organization block for "swapping a module" This OB is required to configure the PROFIsafe modules because a "swap" of the modules for the higher level control is carried out for defined access from I/O check to the PROFIsafe modules. Organization blog for updating processing image. Organization block for module failure Example program should also continue to run as long as a distributed module is not available. Organization block for communication failure Example program should also continue to run as long as a distributed module is not available.

47 Example with Safety Controller from Siemens Safety Program Function Basis The safety program is activated by a function call in OB35, the call sequence and required relationships were established via the "Edit safety program" function of Step Data Transfer from Standard Program To transfer unsafe signals from the standard program, the Step 7 documentation contains corresponding notes that must be observed. Fig. 52 Screenshot of the Step 7 online help "Transfer from the Standard to the Safety Program" Source 4 Online help Step 7 V5.4 SP 5 and Distributed Safety V 5.4 SP5

48 48 Example with Safety Controller from Siemens User Acknowledgement / Reintegration In principle, all PROFIsafe slaves go into a safe state when switched on and wait for the release to transition into standard mode by the safety host. The safe (passivated) slave status can be exited within the safety program by calling the FB219 "F_ACK_GL" or by manually selecting the acknowledgement via the F periphery DB signal "ACK_REI". Within the example program, calling FB219 is realized in FB501 for runtime group FC500 and in FB600 for runtime group FC600. Fig. 53 Screenshot of the reintegration runtime group 1 in FB501 call Fig. 54 Screenshot of the reintegration runtime group 2 in FB601 call Information More detailed information about F periphery DB and the meaning of signals is available in Chapter Fail-safe I/O DB p. 18.

49 Example with Safety Controller from Siemens Evaluation E-Stop Active In the example, 2 E-Stop buttons are evaluated that have the following responses in the example program: - Emergency stop (total) on PROFIsafe module (DP add. 6) shuts down the example completely. - Emergency stop (individual) on PROFIsafe module (DP add. 9) shuts down a part of the demonstration structure. The fast stop (total) is evaluated or detected by the FB215 "F_ESTOP1" within the 1st runtime group. The FB 215 is available via the "F-Application Blocks" library from Distributed Safety. Fig. 55 Screenshot showing evaluation of EStop (total) in runtime group 1 "No active EStop displayed" appears on output Q of FB215 "F_ESTOP1" via Q = TRUE. This information must be provided due to the available editor functions in the next network for both cyclic processing within runtime group 1 and runtime communication via the DB500: Fig. 56 Screenshot showing evaluation of EStop active and transfer to the 2nd runtime group

50 50 Example with Safety Controller from Siemens The fast stop is also evaluated by the FB215 "F_ESTOP1" within the 2nd runtime group. Fig. 57 Screenshot showing evaluation of EStop (individual) in runtime group 2 To implement the required fast stop function, it is evaluated in the next network whether the fast stop was activated total or individual to make this information available to the subsequent application and the runtime communication via DB600. Fig. 58 Screenshot showing evaluation of EStop active and transfer to the 1st runtime group

51 Example with Safety Controller from Siemens Relay Control To control and monitor the relay function, FB216 "F_FDBACK" from the "F- Application Blocks" library is used for each relay. Fig. 59 Screenshot of the call FB216 "F_FDBACK" in the application program Fig. 60 Screenshot of the online help FB216 "F_FDBACK" Source 4 Online help Step 7 V5.4 SP 5 and Distributed Safety V 5.4 SP5 FB input Program variable Use ON Switches ON/OFF the relay FEEDBACK safein_665_dp_1 Feedback drawn from relay (normally closed contact) QBAD_FIO F00010_196.QBAD QBAD status F module from F periphery DB ACK resetsafety Application reset for module Fig. 61 Explanations of module wiring of application program for "F_FDBACK"

52 52 Example with Safety Controller from Siemens Switch 1 (E 0.1), switch 2 (E 0.2) and switch 3 (E 0.3) are used within the application program to activate or deactivate the relay Status Displays of the Safety Program Fig. 62 Screenshot of control relay 1 application program (FB501) At the end of the safety program (FB501 and FB601), the current program and PROFIsafe module status is transferred to DB499, so that this information can be evaluated in the cyclic program. 4.5 Function Activation To activate the example, the following steps are required. The current program status is displayed via outputs. After switching on the voltage supply, the system starts to boot, the system configuration is checked by the CPU and the system goes into cyclic mode. The following status displays are shown on the digital outputs: - Indication safety program active via outputs A0.0, A 20.0, A 50.0 and A Indication EStop active via outputs A0.1, A20.1, A50.1 and A Indication error safety program active via outputs A 0.7, A20.7, A50.7 and A100.7 By activating the reset via input E0.0, all pending messages are reset, the status display on the outputs only displays the message "Safety program active" via outputs A0.0, A20.0, A50.0 and A To control all outputs directly, the respective function requirement is activated within the safety program via switch 1 (input E0.1).

53 Example with Safety Controller from Siemens Using ipar Server General The concept of the "ipar server" refers to the storage of application parameters from devices in a higher level control. The required functions within the control are currently available through a function block and corresponding firmware extensions. For full use of the technology, devices can be exchanged without additional manufacturer tools ipar Server FB24 Fig. 63 Screenshot of the ipar server principle ipar Server implementation documentation For Siemens CPUs, FB24 makes the ipar-server functionality available for CPUs of the 300 and 400 series since 10/26/2010. The FB must be called up for each PROFIsafe module 75x-66x/ as follows: - Use of PROFIBUS-DP Call in OB100 and OB1 - Use of PROFINET Call in OB100, OB56 and OB1 Fig. 64 Screenshot of call FB24 for PROFIsafe module V2 ipar

54 54 Example with Safety Controller from Siemens Information FB24 is available under entry ID in the Support area of Siemens website with documentation (link from module documentation: Fig. 65 Screenshot of the function block description FB24 Siemens Note FB24 in Version 1.2 is included in any example project for this application note. The project can be executed immediately.

55 Example with Safety Controller from Siemens Example Application Note General There is an example in the application note for evaluating all available information of the PROFIsafe modules. All information is stored in a data block (DB2), evaluated by function block FB29 and made available to the application in OB1. Overview of the function blocks: - FB29 Check_Safety_State Evaluation of status information DB2 - FB30 WAGO_iParCheck_Req - Evaluation of status information FB24 - FB31 WAGO_iParState_4_Mod - max. 4 PROFIsafe modules per slave - FB32 WAGO_iParState_8_Mod - max. 8 PROFIsafe modules per slave - FB33 WAGO_iParState_12_Mod - max. 12 PROFIsafe modules per slave Fig. 66 Software structure example using ipar server Note A description of the block functions, input and output assignment are contained in the respective block comment in the first network.

56 56 Example with Safety Controller from Siemens By integrating the FB24 call in the function blocks, the following requirements are placed on the controller per function block call: - FB31 WAGO_iParState_4_Mod - max. 4 PROFIsafe modules per slave Fig. 67 Screenshot of the FB31 memory requirement - FB32 WAGO_iParState_8_Mod - max. 8 PROFIsafe modules per slave Fig. 68 Screenshot of the FB32 memory requirement

57 Example with Safety Controller from Siemens 57 - FB33 WAGO_iParState_12_Mod - max. 12 PROFIsafe modules per slave Fig. 69 Screenshot of the FB33 memory requirement - In addition, the following memory requirement for storing the iparameters within the controller must be provided per PROFIsafe module: Fig. 70 Screenshot of the DB memory requirement for iparameters

58 58 Example with Safety Controller from Siemens Required Block Calls The following block calls are implemented in the example: - FC12 for PROFIsafe modules on PROFIBUS-DP - FC13 for PROFIsafe modules on PROFINET - Call of the FC12 and FC13 functions in start-up OB100 o Input "OB_CALL_ACT" is set to TRUE No evaluation of the F periphery DBs of the PROFIsafe modules Fig. 71 ipar Server call in start-up OB100 - Call of the FC13 function in alarm OB56 for PROFINET use o Input "OB_CALL_ACT" is set to TRUE No evaluation of the F periphery DBs of the PROFIsafe modules Fig. 72 ipar Server call in start-up OB56

59 Example with Safety Controller from Siemens 59 - Call of the FC12 and FC13 functions in OB1 o Input "OB_CALL_ACT" is set to FALSE No evaluation of the F periphery DBs of the PROFIsafe modules - Call status displays FB29 in OB1 Fig. 73 ipar Server call in start-up OB1 Fig. 74 Evaluation of status of PROFIsafe modules OB1 Note As the basis of the status displays via FB29, the following assignments are defined within DB2 in the range DW10 to DW16: - PROFIBUS-DP slave 9 Slave module number 9 in DB2 - PROFINET Device 2 Slave module number 2 in DB2

60 60 Example with Safety Controller from Siemens Function Call for PROFIBUS in FC12 To simplify the required calls, the FB31 call is made within FC12, which is called again within OB1 and OB100. Fig. 75 Screenshot of call FB31 for PROFIBUS-DP in FC12 Note Conformity of the module parameters to the inputs "ADR_MOD_x", "F_PER_DB_MOD_x" and "ipardr_mod_x" is not checked by the function block.

61 Example with Safety Controller from Siemens Function Call for PROFINET FC13 To simplify the required calls, the FB31 call is made within FC13, which is called again within OB1, OB100 and OB56. Fig. 76 Screenshot of call FB31 for PROFINET in FC13 Note Conformity of the module parameters to the inputs "ADR_MOD_x", "F_PER_DB_MOD_x" and "ipardr_mod_x" is not checked by the function block.

62 62 Example with Safety Controller from Siemens Information about Using FB31 The function block "manages" the current status of the ipar server function block FB24 of the PROFIsafe modules and makes an upload requirement available from the application program via the UPLOAD_REQ input Parameterization FB Initialization FB31 To determine the range of functions and internal block functions, the following input parameters must be defined: - UPLOAD_REQ Requirement to upload iparameters of all PROFIsafe modules of the slave - SLAVE_DP_PN Default bus system (VKE 0 PROFIBUS-DP / VKE 1 PROFINET) - MAX_MODULES Number of PROFIsafe modules used in the slave - ADR_MOD_x Default start input address of the PROFIsafe module - F_PER_DB_MOD_x DB number F periphery DB PROFIsafe module - ipardb_mod_x Default data block number for iparameters To apply the current date and time, this information is taken from DB2. By calling the function block in OB100 (start-up OB), the required initialization occurs based on the input wiring: - Input INIT Internal initialization of the block, "saved data" remains in tact in the instance DB. - Input INIT_ALL Internal initialization of the block, "saved data" is deleted in the instance DB all information of the "past" is deleted.

63 Example with Safety Controller from Siemens Status Indication FB31 The current functional status is represented for each module as "bit information" for further use via the inputs/outputs "IND_xxxx". The complete upload of all iparameters by the ipar server is displayed by the UPLOAD_ALL_MODULES output. If manual upload via the UPLOAD_REQ input was required, the requirement is successfully transferred by the UPL_REQ_DONE output (the requirement must be available until a corresponding status indication is output by the block) Information about Using FB29 The function block evaluates the status information of the FB31 call within the project that is stored in DB2 via the input/output interface. Fig. 77 Evaluation of status PROFIsafe modules OB1 The outputs of the block display the current status of the PROFIsafe modules and in doing so, provide a better overview of the current application. Note As the basis of the status displays via FB29, the following assignments are defined within DB2 in the range DW10 to DW16: - PROFIBUS-DP slave 9 Slave module number 9 in DB2 - PROFINET Device 2 Slave module number 2 in DB2

64 64 Example with Safety Controller from Siemens 4.7 System Configuration with ipar Server When using the ipar server functional extension within the safety control, the result is new sequences when creating and change the system configuration within the hardware configuration of Step Creating the System Configuration Use the following steps to create a system configuration to use the ipar server functionality within the Step 7 interface. The current GSD and GSDML files that are each integrated in the interface are used as a data basis. Fig. 78 Screenshot of "Build Start Configuration at HW Config"

65 Example with Safety Controller from Siemens 65 Fig. 79 Screenshot of "Define PROFIsafe Communication" Fig. 80 Screenshot of "Activate Safety Editor Offline"

66 66 Example with Safety Controller from Siemens Fig. 81 Screenshot of "Create iparameter Dataset Offline" Fig. 82 Screenshot of "Transfer System Configuration"

67 Example with Safety Controller from Siemens 67 Fig. 83 Screenshot of "Activate Safety Editor Online" Fig. 84 Screenshot of "Transfer Offline iparameter to PROFIsafe Module"

68 68 Example with Safety Controller from Siemens Fig. 85 Screenshot of "Transfer ipar_crc as F_iPar_CRC HW Config" Fig. 86 Screenshot of "Transfer System Configuration"

69 Example with Safety Controller from Siemens 69 Fig. 87 Screenshot of "Compile Collective CRC and Transfer Project" Fig. 88 Screenshot of " Check System Configuration and Safety Functions"

70 70 Example with Safety Controller from Siemens Adjusting the System Configuration To change iparameters in an existing system with ipar server functionality, the functionality of the ipar server must be temporarily disabled for the affected module within the hardware configuration. Fig. 89 Screenshot of "Deactivate ipar Server Function" Fig. 90 Screenshot of "Adjust iparameter via Safety Editor"

71 Example with Safety Controller from Siemens 71 Fig. 91 Screenshot of "Adjust iparameter via Safety Editor" Fig. 92 Screenshot of "Adjust iparameter via Safety Editor"

72 72 Example with Safety Controller from Siemens Fig. 93 Screenshot of "Transfer System Configuration" Fig. 94 Screenshot of "Compile Collective Signature and Transfer Project"

73 Example with Safety Controller from Siemens 73 Fig. 95 Screenshot of " Check System Configuration and Safety Functions"