Safety Applications with the S FC CPU

Transcription

1 Application Examples 12/2015 Safety Applications with the S FC CPU STEP 7 Safety V13 SP1 (TIA Portal)

2 Warranty and Liability Warranty and Liability The Application Examples are not binding and do not claim to be complete regarding the circuits shown, equipping and any eventuality. The Application Examples do not represent customer-specific solutions. They are only intended to provide support for typical applications. You are responsible for ensuring that the described products are used correctly. These Application Examples do not relieve you of the responsibility to use safe practices in application, installation, operation and maintenance. When using these Application Examples, you recognize that we cannot be made liable for any damage/claims beyond the liability clause described. We reserve the right to make changes to these Application Examples at any time without prior notice. If there are any deviations between the recommendations provided in this Application Example and other Siemens publications e.g. Catalogs the contents of the other documents shall have priority. We do not accept any liability for the information contained in this document. Any claims against us based on whatever legal reason resulting from the use of the examples, information, programs, engineering and performance data etc., described in this application example shall be excluded. Such an exclusion shall not apply in the case of mandatory liability, e.g. under the German Product Liability Act ( Produkthaftungsgesetz ), in case of intent, gross negligence, or injury of life, body or health, guarantee for the quality of a product, fraudulent concealment of a deficiency or breach of fundamental contractual obligations ( wesentliche Vertragspflichten ). The damages for a breach of a substantial contractual obligation are, however, limited to the foreseeable damage, typical for the type of contract, except in the event of intent or gross negligence or injury to life, body or health. The above provisions do not imply a change of the burden of proof to your detriment. Any form of duplication or distribution of these Application Examples or excerpts hereof is prohibited without the expressed consent of Siemens AG. Security informati on Siemens provides products and solutions with industrial security functions that support the secure operation of plants, solutions, machines, equipment and/or networks. They are important components in a holistic industrial security concept. With this in mind, Siemens products and solutions undergo continuous development. Siemens recommends strongly that you regularly check for product updates. For the secure operation of Siemens products and solutions, it is necessary to take suitable preventive action (e.g. cell protection concept) and integrate each component into a holistic, state-of-the-art industrial security concept. Third-party products that may be in use should also be considered. For more information about industrial security, visit To stay informed about product updates as they occur, sign up for a productspecific newsletter. For more information, visit Entry ID: , V1.2, 12/2015 2

3 Table of Contents Table of Contents Warranty and Liability How to Use this Document Why Safety with the S F-CPU? Description of an Automation Task PL and SIL Achieving PL c/sil Interconnection examples Settings in the STEP 7 hardware configuration Achieving PL d/sil Interconnection examples Settings in the STEP 7 hardware configuration Achieving PL e/sil Interconnection examples Settings in the STEP 7 hardware configuration Prepared User Scenarios What applies to all user scenarios Installing the user scenario Interlocking mechanisms for safety doors with guard locking Program structure Brief description of the F-library blocks Passivation and reintegration Value status s on the electric actuators User Scenario 1: Emergency Stop at PL e/sil 3, Electromechanical Actuator Safety function Hardware and software components Wiring Brief description of the core functionality Description of the user block FB F100EStopSIL3PLe Configuration and parameterization Operation of the user scenario User Scenario 2: Emergency Stop at PL d/sil 2, Electromechanical Actuator Safety function Hardware and software components Wiring Brief description of the core functionality Description of the user block FB F02EStopSIL2PLd Configuration and parameterization Operation of the user scenario User Scenario 3: Emergency Stop at PL c/sil 1, Electromechanical Actuator Safety function Hardware and software components Wiring Brief description of the core functionality Description of the user block FB F03EStopSIL1PLc Configuration and parameterization Operation of the user scenario Entry ID: , V1.2, 12/2015 3

4 Table of Contents 6.5 User Scenario 4: Emergency Stop at PL e/sil 3, Electric Actuator Safety function Hardware and software components Wiring Brief description of the core functionality Description of the user block FB F04EStopSIL3PLe Configuration and parameterization Operation of the user scenario User Scenario 5: Emergency Stop at PL d/sil 2, Electric Actuator Safety function Hardware and software components Wiring Brief description of the core functionality Description of the user block FB F05EStopSIL2PLd Configuration and parameterization Operation of the user scenario User Scenario 6: Emergency Stop at PL c/sil 1, Electric Actuator Safety function Hardware and software components Wiring Brief description of the core functionality Description of the user block FB F06EStopSIL1PLc Configuration and parameterization Operation of the user scenario User Scenario 7: Safety Door without Guard Locking at PL e/sil 3, Electromechanical Actuator Safety function Hardware and software components Wiring Brief description of the core functionality Description of the user block FB F07FDoorSIL3PLe Configuration and parameterization Operation of the user scenario User Scenario 8: Safety Door without Guard Locking at PL d/sil 2, Electromechanical Actuator Safety function Hardware and software components Wiring Brief description of the core functionality Description of the user block FB F08FDoorSIL2PLd Configuration and parameterization Operation of the user scenario User Scenario 9: Safety Door without Guard Locking at PL c/sil 1, Electromechanical Actuator Safety function Hardware and software components Wiring Brief description of the core functionality Description of the user block FB F09FDoorSIL1PLc Configuration and parameterization Operation of the user scenario User Scenario 10: Safety Door without Guard Locking at PL e/sil 3, Electric Actuator Safety function Hardware and software components Entry ID: , V1.2, 12/2015 4

5 Table of Contents Wiring Brief description of the core functionality Description of the user block FB F10FDoorSIL3PLe Configuration and parameterization Operation of the user scenario User Scenario 11: Safety Door without Guard Locking at PL d/sil 2, Electric Actuator Safety function Hardware and software components Wiring Brief description of the core functionality Description of the user block FB F11FDoorSIL2PL Configuration and parameterization Operation of the user scenario User Scenario 12: Safety Door without Guard Locking at PL c/sil 1, Electric Actuator Safety function Hardware and software components Wiring Brief description of the core functionality Description of the user block FB F12FDoorSIL1PLc Configuration and parameterization Operation of the user scenario User Scenario 13: Safety Door with Guard Locking at PL e/sil 3, Electromechanical Actuator Safety functions Hardware and software components Wiring Brief description of the core functionality Description of the user block FB F13FDoorSIL3PLe Configuration and parameterization Operation of the user scenario User Scenario 14: Safety Door with Guard Locking at PL d/sil 2, Electromechanical Actuator Safety function Hardware and software components Wiring Brief description of the core functionality Description of the user block FB F14FDoorSIL2PLd Configuration and parameterization Operation of the user scenario User Scenario 15: Safety Door with Guard Locking at PL c/sil 1, Electromechanical Actuator Safety function Hardware and software components Wiring Brief description of the core functionality Description of the user block FB F15FDoorSIL1PLc Configuration and parameterization Operation of the user scenario User Scenario 16: Safety Door with Guard Locking at PL e/sil 3, Electric Actuator Safety function Hardware and software components Wiring Brief description of the core functionality Description of the user block FB F16FDoorSIL3PLe Configuration and parameterization Entry ID: , V1.2, 12/2015 5

6 Table of Contents Operation of the user scenario User Scenario 17: Safety Door with Guard Locking at PL d/sil 2, Electric Actuator Safety function Hardware and software components Wiring Brief description of the core functionality Description of the user block FB F17FDoorSIL2PLd Configuration and parameterization Operation of the user scenario User Scenario 18: Safety Door with Guard Locking at PL c/sil 1, Electric Actuator Safety function Hardware and software components Wiring Brief description of the core functionality Description of the user block FB F18FDoorSIL1PLc Configuration and parameterization Operation of the user scenario User Scenario 19: Emergency Stop + Safety Door without Guard Locking at PL e/sil 3, Electromechanical Actuator Safety function Hardware and software components Wiring Brief description of the core functionality Description of the user block FB F19EStopFDoorSIL3PLe Configuration and parameterization Operation of the user scenario User Scenario 20: Emergency Stop + Safety Door without Guard Locking at PL d/sil 2, Electromechanical Actuator Safety function Hardware and software components Wiring Brief description of the core functionality Description of the user block FB F20EStopFDoorSIL2PLd Configuration and parameterization Operation of the user scenario User Scenario 21: Emergency Stop + Safety Door without Guard Locking at PL c/sil 1, Electromechanical Actuator Safety function Hardware and software components Wiring Brief description of the core functionality Description of the user block FB F21EStopFDoorSIL1PLc Configuration and parameterization Operation of the user scenario User Scenario 22: Emergency Stop and Safety Door without Guard Locking at PL e/sil 3, Electric Actuator Safety function Hardware and software components Wiring Brief description of the core functionality Description of the user block FB F22EStopFDoorSIL3PLe Configuration and parameterization Operation of the user scenario User Scenario 23: Emergency Stop + Safety Door without Guard Locking at PL d/sil 2, Electric Actuator Safety function Entry ID: , V1.2, 12/2015 6

7 Table of Contents Hardware and software components Wiring Brief description of the core functionality Description of the user block FB F23EStopFDoorSIL2PLd Configuration and parameterization Operation of the user scenario User Scenario 24: Emergency Stop + Safety Door without Guard Locking at PL c/sil 1, Electric Actuator Safety function Hardware and software components Wiring Brief description of the core functionality Description of the user block FB F24EStopFDoorSIL1PLc Configuration and parameterization Operation of the user scenario User Scenario 25: Emergency Stop + Safety Door with Guard Locking at PL e/sil 3, Electromechanical Actuator Safety function Hardware and software components Wiring Brief description of the core functionality Description of the user block FB F25EStopFDoorSIL3PLe Configuration and parameterization Implementation of the safety functions in the F-program Operation of the user scenario User Scenario 26: Emergency Stop + Safety Door with Guard Locking at PL d/sil 2, Electromechanical Actuator Safety function Hardware and software components Wiring Brief description of the core functionality Description of the user block FB F26EStopFDoorSIL2PLd Configuration and parameterization Operation of the user scenario User Scenario 27: Emergency Stop + Safety Door with Guard Locking at PL c/sil 1, Electromechanical Actuator Safety function Hardware and software components Wiring Brief description of the core functionality Description of the user block FB F27EStopFDoorSIL1PLc Configuration and parameterization Operation of the user scenario User Scenario 28: Emergency Stop and Safety Door with Guard Locking at PL e/sil 3, Electric Actuator Safety function Hardware and software components Wiring Brief description of the core functionality Description of the user block FB F28EStopFDoorSIL3PLe Configuration and parameterization Operation of the user scenario User Scenario 29: Emergency Stop + Safety Door with Guard Locking at PL d/sil 2, Electric Actuator Safety function Hardware and software components Wiring Brief description of the core functionality Entry ID: , V1.2, 12/2015 7

8 Table of Contents Description of the user block FB F29EStopFDoorSIL2PLd Configuration and parameterization Operation of the user scenario User Scenario 30: Emergency Stop + Safety Door with Guard Locking at PL c/sil 1, Electric Actuator Safety function Hardware and software components Wiring Brief description of the core functionality Description of the user block FB F30EStopFDoorSIL1PLc Configuration and parameterization Operation of the user scenario References/Links History Entry ID: , V1.2, 12/2015 8

9 1 How to Use this Document 1 How to Use this Document This document describes a large number of typical user scenarios from the field of functional safety. From this variety of user scenarios, you can select (chapter 5 and the following chapters) a scenario you are particularly interested in. Therefore, it is not necessary to read the entire document. 2 Why Safety with the S F-CPU? Simple stand-alone solutions SIMATIC S with Safety Integrated is the intelligent choice for all the everyday standard and fail-safe automation tasks with a small project scope: Certified for functional safety according to EN (version 2010) Suitable for use in safety-related applications up to SIL 3 according to IEC and PL e according to ISO Additional password protection for the F-configuration and F-program F-blocks certified by TÜV are available for support. You can integrate these blocks into your solutions. This document supports you in doing so. Economic efficiency As part of Safety Integrated, the S FC CPU stands for the consistent implementation of safety technology in the sense of Totally Integrated Automation. This includes consistent and convenient integration of safety technology into standard automation. This results in tremendous advantages for machine manufacturers and plant operators particularly in economic terms. The TIA Portal automation platform Engineering of the S FC CPU is performed based on the TIA Portal automation platform. This allows you to access all the advantages of Totally Integrated Automation (TIA): TIA Portal is designed for efficiency, intuitive operation and future viability. It allows you to solve all the engineering tasks of automation and drive technology. Entry ID: , V1.2, 12/2015 9

10 3 Description of an Automation Task 3 Description of an Automation Task This document assumes that a risk analysis and assessment have already been performed. Hazard control on the cutting machine to be examined is implemented through the safety devices safety door and emergency stop pushbutton (see the figure below). Figure 3-1 Cutting machine with safety door and emergency stop pushbutton The following questions reflect the automation task to be discussed in this document: Safety door with or without guard locking? Is it possible to open the safety door during operation without shutting down the machine? How do I connect the components? How does the PLC support me? How and what can I parameterize? What can I program? How do I achieve PL e/sil 3? What if I don t need PL e/sil 3 but PL d/sil 2 or PL c/sil 1? This document provides specific answers to these questions. Before chapter 5 refers to a specific user scenario, chapter 4 provides basic information on the safety integrity and performance level. Entry ID: , V1.2, 12/

11 4 PL and SIL 4.1 Achieving PL c/sil 1 4 PL and SIL The performance level (PL) or safety integrity level (SIL) classifies electrical and (programmable) electronic systems in terms of the reliability of safety functions. You implement a PL when you follow ISO SIL when you follow IEC (basic standard) or IEC (sector standard). Table 4 of ISO specifies a relationship between PL and SIL: Table 4-1 Relationship between performance level (PL) and safety integrity level (SIL) from table 4 of ISO PL SIL (high/continuous mode of operation) a - b 1 c 1 d 2 e 3 The following applies: PL e/sil 3 describes the highest degree of safety. NOTICE This document does not replace the standards for functional safety! However, it shows concise aspects of engineering and its aim is to contribute to their clarification. The statements in this chapter are of a general nature. They do not directly relate to the F-library blocks offered with this documentation or settings of the associated hardware configuration. The following sections list the numerical values for the probability of a dangerous failure per hour. You need these PFH D values to assess your safety function. This assessment can be made conveniently using the Safety Evaluation Tool (SET). For the link to the SET, please refer to \6\. Entry ID: , V1.2, 12/

12 4 PL and SIL 4.1 Achieving PL c/sil Achieving PL c/sil 1 General This chapter deals with emergency stops and position switches. The statements generally apply to electromechanical components. The following applies to PL c/sil 1: 10 6 PFH D < The circuit design may be a single-channel design Interconnection examples Example of an emergency stop interconnection Assign the emergency stop signal to the F-DI on a single-channel basis to achieve PL c/sil 1. Figure 4-1 Emergency stop interconnection for PL c/sil 1 F-DI E-stop Example of a safety door interconnection Assign the position switch signal to the F-DI on a single-channel basis to achieve PL c/sil 1. Entry ID: , V1.2, 12/

13 4 PL and SIL 4.1 Achieving PL c/sil 1 Figure 4-2 Interconnection of a position switch for PL c/sil 1 F-DI Position switch Settings in the STEP 7 hardware configuration You can assign on a single-channel basis the emergency stop pushbutton (or position switch) to any channel (shown for channel 0 in the below figure). Figure 4-3 Settings for the F-DI in the hardware configuration Entry ID: , V1.2, 12/

14 4 PL and SIL 4.1 Achieving PL c/sil 1 Table 4-2 Explanation of the above figure No. Explanation Select the appropriate channel pair (here: Channel 0, 8 ). The default setting is 1oo1 evaluation. : 1oo1 = 1 out of 1 The channels are activated by default. : You should deactivate unused channels. For PL c/sil 1, you can set internal or external sensor supply. : We recommend the internal sensor supply offered in the hardware configuration of the respective user scenarios. Entry ID: , V1.2, 12/

15 4 PL and SIL 4.2 Achieving PL d/sil Achieving PL d/sil 2 General This chapter deals with emergency stops and position switches. The statements generally apply to electromechanical components. The following applies to PL d/sil 2: 10 7 PFH D < 10 6 The circuit design should be a two-channel design 1 ). Internal or external sensor supply can be used. 1 ) Single-channel circuit design (hardware fault tolerance (HFT) = 0) is basically possible for PL d/sil 2; in this case, however, you have to increase the safe failure fraction (SFF). When HFT = 0, this value would be in the following range: 90% SFF < 99% The correlation between HFT and SFF can be found in table 5 of IEC (see \4\). For help with IEC 62061, please refer to \7\ Interconnection examples Example of an emergency stop Assign the emergency stop signal to the F-DI on a two-channel basis to achieve PL d/sil 2. Figure 4-4 Emergency stop interconnection for PL d/sil 2 F-DI E-stop Example of a safety door application Use two position switches to achieve PL d/sil 2. Assign each switch to the F-DI on a single-channel basis. The evaluation itself is performed on a two-channel basis (for more information, please refer to chapter 4.2.2). Entry ID: , V1.2, 12/

16 4 PL and SIL 4.2 Achieving PL d/sil 2 Figure 4-5 Interconnection of a position switch for PL d/sil 2 F-DI Position switch 1 Position switch Settings in the STEP 7 hardware configuration Emergency stop You can assign the emergency stop to any provided channel pair (this is shown for the channel pair 0 and 8 in the below figure). Figure 4-6 Settings of the F-DI for the emergency stop in the hardware configuration Entry ID: , V1.2, 12/

17 4 PL and SIL 4.2 Achieving PL d/sil 2 Table 4-3 Explanation of the above figure No. Explanation Select the appropriate channel pair (here: Channel 0, 8 ). Select 1oo2 evaluation, equivalent : 1oo1 = 1 out of 2, equivalent due to the same logic (normally closed contact, NC/NC) of the sensors For PL d/sil 2, after a channel fault, reintegration requires a FALSE signal. The channels are activated by default. For PL d/sil 2, you can set internal or external sensor supply. : We recommend the internal sensor supply offered in the hardware configuration of the respective user scenarios. The channels are activated by default. Same as no. Position switches In the prepared examples, the1oo2 evaluation of the position switches is performed by the FB SFDOOR F-library block. This block requires a single-channel signal at each of two inputs. For this reason, each of the two inputs is parameterized as a 1oo1 evaluation in the hardware configuration. Figure 4-7 Settings of the F-DI for the position switches in the hardware configuration Entry ID: , V1.2, 12/

18 4 PL and SIL 4.3 Achieving PL e/sil 3 Here, too, the following applies: You should deactivate unused channels. For PL d/sil 2, you can set internal or external sensor supply. We recommend internal sensor supply. For PL d/sil 2, after a channel fault, reintegration requires a FALSE signal. For the safety door, this is automatically done by the FB SFDOOR F-library block so that, in the hardware configuration, the Test 0-Signal not necessary setting can be kept. To implement a 1oo1 evaluation with two sensors for each switch, it is not mandatory to select a channel pair (e.g., 0, 8 or 1, 9 or ). Figure 4-8 1oo2 evaluation in the FB SFDOOR F-library block 1oo2 evaluation is performed in the block FB SFDOOR evaluates the signals of the position switch received via IN1 and IN2 in the F-program. 4.3 Achieving PL e/sil 3 General This chapter deals with emergency stops and position switches. The statements generally apply to electromechanical components. The following applies to PL e/sil 3: The circuit design must be a two-channel design and a cross-circuit must be safely detected PFH D < Interconnection examples Example of an emergency stop The interconnection for SIL 3/PL e is the same as the one shown in Figure 4-4 for PL d/sil 2. Example of a safety door application The interconnection for SIL 3/PL e is the same as the one shown in Figure 4-5 for PL d/sil 2. Entry ID: , V1.2, 12/

19 4 PL and SIL 4.3 Achieving PL e/sil Settings in the STEP 7 hardware configuration Emergency stop The settings of PL d/sil 2 apply. In addition, the following applies: The ability to withstand crossover required by PL e/sil 3 can only be implemented using internal sensor supply. Figure 4-9 Activating the short-circuit test You can deactivate the short-circuit test if you can otherwise rule out a crosscircuit, for example, by installing protected lines or in the case of sensors that perform internal short-circuit monitoring. Position switches The statements under Position switches in chapter apply. In addition, the statements made on the emergency stop earlier in this chapter (4.3.2) apply accordingly. Entry ID: , V1.2, 12/

20 5 Prepared User Scenarios 5 Prepared User Scenarios Prepared user scenarios In many areas of production engineering, emergency stop buttons and safety doors are typical safety devices to implement your safety function. Various options exist for implementing typical safety functions with emergency stop and/or safety door. From a total of 30 user scenarios, we offer you solutions for your safety function with emergency stop and safety door. All solutions include the F-block that solves the automation task. Simply select your application from the matrix on the page following the next page. Examples of using the matrix Example 1: You want to safely shut down a drive using an emergency stop pushbutton. Figure 5-1 Emergency stop pushbutton You will find solutions for this requirement in User Scenarios 1 to 6, depending on which PL/SIL and which actuators (electromechanical actuators such as contactors or electric actuators such as drives) you are using. For PL e/sil 3 and contactors as actuators, for example, you can use User Scenario 1. In addition, you are provided with a ready-to-use F-program block that implements the safety function at PL e according to IEC or SIL 3 according to IEC Example 2: You want to safely shut down a drive using an emergency stop pushbutton. The hazardous area should not be accessible during operation and, after shutting down the drive, it should only be accessible after a delay (e.g., due to a dangerous slowing down of a machine). Entry ID: , V1.2, 12/

21 5 Prepared User Scenarios Figure 5-2 Emergency stop pushbutton + safety door with guard locking Depending on which PL/SIL and which actuators (contactor or drive) you are using, you can use User Scenarios 25 to 30 (emergency stop + safety door with guard locking) for these safety functions. In this case, too, you are provided with a readyto-use F-program block that implements the safety function. Entry ID: , V1.2, 12/

22 5 Prepared User Scenarios Matrix of the prepared user scenarios Direct link to the user scenario User Scenario 25 (emergency stop + safety door with guard locking at PL e/sil 3 with contactors as actuators) contains additional information on the structure of the F-program that is also applicable to other user scenarios. User scenario no. and link to the appropriate chapter No Link No Link Entry ID: , V1.2, 12/

23 Each of the 30 user scenarios is discussed in a separate chapter (chapter 6.2 and the following chapters). This concisely provides you with all the information required for the user scenario you are reading. Before we look at the individual user scenarios, global information that applies to all user scenarios is given in the next chapter (6.1). At the appropriate points in the individual user scenarios, there are links to this information. You can read the next chapter (6.1) or specifically access it from the individual user scenarios. 6.1 What applies to all user scenarios Installing the user scenario If you make changes to safety-related settings or the safety program, you will be prompted for a password. This password is siemens. When you have selected your user scenario, the following instructions help you download and use it. Downloading the S7_1200F_LIB library 1. Download the S7_1200F_LIB.zip file to any Windows directory. 2. Extract the zip file: Right-click > 7-Zip > Extract Opening the S7_1200F_LIB library 3. In TIA Portal, create a new S7 project: Project > New. 4. Enter a name and the storage path. 5. Click Libraries Figure 6-1 Opening libraries Entry ID: , V1.2, 12/

24 6. Click the open global library icon Figure 6-2 open global library icon 7. Locate the S7_1200F_LIB file Important: Uncheck Open as read-only before you click Open. Figure 6-3 Open as read-only checked Hardware configuration, F-user block and selection of the user scenario 8. Open the folder of your user scenario (shown here: 01EStopSIL3PLe ). 9. Drag and drop PLC_1 to Devices & networks. Figure 6-4 Drag and drop hardware configuration to STEP 7 project. Drag & Drop 10. Open Program blocks. Entry ID: , V1.2, 12/

25 Figure 6-5 Program blocks folder The F-user block is located in the STEP 7 project. 11. Select PLC_1 [CPU 1215FC DC/DC/RLY] > Right-click > Compile > Hardware (rebuild all). 12. Select PLC_1 [CPU 1215FC DC/DC/RLY] > Right-click > Compile > Software (rebuild all blocks). 13. Save project. Downloading to the CPU 1. Select the PLC_1 F-CPU. Right-click > Download to device > Hardware configuration. 2. Establish an online connection to the S FC CPU. Entry ID: , V1.2, 12/

26 Figure 6-6 Preparing the download 3. Select the PLC_1 F-CPU. Right-click > Download to device > Software (only changes) Interlocking mechanisms for safety doors with guard locking You should read this chapter if you are using a safety door with guard locking. An output of the F-DQ activates a magnet in the position switch. The magnet implements guard locking depending on whether (1 signal from the F-DQ) or not (0 signal from the F-DQ) it is activated. Figure 6-7 Control of the coil in the position switch F-DQ Entry ID: , V1.2, 12/

27 Basically, there are two interlocking mechanisms: Locking with electro-magnetic force Locking with spring force Locking with electro-magnetic force To interlock the safety door, the coil must be controlled with 1 signal. Locking with spring force To interlock the safety door, the coil must be de-energized (0 signal). Which option is preferable? Locking with spring force has the advantage that in the event of a failure of the F-DQ channel that controls the coil of the position switch, this channel safely outputs 0 signal and therefore the coil remains de-energized; this means the guard locking of the safety door remains active or is automatically activated. For this reason, the user scenarios for safety doors with guard locking shown here use the locking with spring force mechanism. Monitoring the locking device The SIRIUS 3SE5 position switch allows monitoring of the locking device position. This information is read in via a standard DI. Safety door signals The following section provides an overview of the safety door signals where fdoorcoil emagnet sepact hingedswitch are variables of the F-program of your user scenario. Figure 6-8 Correlation between control of guard locking (fdoorcoil variable) and monitoring of guard locking (emagnet variable) fdoorcoil = 0 (0 signal from F-DQ) E1 E2 causes 41 emagnet = 1 42 fdoorcoil = 1 (1 signal from F-DQ) E1 E2 causes 41 emagnet = 0 42 Entry ID: , V1.2, 12/

28 Figure 6-9 Correlation between the actuator and the sepact variable Actuator inserted (door closed) causes 11 sepact = 1 Actuator not inserted (door open) causes sepact = 0 Figure 6-10 Hinge switch Hinge switch Unoperated (door closed) hingedswitch = 1 Operated (door open) sepact = 0 12 Normative assessment of guard locking For the normative assessment of a safety door application, a distinction has to made between: Opening and closing of the safety door The guard locking of the safety door Due to the use of spring-actuated lock position switches, guard locking remains active in the event of an electrical fault (e.g., passivation of the channel of the F-DI) (safety door cannot be opened). A fault current on the magnet at a time when the safety door must be closed (hazardous machine active, fdoorcoil=1) must result in the safe shutdown of the machine. Theoretically, someone could open the door at this very moment, which might cause a hazard. Therefore, PL e/sil 3 e cannot be achieved for the guard locking. Chapter 8.4 (see \3\) of DIN EN ISO addresses this subject and assumes that in most cases the required PL or SIL of the guard locking function is lower than the required PL or SIL of the interlocking function. The probability of a guard locking function failure while a person simultaneously enters the area is considered to be very low. The user scenarios provided in this document are based on this assessment. Entry ID: , V1.2, 12/

29 6.1.3 Program structure F-library blocks The block offered for your user scenario is your user interface (F-user FB). All other blocks that are used need not be edited. To provide an overall understanding of the F-user FB within the F-program, some explanations will be given below. To implement the respective safety function, the F-user FBs access certified F-library blocks included in STEP 7 Safety. The following F-library blocks are used in the application examples shown here: Emergency stop (FB ESTOP1) Safety door (FB SFDOOR) Readback (FB FDBACK) Reintegration via all F-I/O (FB ACK_GL) F-user FB The F-user FB of your selected user scenario includes at least two of the above-listed F-library blocks. Figure 6-11 F-user FB and used F-library blocks F-user FB FB SFDOOR FB ESTOP1 FB FDBACK F-library blocks FB ACK_GL While you can change the F-user FB, the F-library blocks are know-how protected. Entry ID: , V1.2, 12/

30 The F-user FBs are also provided to you in a block library. However, this is not the F-library included in STEP 7 Safety. Execution of the F-program The standard program is interrupted by the safety program (F-program) in fixed time slices. During this process, an F-OB (FOB_RTG1) calls the Main_Safety_RTG1 F-block. Figure 6-12 Call of the F-program FB Main_Safety_RTG1 calls the F-user FB Brief description of the F-library blocks The following section provides a brief description of the functionality of the F-library blocks. For related information on the individual F-library blocks, please refer to the STEP 7 online help. Select the F-library block in the F-program editor > Press F5. Emergency stop: FB ESTOP1 The signals from the emergency stop pushbutton are read in to the F-DI on a two-channel basis (except for SIL1/PL c). To achieve PL e/sil 3, both signals must carry the same signal when the emergency stop pushbutton is actuated within a certain configurable time. When this time is exceeded, the block reacts in the same way as when the emergency stop is pressed: By resetting the Q output. Entry ID: , V1.2, 12/

31 Figure 6-13 Discrepancy analysis for the emergency stop F-CPU E-stop F-DI Chnl 1 Chnl 2 Discrepancy analysis The evaluation of the two channels is performed in the F-DI. In the F-program, the processed signal is available as an input in the process image. This always corresponds to the lower address of the two channels. Safety door: FB SFDOOR This F-FB monitors the correct closing of the safety door. In the examples, the evaluation is performed via two input channels: Insertion of the actuator into the position switch Position of the hinge switch Figure 6-14 Reading in position switch/actuator and hinge switch Position switch Actuator Hinge switch If the two signals do not correlate as expected, this will be detected as a fault and the Q output will not be set/reset. Example: An actuator that has broken off the swinging part of the safety door inserted in the position switch outputs the information safety door closed when the safety door is opened. The hinge switch, in contrast, outputs the information safety door open. This discrepancy is detected by FB SFDOOR and the Q output is reset to 0 signal. After such a fault, it is always necessary to completely open and close the safety door before the fault can be acknowledged. This ensures that, for example, an actuator that has broken off is safely detected. Readback: FB FDBACK This block compares, for example for a contactor, whether the state of the contactor coil correctly correlates with the state of the contactor auxiliary contact. Entry ID: , V1.2, 12/

32 Figure 6-15 FB FDBACK Contactor auxiliary contact K1 Contactor coil K1 If these two states are not plausible to each other after a configurable period of time, the Q output (here: the contactor coil) will be safely disabled. This allows you to react, for example, to a welded contactor. Reintegration: FB ACK_GL Passivated F-modules/channels cannot output process values before the fault has been cleared and the F-module/channel has been reintegrated (see also chapter 6.1.5). With FB ACK_GL used here, you reintegrate the entire F-I/O of an F-runtime group Passivation and reintegration Passivation The safety program provides a set of commands that allows you to safely shut down one or more actuators. Typical applications include emergency stop or the unauthorized opening of a safety door. Furthermore, situations can arise where functional errors occur. In this context, the following example describes a discrepancy error: Example: Two sensors (normally closed contacts, NC) are read in via an F-DI. A time value is configured to evaluate the discrepancy time. If a sensor changes its state, e.g. from 1 to 0 signal, this change must also be made within the configured discrepancy time by the sensor on the other channel; otherwise, the F-system detects a functional error (here: discrepancy error). Figure 6-16 Passivation due to discrepancy error F-DI Sensor 1 Sensor 2 Chnl 1 Chnl 2 Discrepancy analysis Time elapsed Discrepancy error The discrepancy error automatically results in passivation of the respective channels. Entry ID: , V1.2, 12/

33 Reintegration In case of passivation, the affected channel outputs substitute values (0 signal) instead of the process values. The author of the F-program must ensure that 0 signal corresponds to the safe state. Even if the error that caused passivation is no longer present, passivation persists. To enable the passivated channel to output process values, reintegration is required. The term depassivation is also used as a synonym for reintegration. This document uses only the term reintegration. Reintegration of the F-I/O after clearing the errors requires user acknowledgment with a positive edge at the ACK_REI variable of the F-I/O DB. For this purpose, you can provide, for example, the acknowledgment button, a separate button or also an HMI. WARNING Death or severe personal injury may result if you implement reintegration in the program without deliberate acknowledgment (automatic reintegration). Automatic reintegration may only be used if it does not result in hazards such as the unexpected startup of hazardous machines. The risk analysis is to confirm this. In addition, the FB ACK_GL F-library block provides you with the option to reintegrate the entire F-I/O (see chapter 6.1.4) Value status The value status is binary additional information on a channel value of an F-I/O and entered in the process input image (PII). Variable names that contain the value status have the VS suffix at the end. The value status provides you with information on the valid channel value: 1: A valid process value is output for the channel. 0: A substitute value is output for the channel. The table below shows an example of the address assignment in the PII for the 16- channel F-DI: Table 6-1 Example of the address assignment in the PII for a fail-safe digital input module with 16 channels Byte in the F-CPU Assigned bits in the F-CPU per F-module: x + 0 DI 8 DI 7 DI 6 DI 5 DI 4 DI 3 DI 2 DI 1 x + 1 DI 16 DI 15 DI 14 DI 13 DI 12 DI 11 DI 10 D I9 x + 2 DI 8 DI 7 DI 6 DI 5 DI 4 DI 3 DI 2 DI 1 Entry ID: , V1.2, 12/

34 Byte in the F-CPU Assigned bits in the F-CPU per F-module: value status value status value status value status value status value status value status value status x + 3 DI 16 value status DI 15 value status DI 14 value status DI 13 value status DI 12 value status DI 11 value status DI 10 value status D I9 value status Example: The address of the value status of a fail-safe input E0.0 would be E s on the electric actuators Among other things, the user scenarios provided in this document differ in the types of actuators used: Electromechanical actuators Electric actuators In the case of electromechanical actuators (e.g., contactors), the readback signal is processed accordingly by the actuator. In the case of certified electric actuators (e.g., F-drives), safety-related checks are performed within the actuator. For this case, we provide you with an appropriate signal on the F-DQ (e.g., signalpldsil2quality) that meets the required PL/SIL of the respective user scenario. NOTICE It is possible that the required PL/SIL is not achieved. Make sure that the electric actuator is also suitable for the required PL/SIL of the safety function. 6.2 User Scenario 1: Emergency Stop at PL e/sil 3, Electromechanical Actuator Safety function The safety function is as follows: Pressing the emergency stop button safely shuts down the actuator Hardware and software components You need the hardware and software components listed below. Entry ID: , V1.2, 12/

35 Hardware components Table 6-2 Hardware Component No. Article number CPU 1215FC DC/DC/RLY SM 1226 F- DI8/16x24VDC SM 1226 F-DQ 4x24VDC Enclosed pushbutton (NO) Enclosed pushbutton (NC) Emergency stop pushbutton (NC/NC) 1 6ES7215-1HF40-0XB0 1 6ES7226-6BA32-0XB0 1 6ES DA32-0XB0 2 3SB3801-0DD3 1 3SB3801-0DB3 1 3SB3801-0EG3 Contactors 2 3RT2015-2BB42 Software components Table 6-3 Software Component No. Article number STEP 7 Basic 1 6ES7822-0AA03-0YA5 Or STEP 7 Professional STEP 7 Safety Basic V13 SP1 1 6ES7833-1FB13-0YA5 Or STEP 7 Safety Advanced Wiring The figure below shows the wiring of the hardware components. Entry ID: , V1.2, 12/

36 Figure 6-17 Emergency stop PL e/sil 3 wiring 24V DC M stop start ack L1 M K2 K1 L+.3.4 L+ M Vs1.0 K1 0+ K2 0- Vs2.0 estop In the F-program, the auxiliary contacts of the contactors K1 and K2 are termed feedback1 and feedback2. Entry ID: , V1.2, 12/

37 6.2.4 Brief description of the core functionality The following flowchart provides a concise description of the core functionality. Figure 6-18 Core functionality Start Actuators switch off Yes E-stop pressed? E-stop released? Yes No No Stop caused by e-stop or 1 st start? Yes No Acknowledge Actuators switch off Yes Operational stop? Start conditions are complied No Actuators on Description of the user block FB F100EStopSIL3PLe The block names of the prepared F-user FBs start with an F and a number for the block number that refers to the user scenario number (e.g., FB F23EStopFDoorSIL3PLe refers to User Scenario 23). The only exception to this convention is FB F100EStopSIL3PLe, which refers to User Scenario was used instead of 1, because the block number 1 is assigned to the Main_Safety_RTG1 by default. Entry ID: , V1.2, 12/

38 Figure 6-19 F-user FB F100EStopSIL3PLe NOTICE For F-blocks, the enable input (EN) must not be wired. Parameter description The following section describes the inputs and outputs of FB F100EStopSIL3PLe. NO: normally open (contact); NC: normally closed (contact) Table 6-4 Inputs of FB F100EStopSIL3PLe Description Symbol Data type Convention Acknowledgment ack BOOL NO 1: Acknowledgment Start request start BOOL NO 1: Start request Stop request stop BOOL NC 0: Stop request Readback signal from auxiliary contact of contactor K1 Readback signal from auxiliary contact of contactor K2 Emergency stop pushbutton Value status for output K1K2 Time between the control command and the response of the contactors readbackk1 readbackk2 BOOL BOOL NC 0: Contactor has picked up estop BOOL NC/NC 0: Emergency stop triggered K1K2_VS BOOL 0: Fault feedbacktime TIME Positive edge required after triggering the safety function to reintegrate F-I/O Entry ID: , V1.2, 12/

39 Table 6-5 Outputs of FB F100EStopSIL3PLe Description Symbol Data type Convention Contactors K1/K2 K1K2 BOOL 1: Control command for the contactors Release emergency stop Acknowledgment required releaseestop BOOL 1: Emergency stop released and acknowledged AckReqEStop BOOL 1: Acknowledgment required Actuator on F-DQ Information of the F-library blocks. Can be read out, for example, in the standard user program Configuration and parameterization The STEP 7 hardware configuration (HW Config) has already been prepared for commissioning FB F100EStopSIL3PLe. Customizations are possible. The associated HW Config can be found in the provided block library. WARNING Inappropriate values for safety-related settings may result in the safety function not being triggered in the event of danger. Please keep this in mind if, due to your requirements, you want to change the settings shown here. For more information on the hardware configuration in this user scenario, please refer to chapter Entry ID: , V1.2, 12/

40 6.2.7 Operation of the user scenario For demonstration purposes, this document shows different user scenarios. These scenarios can also be used as verification steps for validation. For information on installing the user scenario, please refer to chapter Requirements: No faults Emergency stop released Table 6-6 Start actuator No. Action Comment 1 Press ack Acknowledgment mandatory when starting the scenario for the first time 2 Press start K1K2 picks up 3 Press stop K1K2 drops out Table 6-7 Safety function: Trigger emergency stop No. Action Comment 1 Press ack Acknowledgment mandatory when starting the scenario for the first time 2 Press start K1K2 picks up 3 Press the emergency stop (estop) K1K2 drops out 4 Release the emergency stop (estop) 5 Press start K1K2 does not pick up (acknowledgment required) 6 Start again with no. 1 Table 6-8 Trigger readback error No. Action Comment 1 Press ack Acknowledgment mandatory when starting the scenario for the first time 2 Press start K1K2 picks up 3 Make sure that K1 or K2 does not drop out when shutting down Simulated welding of the contactor 4 Press stop Readback error is detected 5 Let the contactor drop out 6 Press start K1K2 does not pick up (acknowledgment required) 7 Start again with no. 1 Entry ID: , V1.2, 12/

41 6.3 User Scenario 2: Emergency Stop at PL d/sil 2, Electromechanical Actuator Safety function The safety function is as follows: Pressing the emergency stop button safely shuts down the actuator Hardware and software components You need the hardware and software components listed below. Hardware components Table 6-9 Hardware Component No. Article number CPU 1215FC DC/DC/RLY SM 1226 F- DI8/16x24VDC SM 1226 F-DQ 4x24VDC Enclosed pushbutton (NO) Enclosed pushbutton (NC) Emergency stop pushbutton (NC/NC) 1 6ES7215-1HF40-0XB0 1 6ES7226-6BA32-0XB0 1 6ES DA32-0XB0 2 3SB3801-0DD3 1 3SB3801-0DB3 1 3SB3801-0EG3 Contactors 2 3RT2015-2BB42 Software components Table 6-10 Software Component No. Article number STEP 7 Basic 1 6ES7822-0AA03-0YA5 Or STEP 7 Professional STEP 7 Safety Basic V13 SP1 1 6ES7833-1FB13-0YA5 Or STEP 7 Safety Advanced Entry ID: , V1.2, 12/

42 6.3.3 Wiring The figure below shows the wiring of the hardware components. Figure 6-20 Emergency stop PL d/sil 2 wiring 24V DC M stop start ack L1 M K2 K1 L+.3.4 L+ M Vs1.0 K1 0+ K2 0- estop In the F-program, the NC auxiliary contacts of the contactors K1 and K2 are termed feedback1 and feedback2. Entry ID: , V1.2, 12/

43 6.3.4 Brief description of the core functionality The following flowchart provides a concise description of the core functionality. Figure 6-21 Core functionality Start Actuators switch off Yes E-stop pressed? E-stop released? Yes No No Stop caused by e-stop or 1 st start? Yes No Acknowledge Actuators switch off Yes Operational stop? Start conditions are complied No Actuators on Description of the user block FB F02EStopSIL2PLd Figure 6-22 F-user FB F02EStopSIL2PLd Entry ID: , V1.2, 12/

44 NOTICE For F-blocks, the enable input (EN) must not be wired. The following section describes the inputs and outputs of FB F02EStopSIL2PLd. NO: normally open (contact); NC: normally closed (contact) Table 6-11 Inputs of FB F02EStopSIL2PLd Description Symbol Data type Convention Acknowledgment ack BOOL NO 1: Acknowledgment Start request start BOOL NO 1: Start request Stop request stop BOOL NC 0: Stop request Readback signal from auxiliary contact of contactor K1 Readback signal from auxiliary contact of contactor K2 Emergency stop pushbutton Value status for output K1K2 Time between the control command and the response of the contactors readbackk1 readbackk2 BOOL BOOL NC 0: Contactor has picked up estop BOOL NC/NC 0: Emergency stop triggered K1K2_VS BOOL 0: Fault feedbacktime TIME Positive edge required after triggering the safety function to reintegrate F-I/O Table 6-12 Outputs of FB F02EStopSIL2PLd Description Symbol Data type Convention Contactors K1/K2 K1K2 BOOL 1: Control command for the contactors Release emergency stop Acknowledgment required releaseestop BOOL 1: Emergency stop released and acknowledged AckReqEStop BOOL 1: Acknowledgment required Actuator on F-DQ Information of the F-library blocks. Can be read out, for example, in the standard user program. Entry ID: , V1.2, 12/

45 6.3.6 Configuration and parameterization The STEP 7 hardware configuration (HW Config) has already been prepared for commissioning FB F02EStopSIL2PLd. Customizations are possible. The associated HW Config can be found in the provided block library. WARNING Inappropriate values for safety-related settings may result in the safety function not being triggered in the event of danger. Please keep this in mind if, due to your requirements, you want to change the settings shown here. For more information on the hardware configuration in this user scenario, please refer to chapter Operation of the user scenario For demonstration purposes, this document shows different user scenarios. These scenarios can also be used as verification steps for validation. For information on installing the user scenario, please refer to chapter Requirements: No faults Emergency stop released Table 6-13 Start actuator No. Action Comment 1 Press ack Acknowledgment mandatory when starting the scenario for the first time 2 Press start K1K2 picks up 3 Press stop K1K2 drops out Table 6-14 Safety function: Trigger emergency stop No. Action Comment 1 Press ack Acknowledgment mandatory when starting the scenario for the first time 2 Press start K1K2 picks up 3 Press the emergency stop (estop) K1K2 drops out 4 Release the emergency stop (estop) 5 Press start K1K2 does not pick up (acknowledgment required) 6 Start again with no. 1 Entry ID: , V1.2, 12/

46 Table 6-15 Trigger readback error No. Action Comment 1 Press ack Acknowledgment mandatory when starting the scenario for the first time 2 Press start K1K2 picks up 3 Make sure that K1 or K2 does not drop out when shutting down Simulated welding of the contactor 4 Press stop Readback error is detected 5 Let the contactor drop out 6 Press start K1K2 does not pick up (acknowledgment required) 7 Start again with no. 1 Entry ID: , V1.2, 12/

47 6.4 User Scenario 3: Emergency Stop at PL c/sil 1, Electromechanical Actuator Safety function The safety function is as follows: Pressing the emergency stop button safely shuts down the actuator Hardware and software components You need the hardware and software components listed below. Hardware components Table 6-16 Hardware Component No. Article number CPU 1215FC DC/DC/RLY SM 1226 F- DI8/16x24VDC SM 1226 F-DQ 4x24VDC Enclosed pushbutton (NO) Enclosed pushbutton (NC) Emergency stop pushbutton (NC) 1 6ES7215-1HF40-0XB0 1 6ES7226-6BA32-0XB0 1 6ES DA32-0XB0 2 3SB3801-0DD3 1 3SB3801-0DB3 1 3SB3801-0DG3 Contactors 1 3RT2015-2BB42 Software components Table 6-17 Software Component No. Article number STEP 7 Basic 1 6ES7822-0AA03-0YA5 Or STEP 7 Professional STEP 7 Safety Basic V13 SP1 1 6ES7833-1FB13-0YA5 Or STEP 7 Safety Advanced Entry ID: , V1.2, 12/

48 6.4.3 Wiring The figure below shows the wiring of the hardware components. Figure 6-23 Emergency stop PL c/sil 1 wiring 24V DC M stop start ack L1 M K1 L+.3 L+ M Vs1.0 K estop In the F-program, the auxiliary contact of contactor K1 is termed feedback. Due to the use of the FB FDBACK F-library block, it is useful to monitor readback. Basically, monitoring the readback signals is not required for PL c/sil 1. Entry ID: , V1.2, 12/

49 6.4.4 Brief description of the core functionality The following flowchart provides a concise description of the core functionality. Figure 6-24 Core functionality Start Actuator switches off Yes E-stop pressed? E-stop pressed? Yes No No Stop caused by e-stop or 1 st start? Yes No Acknowledge Actuator switches off Yes Operational stop? Start conditions are complied No Actuator on Description of the user block FB F03EStopSIL1PLc Figure 6-25 F-user FB F03EStopSIL1PLc Entry ID: , V1.2, 12/

50 NOTICE For F-blocks, the enable input (EN) must not be wired. The following section describes the inputs and outputs of FB F03EStopSIL1PLc. NO: normally open (contact); NC: normally closed (contact) Table 6-18 Inputs of FB F03EStopSIL1PLc Description Symbol Data type Convention Acknowledgment ack BOOL NO 1: Acknowledgment Start request start BOOL NO 1: Start request Stop request stop BOOL NC 0: Stop request Readback signal from auxiliary contact of contactor K1 Emergency stop pushbutton readbackk1 BOOL NC 0: Contactor has picked up estop BOOL NC 0: Emergency stop triggered Value status of output K1 K1VS BOOL 0: Fault Time between the control command and the response of the contactor feedbacktime TIME Positive edge required after triggering the safety function to reintegrate F-I/O Table 6-19 Outputs of FB F03EStopSIL1PLc Description Symbol Data type Convention Contactor K1 K1 BOOL 1: Actuator switched (contactor has picked up) Release emergency stop Acknowledgment required releaseestop BOOL 1: Emergency stop released and acknowledged AckReqEStop BOOL 1: Acknowledgment required Actuator on F-DQ Information of the F-library blocks. Can be read out, for example, in the standard user program. Entry ID: , V1.2, 12/

51 6.4.6 Configuration and parameterization The STEP 7 hardware configuration (HW Config) has already been prepared for commissioning FB F03EStopSIL1PLc. Customizations are possible. The associated HW Config can be found in the provided block library. WARNING Inappropriate values for safety-related settings may result in the safety function not being triggered in the event of danger. Please keep this in mind if, due to your requirements, you want to change the settings shown here. For more information on the hardware configuration in this user scenario, please refer to chapter Operation of the user scenario For demonstration purposes, this document shows different user scenarios. These scenarios can also be used as verification steps for validation. For information on installing the user scenario, please refer to chapter Requirements: No faults Emergency stop released Table 6-20 Start actuator No. Action Comment 1 Press ack Acknowledgment mandatory when starting the scenario for the first time 2 Press start K1 picks up 3 Press stop K1 drops out Table 6-21 Safety function: Trigger emergency stop No. Action Comment 1 Press ack Acknowledgment mandatory when starting the scenario for the first time 2 Press start K1 picks up 3 Press the emergency stop (estop) K1 drops out 4 Release the emergency stop (estop) 5 Press start K1 does not pick up (acknowledgment required) Entry ID: , V1.2, 12/

52 No. Action Comment 6 Start again with no. 1 Table 6-22 Trigger readback error No. Action Comment 1 Press ack Acknowledgment mandatory when starting the scenario for the first time 2 Press start K1 picks up 3 Make sure that K1 does not drop out when shutting down Simulated welding of the contactor 4 Press stop Readback error is detected 5 Let the contactor drop out 6 Press start K1 does not pick up (acknowledgment required) 7 Start again with no. 1 Entry ID: , V1.2, 12/

53 6.5 User Scenario 4: Emergency Stop at PL e/sil 3, Electric Actuator Safety function The safety function is as follows: Pressing the emergency stop button safely shuts down the actuator Hardware and software components You need the hardware and software components listed below. Hardware components Table 6-23 Hardware Component No. Article number CPU 1215FC DC/DC/RLY SM 1226 F- DI8/16x24VDC SM 1226 F-DQ 4x24VDC Enclosed pushbutton (NO) Enclosed pushbutton (NC) Emergency stop pushbutton (NC/NC) 1 6ES7215-1HF40-0XB0 1 6ES7226-6BA32-0XB0 1 6ES DA32-0XB0 2 3SB3801-0DD3 1 3SB3801-0DB3 1 3SB3801-0EG3 Software components Table 6-24 Software Component No. Article number STEP 7 Basic 1 6ES7822-0AA03-0YA5 Or STEP 7 Professional STEP 7 Safety Basic V13 SP1 1 6ES7833-1FB13-0YA5 Or STEP 7 Safety Advanced Entry ID: , V1.2, 12/

54 6.5.3 Wiring The figure below shows the wiring of the hardware components. Figure 6-26 Emergency stop PL e/sil 3 wiring 24V DC M stop start ack L1 M L+ L+ M Vs signalplesil3quality 0- estop For the actuators used in this user scenario, please also refer to chapter Entry ID: , V1.2, 12/

55 6.5.4 Brief description of the core functionality The following flowchart provides a concise description of the core functionality. Figure 6-27 Core functionality Start Actuators switch off Yes E-stop pressed? E-stop released? Yes No No Stop caused by e-stop or 1 st start? Yes No Acknowledge Actuators switch off Yes Operational stop? Start conditions are complied No Actuators on Description of the user block FB F04EStopSIL3PLe Figure 6-28 F-user FB F04EStopSIL3PLe Entry ID: , V1.2, 12/

56 NOTICE For F-blocks, the enable input (EN) must not be wired. Parameter description The following section describes the inputs and outputs of FB F04EStopSIL3PLe. NO: normally open (contact); NC: normally closed (contact) Table 6-25 Inputs of FB F04EStopSIL3PLe Description Symbol Data type Convention Acknowledgment ack BOOL NO 1: Acknowledgment Start request start BOOL NO 1: Start request Stop request stop BOOL NC 0: Stop request Emergency stop pushbutton Value status of output signalplesil3quality estop BOOL NC/NC 0: Emergency stop triggered signalplesil3qualityvs BOOL 0: Fault Positive edge required after triggering the safety function to reintegrate F- I/O Table 6-26 Outputs of FB F04EStopSIL3PLe Description Symbol Data type Convention Output signal from the F-DQ to the electric actuator Release emergency stop signalplesil3quality BOOL 1: F-DQ output set releaseestop BOOL 1: Emergency stop released and acknowledged Information of the F-library blocks. Can be read out, for example, in the standard user program Configuration and parameterization The STEP 7 hardware configuration (HW Config) has already been prepared for commissioning FB F04EStopSIL3PLe. Customizations are possible. The associated HW Config can be found in the provided block library. Entry ID: , V1.2, 12/

57 WARNING Inappropriate values for safety-related settings may result in the safety function not being triggered in the event of danger. Please keep this in mind if, due to your requirements, you want to change the settings shown here. For more information on the hardware configuration in this user scenario, please refer to chapter Operation of the user scenario For demonstration purposes, this document shows different user scenarios. These scenarios can also be used as verification steps for validation. For information on installing the user scenario, please refer to chapter Requirements: No faults Emergency stop released Table 6-27 Start actuator No. Action Comment 1 Press ack Acknowledgment mandatory when starting the scenario for the first time 2 Press start signalplesil3quality=1 3 Press stop signalplesil3quality=0 Table 6-28 Safety function: Trigger emergency stop No. Action Comment 1 Press ack Acknowledgment mandatory when starting the scenario for the first time 2 Press start signalplesil3quality=1 3 Press the emergency stop (estop) signalplesil3quality=0 4 Release the emergency stop (estop) 5 Press start signalplesil3quality=0 (acknowledgment required) 6 Start again with no. 1 Entry ID: , V1.2, 12/

58 6.6 User Scenario 5: Emergency Stop at PL d/sil 2, Electric Actuator You are using a drive as an actuator. Please also follow the information in chapter Safety function The safety function is as follows: Pressing the emergency stop button safely shuts down the actuator Hardware and software components You need the hardware and software components listed below. Hardware components Table 6-29 Hardware Component No. Article number CPU 1215FC DC/DC/RLY SM 1226 F- DI8/16x24VDC SM 1226 F-DQ 4x24VDC Enclosed pushbutton (NO) Enclosed pushbutton (NC) Emergency stop pushbutton (NC/NC) 1 6ES7215-1HF40-0XB0 1 6ES7226-6BA32-0XB0 1 6ES DA32-0XB0 2 3SB3801-0DD3 1 3SB3801-0DB3 1 3SB3801-0EG3 Software components Table 6-30 Software Component No. Article number STEP 7 Basic 1 6ES7822-0AA03-0YA5 Or STEP 7 Professional STEP 7 Safety Basic V13 SP1 1 6ES7833-1FB13-0YA5 Or STEP 7 Safety Advanced Wiring The figure below shows the wiring of the hardware components. Entry ID: , V1.2, 12/

59 Figure 6-29 Emergency stop PL d/sil 2 wiring 24V DC M stop start ack L1 M L+ L+ M Vs signalpldsil2quality 0- estop For the actuators used in this user scenario, please also refer to chapter Entry ID: , V1.2, 12/

60 6.6.4 Brief description of the core functionality The following flowchart provides a concise description of the core functionality. Figure 6-30 Core functionality Start Actuators switch off Yes E-stop pressed? E-stop released? Yes No No Stop caused by e-stop or 1 st start? Yes No Acknowledge Actuators switch off Yes Operational stop? Start conditions are complied No Actuators on Description of the user block FB F05EStopSIL2PLd Figure 6-31 F-user FB F05EStopSIL2PLd Entry ID: , V1.2, 12/

61 NOTICE For F-blocks, the enable input (EN) must not be wired. The following section describes the inputs and outputs of FB F05EStopSIL2PLd. NO: normally open (contact); NC: normally closed (contact) Table 6-31 Inputs of FB F05StopSIL2PLd Description Symbol Data type Convention Acknowledgment ack BOOL NO 1: Acknowledgment Start request start BOOL NO 1: Start request Stop request stop BOOL NC 0: Stop request Emergency stop pushbutton Value status of output signalpldsil2quality estop BOOL NC/NC 0: Emergency stop triggered signalpldsil2qualityvs BOOL 0: Fault Positive edge required after triggering the safety function to reintegrate F- I/O Table 6-32 Outputs of FB F05StopSIL2PLd Description Symbol Data type Convention Output signal from the F-DQ to the electric actuator Release emergency stop signalpldsil2quality BOOL 1: F-DQ output set releaseestop BOOL 1: Emergency stop released and acknowledged Information of the F-library blocks. Can be read out, for example, in the standard user program Configuration and parameterization The STEP 7 hardware configuration (HW Config) has already been prepared for commissioning FB F05StopSIL2PLd. Customizations are possible. The associated HW Config can be found in the provided block library. Entry ID: , V1.2, 12/

62 WARNING Inappropriate values for safety-related settings may result in the safety function not being triggered in the event of danger. Please keep this in mind if, due to your requirements, you want to change the settings shown here. For more information on the hardware configuration in this user scenario, please refer to chapter Operation of the user scenario For demonstration purposes, this document shows different user scenarios. These scenarios can also be used as verification steps for validation. For information on installing the user scenario, please refer to chapter Requirements: No faults Emergency stop released Table 6-33 Start actuator No. Action Comment 1 Press ack Acknowledgment mandatory when starting the scenario for the first time 2 Press start signalpldsil2quality=1 3 Press stop signalpldsil2quality=0 Table 6-34 Safety function: Trigger emergency stop No. Action Comment 1 Press ack Acknowledgment mandatory when starting the scenario for the first time 2 Press start signalpldsil2quality=1 3 Press the emergency stop (estop) signalpldsil2quality=0 4 Release the emergency stop (estop) 5 Press start signalpldsil2quality=0 (acknowledgment required) 6 Start again with no. 1 Entry ID: , V1.2, 12/

63 6.7 User Scenario 6: Emergency Stop at PL c/sil 1, Electric Actuator Safety function The safety function is as follows: Pressing the emergency stop button safely shuts down the actuator Hardware and software components You need the hardware and software components listed below. Hardware components Table 6-35 Hardware Component No. Article number CPU 1215FC DC/DC/RLY SM 1226 F- DI8/16x24VDC SM 1226 F-DQ 4x24VDC Enclosed pushbutton (NO) Enclosed pushbutton (NC) Emergency stop pushbutton (NC) 1 6ES7215-1HF40-0XB0 1 6ES7226-6BA32-0XB0 1 6ES DA32-0XB0 2 3SB3801-0DD3 1 3SB3801-0DB3 1 3SB3801-0DG3 Software components Table 6-36 Software Component No. Article number STEP 7 Basic 1 6ES7822-0AA03-0YA5 Or STEP 7 Professional STEP 7 Safety Basic V13 SP1 1 6ES7833-1FB13-0YA5 Or STEP 7 Safety Advanced Entry ID: , V1.2, 12/

64 6.7.3 Wiring The figure below shows the wiring of the hardware components. Figure 6-32 Emergency stop PL c/sil 1 wiring 24V DC M stop start ack L1 M L+ L+ M Vs signalplcsil1quality 0- estop For the actuators used in this user scenario, please also refer to chapter Entry ID: , V1.2, 12/

65 6.7.4 Brief description of the core functionality The following flowchart provides a concise description of the core functionality. Figure 6-33 Core functionality Start Actuator switches off Yes E-stop pressed? E-stop released? Yes No No Stop caused by e-stop or 1 st start? Yes No Acknowledge Actuator switches off Yes Operational stop? Start conditions are complied No Actuator on Description of the user block FB F06EStopSIL1PLc Figure 6-34 F-user FB F06EStopSIL1PLc Entry ID: , V1.2, 12/

66 NOTICE For F-blocks, the enable input (EN) must not be wired. The following section describes the inputs and outputs of FB F06EStopSIL1PLc. NO: normally open (contact); NC: normally closed (contact) Table 6-37 Inputs of FB F06EStopSIL1PLc Description Symbol Data type Convention Acknowledgment ack BOOL NO 1: Acknowledgment Start request start BOOL NO 1: Start request Stop request stop BOOL NC 0: Stop request Emergency stop pushbutton Value status of output signalplcsil1quality estop BOOL NC 0: Emergency stop triggered signalplcsil1qualityvs BOOL 0: Fault Positive edge required after triggering the safety function to reintegrate F- I/O Table 6-38 Outputs of FB F06EStopSIL1PLc Description Symbol Data type Convention Output signal from the F-DQ to the electric actuator Release emergency stop Acknowledgment required signalplcsil1quality BOOL 1: F-DQ output set releaseestop BOOL 1: Emergency stop released and acknowledged AckReqEStop BOOL 1: Acknowledgment required Information of the F-library blocks. Can be read out, for example, in the standard user program. Entry ID: , V1.2, 12/

67 6.7.6 Configuration and parameterization The STEP 7 hardware configuration (HW Config) has already been prepared for commissioning FB F06EStopSIL1PLc. Customizations are possible. The associated HW Config can be found in the provided block library. WARNING Inappropriate values for safety-related settings may result in the safety function not being triggered in the event of danger. Please keep this in mind if, due to your requirements, you want to change the settings shown here. For more information on the hardware configuration in this user scenario, please refer to chapter Operation of the user scenario For demonstration purposes, this document shows different user scenarios. These scenarios can also be used as verification steps for validation. For information on installing the user scenario, please refer to chapter Requirements: No faults Table 6-39 Start actuator Emergency stop released No. Action Comment 1 Press ack Acknowledgment mandatory when starting the scenario for the first time 2 Press start signalplcsil1quality=1 3 Press stop signalplcsil1quality=0 Table 6-40 Safety function: Trigger emergency stop No. Action Comment 1 Press ack Acknowledgment mandatory when starting the scenario for the first time 2 Press start signalplcsil1quality=1 3 Press the emergency stop (estop) signalplcsil1quality=0 4 Release the emergency stop (estop) 5 Press start signalplcsil1quality=0 (acknowledgment required) 6 Start again with no. 1 Entry ID: , V1.2, 12/

68 6.8 User Scenario 7: Safety Door without Guard Locking at PL e/sil 3, Electromechanical Actuator Safety function The safety function is as follows: Opening the safety door safely shuts down the actuator Hardware and software components You need the hardware and software components listed below. Hardware components Table 6-41 Hardware Component No. Article number CPU 1215FC DC/DC/RLY SM 1226 F- DI8/16x24VDC SM 1226 F-DQ 4x24VDC Enclosed pushbutton (NO) Enclosed pushbutton (NC) Position switch without tumbler Actuator for position switch 1 6ES7215-1HF40-0XB0 1 6ES7226-6BA32-0XB0 1 6ES DA32-0XB0 2 3SB3801-0DD3 1 3SB3801-0DB3 2 3SE5132-1QV20 2 3SE5000-0AV0 Contactors 2 3RT2015-2BB42 Software components Table 6-42 Software Component No. Article number STEP 7 Basic 1 6ES7822-0AA03-0YA5 Or STEP 7 Professional STEP 7 Safety Basic V13 SP1 1 6ES7833-1FB13-0YA5 Or STEP 7 Safety Advanced Entry ID: , V1.2, 12/

69 6.8.3 Wiring The figure below shows the wiring of the hardware components. Figure 6-35 Safety door without guard locking PL e/sil 3 wiring 24V DC M stop start ack L1 M K2 K1 L+.3.4 L+ M Vs1.0 K1 0+ K2 0- posswitch2 posswitch1 In the F-program, the NC auxiliary contacts of the contactors K1 and K2 are termed feedback1 and feedback2. Entry ID: , V1.2, 12/

70 6.8.4 Brief description of the core functionality Before starting the scenario for the first time, open and close the safety door once. Then acknowledge with ACK=1. Figure 6-36 Safety door without guard locking core functionality Start Actuators switch off Yes No Safety door open? Safety door closed? Yes No Actuators switch off Yes Operational stop? No No Safety door closed? Acknowledge Yes Start conditions are complied Actuators on Entry ID: , V1.2, 12/

71 6.8.5 Description of the user block FB F07FDoorSIL3PLe Figure 6-37 F-user FB F07FDoorSIL3PLe NOTICE For F-blocks, the enable input (EN) must not be wired. Parameter description The following section describes the inputs and outputs of FB F07FDoorSIL3PLe. NO: normally open (contact); NC: normally closed (contact) Table 6-43 Inputs of FB F07FDoorSIL3PLe Description Symbol Data type Convention Acknowledgment ack BOOL NO 1: Acknowledgment Start request start BOOL NO 1: Start request Stop request stop BOOL NC 0: Stop request Readback signal from auxiliary contact of contactor K1 Readback signal from auxiliary contact of contactor K2 readbackk1 readbackk2 BOOL BOOL NC 0: Contactor has picked up Position switch 1 posswitch1 BOOL NC 1: Actuator Positive edge required after triggering the safety function to reintegrate F-I/O Entry ID: , V1.2, 12/

72 Description Symbol Data type Convention inserted (safety door closed) Position switch 2 posswitch2 BOOL NC 1: Actuator inserted (safety door closed) Position switch 1 value status Position switch 2 value status posswitch1vs posswitch2vs BOOL BOOL Value status of output K1K2 K1K2VS BOOL Time between the control command and the response of the contactors feedbacktime TIME 0: Fault VS: value status Chapter Table 6-44 Outputs of FB F07FDoorSIL3PLe Description Symbol Data type Convention Contactors K1/K2 K1K2 BOOL 1: Control command for the contactors Release safety door Acknowledgment for safety door releasefdoor BOOL 1: With regard to safety door, start is possible (safety door closed) ackreqfdoor BOOL 1: Acknowledgment required Actuator on F-DQ Information of the F-library blocks. Can be read out, for example, in the standard user program Configuration and parameterization The STEP 7 hardware configuration (HW Config) has already been prepared for commissioning FB F07FDoorSIL3PLe. Customizations are possible. The associated HW Config can be found in the provided block library. WARNING Inappropriate values for safety-related settings may result in the safety function not being triggered in the event of danger. Please keep this in mind if, due to your requirements, you want to change the settings shown here. For more information on the hardware configuration in this user scenario, please refer to chapter Entry ID: , V1.2, 12/

73 6.8.7 Operation of the user scenario For demonstration purposes, this document shows different user scenarios. These scenarios can also be used as verification steps for validation. For information on installing the user scenario, please refer to chapter Requirements: No faults Table 6-45 Start actuator Safety door closed No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start K1K2 picks up 4 Press stop K1K2 drops out Table 6-46 Safety function: Safe shutdown when the safety door is opened No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start K1K2 picks up 4 Open the safety door K1K2 drops out 5 Close the safety door 6 Start again with no. 2 Table 6-47 Trigger readback error No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Acknowledgment mandatory when starting the scenario for the first time 3 Press start K1K2 picks up 4 Make sure that K1 or K2 does not drop out when shutting down Simulated welding of the contactor 5 Press stop Readback error is detected 6 Let the contactor drop out 7 Press start K1K2 does not pick up (acknowledgment Entry ID: , V1.2, 12/

74 No. Action Comment 8 Start with no. 2 required) 6.9 User Scenario 8: Safety Door without Guard Locking at PL d/sil 2, Electromechanical Actuator Safety function The safety function is as follows: Opening the safety door safely shuts down the actuator Hardware and software components You need the hardware and software components listed below. Hardware components Table 6-48 Hardware Component No. Article number CPU 1215FC DC/DC/RLY SM 1226 F- DI8/16x24VDC SM 1226 F-DQ 4x24VDC Enclosed pushbutton (NO) Enclosed pushbutton (NC) Position switch without tumbler Actuator for position switch 1 6ES7215-1HF40-0XB0 1 6ES7226-6BA32-0XB0 1 6ES DA32-0XB0 2 3SB3801-0DD3 1 3SB3801-0DB3 2 3SE5132-1QV20 2 3SE5000-0AV0 Contactors 2 3RT2015-2BB42 Software components Table 6-49 Software Component No. Article number STEP 7 Basic 1 6ES7822-0AA03-0YA5 Or STEP 7 Professional STEP 7 Safety Basic V13 SP1 1 6ES7833-1FB13-0YA5 Or STEP 7 Safety Advanced Entry ID: , V1.2, 12/

75 6.9.3 Wiring The figure below shows the wiring of the hardware components. Figure 6-38 Safety door without guard locking PL d/sil 2 wiring 24V DC M stop start ack L1 M K2 K1 L+.3.4 L+ M Vs1.0 K1 0+ K2 0- posswitch2 posswitch1 In the F-program, the NC auxiliary contacts of the contactors K1 and K2 are termed feedback1 and feedback2. Entry ID: , V1.2, 12/

76 6.9.4 Brief description of the core functionality Before starting the scenario for the first time, open and close the safety door once. Then acknowledge with ACK=1. Figure 6-39 Safety door without guard locking core functionality Start Actuators switch off Yes No Safety door open? Safety door closed? Yes No Actuators switch off Yes Operational stop? No No Safety door closed? Acknowledge Yes Start conditions are complied Actuators on Entry ID: , V1.2, 12/

77 6.9.5 Description of the user block FB F08FDoorSIL2PLd Figure 6-40 F-user FB F08FDoorSIL2PLd NOTICE For F-blocks, the enable input (EN) must not be wired. The following section describes the inputs and outputs of FB F08FDoorSIL2PLd. NO: normally open (contact); NC: normally closed (contact) Table 6-50 Inputs of FB F09FDoorSIL1PLc Description Symbol Data type Convention Acknowledgment ack BOOL NO 1: Acknowledgment Start request start BOOL NO 1: Start request Stop request stop BOOL NC 0: Stop request Readback signal from auxiliary contact of contactor K1 Readback signal from auxiliary contact of contactor K2 readbackk1 readbackk2 BOOL BOOL NC 0: Contactor has picked up Position switch 1 posswitch1 BOOL NC 1: Actuator inserted (safety door closed) Positive edge required after triggering the safety function to reintegrate F-I/O Entry ID: , V1.2, 12/

78 Description Symbol Data type Convention Position switch 2 posswitch2 BOOL NC 1: Actuator inserted (safety door closed) Position switch 1 value status Position switch 2 value status posswitch1vs posswitch2vs BOOL BOOL Value status of output K1K2 K1K2VS BOOL Time between the control command and the response of the contactors feedbacktime TIME 0: Fault VS: value status Chapter Table 6-51 Outputs of FB F08FDoorSIL2PLd Description Symbol Data type Convention Contactors K1/K2 K1K2 BOOL 1: Control command for the contactors Release safety door Acknowledgment for safety door releasefdoor BOOL 1: With regard to safety door, start is possible (safety door closed) ackreqfdoor BOOL 1: Acknowledgment required Actuator on F-DQ Information of the F-library blocks. Can be read out, for example, in the standard user program Configuration and parameterization The STEP 7 hardware configuration (HW Config) has already been prepared for commissioning FB F08FDoorSIL2PLd. Customizations are possible. The associated HW Config can be found in the provided block library. WARNING Inappropriate values for safety-related settings may result in the safety function not being triggered in the event of danger. Please keep this in mind if, due to your requirements, you want to change the settings shown here. For more information on the hardware configuration in this user scenario, please refer to chapter Entry ID: , V1.2, 12/

79 6.9.7 Operation of the user scenario For demonstration purposes, this document shows different user scenarios. These scenarios can also be used as verification steps for validation. For information on installing the user scenario, please refer to chapter Requirements: No faults Safety door closed Table 6-52 Start actuator No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start K1K2 picks up 4 Press stop K1K2 drops out Table 6-53 Safety function: Safe shutdown when the safety door is opened No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start K1K2 picks up 4 Open the safety door K1K2 drops out 5 Close the safety door 6 Start again with no. 2 Table 6-54 Trigger readback error No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Acknowledgment mandatory when starting the scenario for the first time 3 Press start K1K2 picks up 4 Make sure that K1 or K2 does not drop out when shutting down Simulated welding of the contactor 5 Press stop Readback error is detected 6 Let the contactor drop out Entry ID: , V1.2, 12/

80 No. Action Comment 7 Press start K1K2 does not pick up (acknowledgment required) 8 Start with no User Scenario 9: Safety Door without Guard Locking at PL c/sil 1, Electromechanical Actuator Safety function The safety function is as follows: Opening the safety door safely shuts down the actuator Hardware and software components You need the hardware and software components listed below. Hardware components Table 6-55 Hardware Component No. Article number CPU 1215FC DC/DC/RLY SM 1226 F- DI8/16x24VDC SM 1226 F-DQ 4x24VDC Enclosed pushbutton (NO) Enclosed pushbutton (NC) Position switch without tumbler Actuator for position switch 1 6ES7215-1HF40-0XB0 1 6ES7226-6BA32-0XB0 1 6ES DA32-0XB0 2 3SB3801-0DD3 1 3SB3801-0DB3 1 3SE5132-1QV20 1 3SE5000-0AV0 Contactors 1 3RT2015-2BB42 Software components Table 6-56 Software Component No. Article number STEP 7 Basic 1 6ES7822-0AA03-0YA5 Or STEP 7 Professional STEP 7 Safety Basic V13 SP1 1 6ES7833-1FB13-0YA5 Or STEP 7 Safety Advanced Entry ID: , V1.2, 12/

81 Wiring The figure below shows the wiring of the hardware components. Figure 6-41 Safety door without guard locking PL c/sil 1 wiring 24V DC M stop start ack L1 M K1 L+.3 L+ M Vs1.0 K posswitch In the F-program, the auxiliary contact of contactor K1 is termed feedback. Due to the use of the FB FDBACK F-library block, it is useful to monitor readback. Basically, monitoring the readback signals is not required for PL c/sil 1. Entry ID: , V1.2, 12/

82 Brief description of the core functionality Before starting the scenario for the first time, open and close the safety door once. Then acknowledge with ACK=1. Figure 6-42 Safety door without guard locking core functionality Start Actuator switches off Yes No Safety door open? Safety door closed? Yes No Actuator switches off Yes Operational stop? No No Safety door closed? Acknowledge Yes Start conditions are complied Actuator on Entry ID: , V1.2, 12/

83 Description of the user block FB F09FDoorSIL1PLc Figure 6-43 F-user FB F09FDoorSIL1PLc NOTICE For F-blocks, the enable input (EN) must not be wired. The following section describes the inputs and outputs of FB F09FDoorSIL1PLc. NO: normally open (contact); NC: normally closed (contact) Table 6-57 Inputs of FB F09FDoorSIL1PLc Description Symbol Data type Convention Acknowledgment ack BOOL NO 1: Acknowledgment Start request start BOOL NO 1: Start request Stop request stop BOOL NC 0: Stop request Readback signal from auxiliary contact of contactor K1 readbackk1 BOOL NC 0: Contactor has picked up Position switch posswitch BOOL NC 1: Actuator inserted (safety door closed) Position switch value status posswitch1vs BOOL Value status of output K1 K1VS BOOL Time between the control command and the response of the contactor feedbacktime TIME 0: Fault Positive edge required after triggering the safety function to reintegrate F-I/O VS: value status Chapter Entry ID: , V1.2, 12/

84 Table 6-58 Outputs of FB F08FDoorSIL2PLd Description Symbol Data type Convention Contactor K1 K1 BOOL 1: Actuator switched (contactor has picked up) Release safety door Acknowledgment for safety door releasefdoor BOOL 1: With regard to safety door, start is possible (safety door closed) ackreqfdoor BOOL 1: Acknowledgment required Actuator on F-DQ Information of the F-library blocks. Can be read out, for example, in the standard user program Configuration and parameterization The STEP 7 hardware configuration (HW Config) has already been prepared for commissioning FB F09FDoorSIL1PLc. Customizations are possible. The associated HW Config can be found in the provided block library. WARNING Inappropriate values for safety-related settings may result in the safety function not being triggered in the event of danger. Please keep this in mind if, due to your requirements, you want to change the settings shown here. For more information on the hardware configuration in this user scenario, please refer to chapter Operation of the user scenario For demonstration purposes, this document shows different user scenarios. These scenarios can also be used as verification steps for validation. For information on installing the user scenario, please refer to chapter Requirements: No faults Safety door closed Entry ID: , V1.2, 12/

85 Table 6-59 Start actuator No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start K1 picks up 4 Press stop K1 drops out Table 6-60 Safety function: Safe shutdown when the safety door is opened No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start K1 picks up 4 Open the safety door K1 drops out 5 Close the safety door 6 Start again with no. 2 Table 6-61 Trigger readback error No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Acknowledgment mandatory when starting the scenario for the first time 3 Press start K1 picks up 4 Make sure that K1 does not drop out when shutting down Simulated welding of the contactor 5 Press stop Readback error is detected 6 Let the contactor drop out 7 Press start K1 does not pick up (acknowledgment required) 8 Start with no. 2 Entry ID: , V1.2, 12/

86 6.11 User Scenario 10: Safety Door without Guard Locking at PL e/sil 3, Electric Actuator Safety function The safety function is as follows: Opening the safety door safely shuts down the actuator Hardware and software components You need the hardware and software components listed below. Hardware components Table 6-62 Hardware Component No. Article number CPU 1215FC DC/DC/RLY SM 1226 F- DI8/16x24VDC SM 1226 F-DQ 4x24VDC Enclosed pushbutton (NO) Enclosed pushbutton (NC) Position switch without tumbler Actuator for position switch 1 6ES7215-1HF40-0XB0 1 6ES7226-6BA32-0XB0 1 6ES DA32-0XB0 2 3SB3801-0DD3 1 3SB3801-0DB3 2 3SE5132-1QV20 2 3SE5000-0AV0 Software components Table 6-63 Software Component No. Article number STEP 7 Basic 1 6ES7822-0AA03-0YA5 Or STEP 7 Professional STEP 7 Safety Basic V13 SP1 1 6ES7833-1FB13-0YA5 Or STEP 7 Safety Advanced Entry ID: , V1.2, 12/

87 Wiring The figure below shows the wiring of the hardware components. Figure 6-44 Safety door without guard locking PL e/sil 3 wiring 24V DC M stop start ack L1 M L+ L+ M Vs signalplesil3quality 0-.0 Vs2 posswitch2 posswitch1 For the actuators used in this user scenario, please also refer to chapter Entry ID: , V1.2, 12/

88 Brief description of the core functionality Before starting the scenario for the first time, open and close the safety door once. Then acknowledge with ACK=1. Figure 6-45 Safety door without guard locking core functionality Start Actuators switch off Yes No Safety door open? Safety door closed? Yes No Actuators switch off Yes Operational stop? No No Safety door closed? Acknowledge Yes Start conditions are complied Actuators on Entry ID: , V1.2, 12/

89 Description of the user block FB F10FDoorSIL3PLe Figure 6-46 F-user FB F10FDoorSIL3PLe NOTICE For F-blocks, the enable input (EN) must not be wired. Parameter description The following section describes the inputs and outputs of FB F10FDoorSIL3PLe. NO: normally open (contact); NC: normally closed (contact) Table 6-64 Inputs of FB F10FDoorSIL3PLe Description Symbol Data type Convention Acknowledgment ack BOOL NO 1: Acknowledgment Start request start BOOL NO 1: Start request Stop request stop BOOL NC 0: Stop request Position switch 1 posswitch1 BOOL NC 1: Actuator inserted (safety door closed) Position switch 2 posswitch2 BOOL NC 1: Actuator inserted (safety Positive edge required after triggering the safety function to reintegrate F-I/O Entry ID: , V1.2, 12/

90 Description Symbol Data type Position switch 1 value status Position switch 2 value status Value status of output signalplesil3quality posswitch1vs posswitch2vs signalplesil3qualityvs BOOL BOOL BOOL Convention door closed) 0: Fault VS: value status Chapter Table 6-65 Outputs of FB F10FDoorSIL3PLe Description Symbol Data type Convention Output signal from the F-DQ to the electric actuator Release safety door Acknowledgment for safety door signalplesil3quality BOOL 1: F-DQ output set releasefdoor BOOL 1: With regard to safety door, start is possible (safety door closed) ackreqfdoor BOOL 1: Acknowledgment required Information of the F-library blocks. Can be read out, for example, in the standard user program Configuration and parameterization The STEP 7 hardware configuration (HW Config) has already been prepared for commissioning FB FF10EStopSIL3PLe. Customizations are possible. The associated HW Config can be found in the provided block library. WARNING Inappropriate values for safety-related settings may result in the safety function not being triggered in the event of danger. Please keep this in mind if, due to your requirements, you want to change the settings shown here. For more information on the hardware configuration in this user scenario, please refer to chapter Entry ID: , V1.2, 12/

91 Operation of the user scenario For demonstration purposes, this document shows different user scenarios. These scenarios can also be used as verification steps for validation. For information on installing the user scenario, please refer to chapter Requirements: No faults Safety door closed Table 6-66 Start actuator No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start signalplesil3quality =1 4 Press stop signalplesil3quality = 0 Table 6-67 Safety function: Safe shutdown when the safety door is opened No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start signalplesil3quality = 1 4 Open the safety door signalplesil3quality =0 5 Close the safety door 6 Start again with no. 2 Entry ID: , V1.2, 12/

92 6.12 User Scenario 11: Safety Door without Guard Locking at PL d/sil 2, Electric Actuator You are using a drive as an actuator. Please also follow the information in chapter Safety function The safety function is as follows: Opening the safety door safely shuts down the actuator Hardware and software components You need the hardware and software components listed below. Hardware components Table 6-68 Hardware Component No. Article number CPU 1215FC DC/DC/RLY SM 1226 F- DI8/16x24VDC SM 1226 F-DQ 4x24VDC Enclosed pushbutton (NO) Enclosed pushbutton (NC) Position switch without tumbler Actuator for position switch 1 6ES7215-1HF40-0XB0 1 6ES7226-6BA32-0XB0 1 6ES DA32-0XB0 2 3SB3801-0DD3 1 3SB3801-0DB3 2 3SE5132-1QV20 2 3SE5000-0AV0 Software components Table 6-69 Software Component No. Article number STEP 7 Basic 1 6ES7822-0AA03-0YA5 Or STEP 7 Professional STEP 7 Safety Basic V13 SP1 1 6ES7833-1FB13-0YA5 Or STEP 7 Safety Advanced Entry ID: , V1.2, 12/

93 Wiring The figure below shows the wiring of the hardware components. Figure 6-47 Safety door without guard locking PL d/sil 2 wiring 24V DC M stop start ack L1 M L+ L+ M Vs signalpldsil2quality 0- Vs2.0 posswitch2 posswitch1 For the actuators used in this user scenario, please also refer to chapter Entry ID: , V1.2, 12/

94 Brief description of the core functionality The following flowchart provides a concise description of the core functionality. Before starting the scenario for the first time, open and close the safety door once. Then acknowledge with ACK=1. Figure 6-48 Safety door without guard locking core functionality Start Actuators switch off Yes No Safety door open? Safety door closed? Yes No Actuators switch off Yes Operational stop? No No Safety door closed? Acknowledge Yes Start conditions are complied Actuators on Entry ID: , V1.2, 12/

95 Description of the user block FB F11FDoorSIL2PL Figure 6-49 F-user FB F11FDoorSIL2PL NOTICE For F-blocks, the enable input (EN) must not be wired. Parameter description The following section describes the inputs and outputs of FB F11FDoorSIL2PL. NO: normally open (contact); NC: normally closed (contact) Table 6-70 Inputs of FB F11FDoorSIL2PL Description Symbol Data type Convention Acknowledgment ack BOOL NO 1: Acknowledgment Start request start BOOL NO 1: Start request Stop request stop BOOL NC 0: Stop request Position switch 1 posswitch1 BOOL NC 1: Actuator inserted (safety door closed) Position switch 2 posswitch2 BOOL NC 1: Actuator inserted (safety Positive edge required after triggering the safety function to reintegrate F-I/O Entry ID: , V1.2, 12/

96 Description Symbol Data type Position switch 1 value status Position switch 2 value status Value status of output signalpldsil2quality posswitch1vs posswitch2vs signalpldsil2qualityvs BOOL BOOL BOOL Convention door closed) 0: Fault VS: value status Chapter Table 6-71 Outputs of FB F11FDoorSIL2PLd Description Symbol Data type Convention Output signal from the F-DQ to the electric actuator Release safety door Acknowledgment for safety door signalpldsil2quality BOOL 1: F-DQ output set releasefdoor BOOL 1: With regard to safety door, start is possible (safety door closed) ackreqfdoor BOOL 1: Acknowledgment required Information of the F-library blocks. Can be read out, for example, in the standard user program Configuration and parameterization The STEP 7 hardware configuration (HW Config) has already been prepared for commissioning FB F11FDoorSIL2PLd. Customizations are possible. The associated HW Config can be found in the provided block library. WARNING Inappropriate values for safety-related settings may result in the safety function not being triggered in the event of danger. Please keep this in mind if, due to your requirements, you want to change the settings shown here. For more information on the hardware configuration in this user scenario, please refer to chapter Entry ID: , V1.2, 12/

97 Operation of the user scenario For demonstration purposes, this document shows different user scenarios. These scenarios can also be used as verification steps for validation. For information on installing the user scenario, please refer to chapter Requirements: No faults Safety door closed Table 6-72 Start actuator No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start signalpldsil2quality =1 4 Press stop signalpldsil2quality = 0 Table 6-73 Safety function: Safe shutdown when the safety door is opened No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start signalpldsil2quality = 1 4 Open the safety door signalpldsil2quality = 0 5 Close the safety door 6 Start again with no. 2 Entry ID: , V1.2, 12/

98 6.13 User Scenario 12: Safety Door without Guard Locking at PL c/sil 1, Electric Actuator Safety function The safety function is as follows: Opening the safety door safely shuts down the actuator Hardware and software components You need the hardware and software components listed below. Hardware components Table 6-74 Hardware Component No. Article number CPU 1215FC DC/DC/RLY SM 1226 F- DI8/16x24VDC SM 1226 F-DQ 4x24VDC Enclosed pushbutton (NO) Enclosed pushbutton (NC) Position switch without tumbler Actuator for position switch 1 6ES7215-1HF40-0XB0 1 6ES7226-6BA32-0XB0 1 6ES DA32-0XB0 2 3SB3801-0DD3 1 3SB3801-0DB3 1 3SE5132-1QV20 1 3SE5000-0AV0 Software components Table 6-75 Software Component No. Article number STEP 7 Basic 1 6ES7822-0AA03-0YA5 Or STEP 7 Professional STEP 7 Safety Basic V13 SP1 1 6ES7833-1FB13-0YA5 Or STEP 7 Safety Advanced Entry ID: , V1.2, 12/

99 Wiring The figure below shows the wiring of the hardware components. Figure 6-50 Safety door without guard locking PL c/sil 1 wiring 24V DC M stop start ack L1 M L+ L+ M Vs signalplcsil1quality 0- posswitch For the actuators used in this user scenario, please also refer to chapter Entry ID: , V1.2, 12/

100 Brief description of the core functionality The following flowchart provides a concise description of the core functionality. Before starting the scenario for the first time, open and close the safety door once. Then acknowledge with ACK=1. Figure 6-51 Safety door without guard locking core functionality Start Actuator switches off Yes No Safety door open? Safety door closed? Yes No Actuator switches off Yes Operational stop? No No Safety door closed? Acknowledge Yes Start conditions are complied Actuator on Entry ID: , V1.2, 12/

101 Description of the user block FB F12FDoorSIL1PLc Figure 6-52 F-user FB F12FDoorSIL1PLc NOTICE For F-blocks, the enable input (EN) must not be wired. Parameter description The following section describes the inputs and outputs of FB F12FDoorSIL1PLc. NO: normally open (contact); NC: normally closed (contact) Table 6-76 Inputs of FB F12FDoorSIL1PLc Description Symbol Data type Convention Acknowledgment ack BOOL NO 1: Acknowledgment Start request start BOOL NO 1: Start request Stop request stop BOOL NC 0: Stop request Position switch posswitch BOOL NC 1: Actuator inserted (safety door closed) Positive edge required after triggering the safety function to reintegrate F-I/O Entry ID: , V1.2, 12/

102 Description Symbol Data type Convention Position switch 1 value status posswitchvs BOOL 0: Fault VS: value status Chapter Value status of output signalplcsil1quality signalplcsil1qualityvs BOOL Table 6-77 Outputs of FB F12FDoorSIL1PLc Description Symbol Data type Convention Output signal from the F-DQ to the electric actuator Release safety door Acknowledgment for safety door signalplcsil1quality BOOL 1: F-DQ output set releasefdoor BOOL 1: With regard to safety door, start is possible (safety door closed) ackreqfdoor BOOL 1: Acknowledgment required Information of the F-library blocks. Can be read out, for example, in the standard user program Configuration and parameterization The STEP 7 hardware configuration (HW Config) has already been prepared for commissioning FB F12FDoorSIL1PLc. Customizations are possible. The associated HW Config can be found in the provided block library. WARNING Inappropriate values for safety-related settings may result in the safety function not being triggered in the event of danger. Please keep this in mind if, due to your requirements, you want to change the settings shown here. For more information on the hardware configuration in this user scenario, please refer to chapter Entry ID: , V1.2, 12/

103 Operation of the user scenario For demonstration purposes, this document shows different user scenarios. These scenarios can also be used as verification steps for validation. For information on installing the user scenario, please refer to chapter Requirements: No faults Safety door closed Table 6-78 Start actuator No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start signalplcsil1quality = 1 4 Press stop signalplcsil1quality = 0 Table 6-79 Safety function: Safe shutdown when the safety door is opened No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start signalplcsil1quality = 1 4 Open the safety door signalplcsil1quality = 0 5 Close the safety door 6 Start again with no. 2 Entry ID: , V1.2, 12/

104 6.14 User Scenario 13: Safety Door with Guard Locking at PL e/sil 3, Electromechanical Actuator Safety functions This user scenario has the following safety functions: Safety function with regard to opening/closing the safety door Opening the safety door during operation safely shuts down the actuator. Safety function with regard to guard locking After shutdown of the actuator, the safety door may only be opened when the actuator no longer constitutes a hazard. Under Normative assessment of guard locking, chapter addresses the situation where there is a safety function with regard to guard locking Hardware and software components Hardware components You need the hardware and software components listed below. Table 6-80 Hardware Component No. Article number CPU 1215FC DC/DC/RLY SM 1226 F- DI8/16x24VDC SM 1226 F-DQ 4x24VDC Enclosed pushbutton (NO) Enclosed pushbutton (NC) Position switch with solenoid interlocking (spring-locked) 1 6ES7215-1HF40-0XB0 1 6ES7226-6BA32-0XB0 1 6ES DA32-0XB0 2 3SB3801-0DD3 1 3SB3801-0DB3 1 3SE5322-0SD21 Hinge switch 1 3SE5132-0LU21 Actuator for position switch 1 3SE5000-0AV0 Contactors 2 3RT2015-2BB42 Entry ID: , V1.2, 12/

105 Software components Table 6-81 Software Component No. Article number STEP 7 Basic 1 6ES7822-0AA03-0YA5 Or STEP 7 Professional STEP 7 Safety Basic V13 SP1 1 6ES7833-1FB13-0YA5 Or STEP 7 Safety Advanced Wiring The figure below shows the wiring of the hardware components. Figure 6-53 Safety door with guard locking PL e/sil 3 wiring 24V DC M stop start ack L+.5 M L1 M K2.4 K1 0+ L+ Vs1 K1 K2.3 emagnet fdoorcoil.0 Vs2 hingedswitch sepact In the F-program, the NC auxiliary contacts of the contactors K1 and K2 are termed feedback1 and feedback2. The following signals from the above connection diagram are connected to the position switch (sepact): sepact (monitoring of the actuator position) sepact (monitoring of the locking device position) Entry ID: , V1.2, 12/

106 fdoorcoil (control of guard locking) The following figure shows the wiring on the position switch and therefore complements the above connection diagram. Figure 6-54 Internal terminals of the position switch with solenoid interlocking sepact (F-DI) CH + (F-DQ) emagnet (Standard-DI) Vs1 (F-DI) L+ (F-CPU) CH (F-DQ) Entry ID: , V1.2, 12/

107 Brief description of the core functionality The following flowchart provides a concise description of the core functionality. Before starting the scenario for the first time, open and close the safety door once. Then acknowledge with ACK=1. Figure 6-55 Safety door with guard locking core functionality Start Safety door closed? Yes No No Stop request? Yes Actuators stop Previous stop was operational stop? No Yes Timer starts Acknowledge Unlock No timer expired? Yes Start conditions are complied Safety door interlocking is released Actuators on Entry ID: , V1.2, 12/

108 WARNING In this example for electromechanical actuators, the safety door s guard locking is deactivated when the timer has expired. For moving parts, a hazard cannot be automatically ruled out when the timer has expired. Make sure that the safety door s guard locking is deactivated only when a hazard no longer exists Description of the user block FB F13FDoorSIL3PLe Figure 6-56 F-user FB F13FDoorSIL3PLe NOTICE For F-blocks, the enable input (EN) must not be wired. This example assumes that you are using a hinge switch (hingedswitch) as a second channel. However, it is not mandatory to use a hinge switch. The required dual-channel redundancy can also be implemented with a different switch. WARNING Death or severe personal injury may result if you select a delaytimeunlock time that is too short. Customize these times to your requirements, for example to the slow-down time of a hazardous machine, to release the safety door when the delaytimeunlock time has expired. Entry ID: , V1.2, 12/

109 Parameter description The following section describes the inputs and outputs of FB F13FDoorSIL3PLe. NO: normally open (contact); NC: normally closed (contact) Table 6-82 Inputs of FB F13FDoorSIL3PLe Description Symbol Data type Convention Acknowledgment ack BOOL NO 1: Acknowledgment Start request start BOOL NO 1: Start request Stop request stop BOOL NC 0: Stop request Monitoring of magnet in position switch Readback signal from auxiliary contact of contactor K1 Readback signal from auxiliary contact of contactor K2 emagnet BOOL NC 0: Magnet in position switch energized 1: Magnet in position switch de-energized readbackk1 readbackk2 BOOL BOOL NC 0: Contactor has picked up Position switch sepact BOOL NC 1: Actuator inserted (safety door closed) Hinge switch hingedswitch BOOL NC 1: Unoperated (safety door closed) Position switch value status sepactvs BOOL Hinge switch value status hingedswitchvs BOOL Value status of output K1K2 K1K2VS BOOL Value status of output fdoorcoil Time between the control command and the response of the contactors Time delay after shutdown of the actuators to release the safety door. fdoorcoilvs feedbacktime BOOL TIME 0: Fault Positive edge required after triggering the safety function to reintegrate F-I/O Chapter Chapter VS: value status Chapter delaytimeunlock TIME Choose a time which is long enough Entry ID: , V1.2, 12/

110 Table 6-83 Outputs of FB F13FDoorSIL3PLe Description Symbol Data type Convention Contactors K1/K2 K1K2 BOOL 1: Control command for the contactors Magnet in the position switch Release safety door Acknowledgment for safety door fdoorcoil BOOL 0: Guard locking active releasefdoor BOOL 1: With regard to safety door, start is possible (safety door closed) ackreqfdoor BOOL 1: Acknowledgment required Actuator on F-DQ Information of the F-library blocks. Can be read out, for example, in the standard user program Configuration and parameterization The STEP 7 hardware configuration (HW Config) has already been prepared for commissioning FB F13FDoorSIL3PL3. Customizations are possible. The associated HW Config can be found in the provided block library. WARNING Inappropriate values for safety-related settings may result in the safety function not being triggered in the event of danger. Please keep this in mind if, due to your requirements, you want to change the settings shown here. For more information on the hardware configuration in this user scenario, please refer to chapter Operation of the user scenario For demonstration purposes, this document shows different user scenarios. These scenarios can also be used as verification steps for validation. For information on installing the user scenario, please refer to chapter Requirements: No faults Safety door closed Entry ID: , V1.2, 12/

111 Table 6-84 Start actuator No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start Guard locking is activated, then K1K2 picks up 4 Press stop K1K2 drops out; then the timer for the delayed release of the safety door starts. 5 Wait until the timer expires. When the timer has expired, the safety door can be opened. Table 6-85 Safety function: Safety door fault No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start Guard locking is activated, then K1K2 picks up 4 Turn the hinge switch until it outputs 0 signal. K1K2 drops out; then the timer for the delayed release of the safety door starts. 5 Wait until the timer expires. When the timer has expired, the safety door can be opened. 6 Close the safety door 7 Start again with no. 1 Table 6-86 Trigger readback error No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Acknowledgment mandatory when starting the scenario for the first time 3 Press start K1K2 picks up 4 Make sure that K1 or K2 does not drop out when shutting down Simulated welding of the contactor 5 Press stop Readback error is detected 6 Let the contactor drop out 7 Press start K1K2 does not pick up (acknowledgment required) 8 Wait until the timer expires. 9 Start with no. 2 Entry ID: , V1.2, 12/

112 6.15 User Scenario 14: Safety Door with Guard Locking at PL d/sil 2, Electromechanical Actuator Safety function This user scenario has the following safety functions: Safety function with regard to the position of the safety door (interlocking) Opening the safety door during operation safely shuts down the actuator. Safety function with regard to guard locking After shutdown of the actuator, the safety door may only be opened when the actuator no longer constitutes a hazard. Under Normative assessment of guard locking, chapter addresses the situation where there is a safety function with regard to guard locking Hardware and software components Hardware components You need the hardware and software components listed below. Table 6-87 Hardware Component No. Article number CPU 1215FC DC/DC/RLY SM 1226 F- DI8/16x24VDC SM 1226 F-DQ 4x24VDC Enclosed pushbutton (NO) Enclosed pushbutton (NC) Position switch with solenoid interlocking (spring-locked) 1 6ES7215-1HF40-0XB0 1 6ES7226-6BA32-0XB0 1 6ES DA32-0XB0 2 3SB3801-0DD3 1 3SB3801-0DB3 1 3SE5322-0SD21 Hinge switch 1 3SE5132-0LU21 Actuator for position switch Software components 1 3SE5000-0AV0 Contactors 2 3RT2015-2BB42 Table 6-88 Software Component No. Article number STEP 7 Basic 1 6ES7822-0AA03-0YA5 Or STEP 7 Professional STEP 7 Safety 1 6ES7833-1FB13-0YA5 Or STEP 7 Safety Advanced Entry ID: , V1.2, 12/

113 Component No. Article number Basic V13 SP Wiring The figure below shows the wiring of the hardware components. Figure 6-57 Safety door with guard locking PL d/sil 2 wiring 24V DC M stop start ack L+.5 M L1 M K2.4 K1 0+ L+ Vs1 K1 K2.3 emagnet fdoorcoil.0 Vs2 hingedswitch sepact In the F-program, the NC auxiliary contacts of the contactors K1 and K2 are termed feedback1 and feedback2. Entry ID: , V1.2, 12/

114 In the safety program, the signals of the position switch are defined as follows: sepact (monitoring of the actuator position) sepact (monitoring of the locking device position) fdoorcoil (control of guard locking) The following figure shows the wiring on the position switch and therefore complements the above connection diagram. Figure 6-58 Internal terminals of the position switch with solenoid interlocking sepact (F-DI) CH + (F-DQ) emagnet (Standard-DI) Vs1 (F-DI) L+ (F-CPU) CH (F-DQ) Entry ID: , V1.2, 12/

115 Brief description of the core functionality The following flowchart provides a concise description of the core functionality. Before starting the scenario for the first time, open and close the safety door once. Then acknowledge with ACK=1. Figure 6-59 Safety door with guard locking core functionality Start Safety door closed? Yes No No Stop request? Yes Actuators stop Previous stop was operational stop? No Yes Timer starts Acknowledge Unlock No timer expired? Yes Start conditions are complied Safety door interlocking is released Actuators on Entry ID: , V1.2, 12/

116 WARNING In this example for electromechanical actuators, the safety door s guard locking is deactivated when the timer has expired. For moving parts, a hazard cannot be automatically ruled out when the timer has expired. Make sure that the safety door s guard locking is deactivated only when a hazard no longer exists Description of the user block FB F14FDoorSIL2PLd Figure 6-60 F-user FB F14FDoorSIL2PLd NOTICE For F-blocks, the enable input (EN) must not be wired. This example assumes that you are using a hinge switch (hingedswitch) as a second channel. However, it is not mandatory to use a hinge switch. The required dual-channel redundancy can also be implemented with a different switch. WARNING Death or severe personal injury may result if you select a delaytimeunlock time that is too short. Customize these times to your requirements, for example to the slow-down time of a hazardous machine, to release the safety door when the delaytimeunlock time has expired. Entry ID: , V1.2, 12/

117 Parameter description The following section describes the inputs and outputs of FB F14FDoorSIL2PLd. NO: normally open (contact); NC: normally closed (contact) Table 6-89 Inputs of FB F14FDoorSIL2PLd Description Symbol Data type Convention Acknowledgment ack BOOL NO 1: Acknowledgment Start request start BOOL NO 1: Start request Stop request stop BOOL NC 0: Stop request Monitoring of magnet in position switch Readback signal from auxiliary contact of contactor K1 Readback signal from auxiliary contact of contactor K2 emagnet BOOL NC 0: Magnet in position switch energized 1: Magnet in position switch de-energized readbackk1 readbackk2 BOOL BOOL NC 0: Contactor has picked up Position switch sepact BOOL NC 1: Actuator inserted (safety door closed) Hinge switch hingedswitch BOOL NC 1: Unoperated (safety door closed) Position switch value status sepactvs BOOL Hinge switch value status hingedswitchvs BOOL Value status of output K1K2 K1K2VS BOOL Value status of output fdoorcoil Time between the control command and the response of the contactors Time delay after shutdown of the actuators to release the safety door. fdoorcoilvs feedbacktime BOOL TIME 0: Fault Positive edge required after triggering the safety function to reintegrate F-I/O Chapter Chapter VS: value status Chapter delaytimeunlock TIME Choose a time which is long enough Entry ID: , V1.2, 12/

118 Table 6-90 Outputs of FB F14FDoorSIL2PLd Description Symbol Data type Convention Contactors K1/K2 K1K2 BOOL 1: Control command for the contactors Magnet in the position switch Release safety door Acknowledgment for safety door fdoorcoil BOOL 0: Guard locking active releasefdoor BOOL 1: With regard to safety door, start is possible (safety door closed) ackreqfdoor BOOL 1: Acknowledgment required Actuator on F-DQ Information of the F-library blocks. Can be read out, for example, in the standard user program Configuration and parameterization The STEP 7 hardware configuration (HW Config) has already been prepared for commissioning FB F14FDoorSIL2PLd. Customizations are possible. The associated HW Config can be found in the provided block library. WARNING Inappropriate values for safety-related settings may result in the safety function not being triggered in the event of danger. Please keep this in mind if, due to your requirements, you want to change the settings shown here. For more information on the hardware configuration in this user scenario, please refer to chapter Operation of the user scenario For demonstration purposes, this document shows different user scenarios. These scenarios can also be used as verification steps for validation. For information on installing the user scenario, please refer to chapter Requirements: No faults Safety door closed Entry ID: , V1.2, 12/

119 Table 6-91 Start actuator No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start Guard locking is activated, then K1K2 picks up 4 Press stop K1K2 drops out; then the timer for the delayed release of the safety door starts. 5 Wait until the timer expires. When the timer has expired, the safety door can be opened. Table 6-92 Safety function: Safety door fault No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start Guard locking is activated, then K1K2 picks up 4 Turn the hinge switch until it outputs 0 signal. K1K2 drops out; then the timer for the delayed release of the safety door starts. 5 Wait until the timer expires. When the timer has expired, the safety door can be opened. 6 Close the safety door 7 Start again with no. 1 Table 6-93 Trigger readback error No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Acknowledgment mandatory when starting the scenario for the first time 3 Press start K1K2 picks up 4 Make sure that K1 or K2 does not drop out when shutting down Simulated welding of the contactor 5 Press stop Readback error is detected 6 Let the contactor drop out 7 Press start K1K2 does not pick up (acknowledgment required) 8 Wait until the timer expires. 9 Start with no. 2 Entry ID: , V1.2, 12/

120 6.16 User Scenario 15: Safety Door with Guard Locking at PL c/sil 1, Electromechanical Actuator Safety function This user scenario has the following safety functions: Safety function with regard to the position of the safety door (interlocking) Opening the safety door during operation safely shuts down the actuator. Safety function with regard to guard locking After shutdown of the actuator, the safety door may only be opened when the actuator no longer constitutes a hazard. Under Normative assessment of guard locking, chapter addresses the situation where there is a safety function with regard to guard locking Hardware and software components You need the hardware and software components listed below. Hardware components Table 6-94 Hardware Component No. Article number CPU 1215FC DC/DC/RLY SM 1226 F- DI8/16x24VDC SM 1226 F-DQ 4x24VDC Enclosed pushbutton (NO) Enclosed pushbutton (NC) Position switch with solenoid interlocking (spring-locked) Actuator for position switch Software components 1 6ES7215-1HF40-0XB0 1 6ES7226-6BA32-0XB0 1 6ES DA32-0XB0 2 3SB3801-0DD3 1 3SB3801-0DB3 1 3SE5322-0SD21 1 3SE5000-0AV0 Contactors 1 3RT2015-2BB42 Table 6-95 Software Component No. Article number STEP 7 Basic 1 6ES7822-0AA03-0YA5 Or STEP 7 Professional STEP 7 Safety Basic V13 SP1 1 6ES7833-1FB13-0YA5 Or STEP 7 Safety Advanced Entry ID: , V1.2, 12/

121 Wiring The figure below shows the wiring of the hardware components. Figure 6-61 Safety door with guard locking PL c/sil 1 wiring 24V DC M stop start ack L+ M L1 M L+.4 K1 emagnet.3 Vs1.0 K fdoorcoil sepact In the F-program, the auxiliary contact of contactor K1 is termed feedback. In the safety program, the signals of the position switch are defined as follows: sepact (monitoring of the actuator position) sepact (monitoring of the locking device position) fdoorcoil (control of guard locking) Entry ID: , V1.2, 12/

122 The following figure shows the wiring on the position switch and therefore complements the above connection diagram. Figure 6-62 Internal terminals of the position switch with solenoid interlocking sepact (F-DI) CH + (F-DQ) emagnet (Standard-DI) Vs1 (F-DI) L+ (F-CPU) CH (F-DQ) Brief description of the core functionality The following flowchart provides a concise description of the core functionality. Before starting the scenario for the first time, open and close the safety door once. Then acknowledge with ACK=1. Entry ID: , V1.2, 12/

123 Figure 6-63 Safety door with guard locking core functionality Start Safety door closed? Yes No Stop request? Yes Actuator stops No Previous stop was operational stop? No Yes Timer starts Acknowledge Unlock No timer expired? Yes Start conditions are complied Safety door interlocking is released Actuator on WARNING In this example for electromechanical actuators, the safety door s guard locking is deactivated when the timer has expired. For moving parts, a hazard cannot be automatically ruled out when the timer has expired. Make sure that the safety door s guard locking is deactivated only when a hazard no longer exists. Entry ID: , V1.2, 12/

124 Description of the user block FB F15FDoorSIL1PLc Figure 6-64 F-user FB F15FDoorSIL1PLc NOTICE For F-blocks, the enable input (EN) must not be wired. Death or severe personal injury may result if you select a delaytimeunlock time that is too short. WARNING Customize these times to your requirements, for example to the slow-down time of a hazardous machine, to release the safety door when the delaytimeunlock time has expired. Parameter description The following section describes the inputs and outputs of FB F15FDoorSIL1PLc. NO: normally open (contact); NC: normally closed (contact) Table 6-96 Inputs of FB F15FDoorSIL1PLc Description Symbol Data type Convention Acknowledgment ack BOOL NO 1: Acknowledgment Start request start BOOL NO 1: Start request Positive edge required after triggering the safety function to reintegrate F-I/O Entry ID: , V1.2, 12/

125 Description Symbol Data type Convention Stop request stop BOOL NC 0: Stop request Monitoring of magnet in position switch Readback signal from auxiliary contact of contactor K1 emagnet BOOL NC 0: Magnet in position switch energized 1: Magnet in position switch de-energized readbackk1 BOOL NC 0: Contactor has picked up Position switch sepact BOOL NC 1: Actuator inserted (safety door closed) Chapter Chapter Position switch value status sepactvs BOOL 0: Fault Value status of output K1 K1VS BOOL Time between the control command and the response of the contactor Time delay after shutdown of the actuators to release the safety door. feedbacktime TIME VS: value status Chapter delaytimeunlock TIME Choose a time which is long enough Table 6-97 Outputs of FB F13FDoorSIL1PLc Description Symbol Data type Convention Contactor K1 K1 BOOL 1: Actuator switched (contactor has picked up) Magnet in the position switch Release safety door Acknowledgment for safety door fdoorcoil BOOL 0: Guard locking active releasefdoor BOOL 1: With regard to safety door, start is possible (safety door closed) ackreqfdoor BOOL 1: Acknowledgment required Actuator on F-DQ Information of the F-library blocks. Can be read out, for example, in the standard user program. Entry ID: , V1.2, 12/

126 Configuration and parameterization The STEP 7 hardware configuration (HW Config) has already been prepared for commissioning FB F15FDoorSIL1PLc. Customizations are possible. The associated HW Config can be found in the provided block library. WARNING Inappropriate values for safety-related settings may result in the safety function not being triggered in the event of danger. Please keep this in mind if, due to your requirements, you want to change the settings shown here. For more information on the hardware configuration in this user scenario, please refer to chapter Operation of the user scenario For demonstration purposes, this document shows different user scenarios. These scenarios can also be used as verification steps for validation. For information on installing the user scenario, please refer to chapter Requirements: No faults Safety door closed Table 6-98 Start actuator No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start Guard locking is activated, then K1 picks up 4 Press stop K1 drops out; then the timer for the delayed release of the safety door starts. 5 Wait until the timer expires. When the timer has expired, the safety door can be opened. Entry ID: , V1.2, 12/

127 Table 6-99 Safety function: Safe shutdown when the safety door is opened No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start Guard locking is activated, then K1 picks up 4 Release the interlocking and open the safety door K1 drops out Table Trigger readback error No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Acknowledgment mandatory when starting the scenario for the first time 3 Press start K1 picks up 4 Make sure that K1 does not drop out when shutting down Simulated welding of the contactor 5 Press stop Readback error is detected 6 Let the contactor drop out 7 Press start K1 does not pick up (acknowledgment required) 8 Wait until the timer expires. 9 Start with no. 2 Entry ID: , V1.2, 12/

128 6.17 User Scenario 16: Safety Door with Guard Locking at PL e/sil 3, Electric Actuator Safety function This user scenario has the following safety functions: Safety function with regard to the position of the safety door (interlocking) Opening the safety door during operation safely shuts down the actuator. Safety function with regard to guard locking After shutdown of the actuator, the safety door may only be opened when the actuator no longer constitutes a hazard. Under Normative assessment of guard locking, chapter addresses the situation where there is a safety function with regard to guard locking Hardware and software components Hardware components You need the hardware and software components listed below. Table Hardware Component No. Article number CPU 1215FC DC/DC/RLY SM 1226 F- DI8/16x24VDC SM 1226 F-DQ 4x24VDC Enclosed pushbutton (NO) Enclosed pushbutton (NC) Position switch with solenoid interlocking (spring-locked) 1 6ES7215-1HF40-0XB0 1 6ES7226-6BA32-0XB0 1 6ES DA32-0XB0 2 3SB3801-0DD3 1 3SB3801-0DB3 1 3SE5322-0SD21 Hinge switch 1 3SE5132-0LU21 Actuator for position switch Software components Table Software 1 3SE5000-0AV0 Component No. Article number STEP 7 Basic 1 6ES7822-0AA03-0YA5 Or STEP 7 Professional STEP 7 Safety 1 6ES7833-1FB13-0YA5 Or STEP 7 Safety Advanced Entry ID: , V1.2, 12/

129 Component No. Article number Basic V13 SP Wiring The figure below shows the wiring of the hardware components. Figure 6-65 Safety door with guard locking PL e/sil 3 wiring 24V DC M stop start ack.0.1 L+.2 M L1 M L+.3 emagnet Vs SignalPLeSIL3Quality fdoorcoil.0 Vs2 hingedswitch sepact For the actuator signals, please refer to chapter In the safety program, the signals of the position switch are defined as follows: sepact (monitoring of the actuator position) sepact (monitoring of the locking device position) fdoorcoil (control of guard locking) Entry ID: , V1.2, 12/

130 The following figure shows the wiring on the position switch and therefore complements the above connection diagram. Figure 6-66 Internal terminals of the position switch with solenoid interlocking sepact (F-DI) CH + (F-DQ) emagnet (Standard-DI) Vs1 (F-DI) L+ (F-CPU) CH (F-DQ) Brief description of the core functionality The following flowchart provides a concise description of the core functionality. Before starting the scenario for the first time, open and close the safety door once. Then acknowledge with ACK=1. Entry ID: , V1.2, 12/

131 Figure 6-67 Safety door with guard locking core functionality Start Safety door closed? Yes No Stop request? Yes Actuators stop No Previous stop was operational stop? No Yes Timer starts Acknowledge Unlock No timer expired? Yes Start conditions are complied Safety door interlocking is released Actuators on WARNING In this example for electric actuators, the safety door s guard locking is deactivated when the timer has expired. For moving parts, a hazard cannot be automatically ruled out when the timer has expired. Make sure that the safety door s guard locking is deactivated only when a hazard no longer exists. Entry ID: , V1.2, 12/

132 Description of the user block FB F16FDoorSIL3PLe Figure 6-68 F-user block FB F16FDoorSIL3PLe NOTICE For F-blocks, the enable input (EN) must not be wired. This example assumes that you are using a hinge switch (hingedswitch) as a second channel. However, it is not mandatory to use a hinge switch. The required dual-channel redundancy can also be implemented with a different switch. WARNING Death or severe personal injury may result if you select a delaytimeunlock time that is too short. Customize these times to your requirements, for example to the slow-down time of a hazardous machine, to release the safety door when the delaytimeunlock time has expired. Parameter description The following section describes the inputs and outputs of FB F16FDoorSIL3PLe. NO: normally open (contact); NC: normally closed (contact) Entry ID: , V1.2, 12/

133 Table Inputs of FB F15F16FDoorSIL3PLe Description Symbol Data type Convention Acknowledgment ack BOOL NO 1: Acknowledgment Start request start BOOL NO 1: Start request Stop request stop BOOL NC 0: Stop request Monitoring of magnet in position switch emagnet BOOL NC 0: Magnet in position switch energized 1: Magnet in position switch deenergized Position switch sepact BOOL NC 1: Actuator inserted (safety door closed) Hinge switch hingedswitch BOOL NC 1: Unoperated (safety door closed) Position switch value status sepactvs BOOL Hinge switch value status hingedswitchvs BOOL Value status of output signalplesil3quality Value status of output fdoorcoil In the position switch: Time between the response of the magnet and the monitoring contact Time delay after shutdown of the actuators to release the safety door. signalplesil3qualityvs fdoorcoilvs feedbacktime BOOL BOOL TIME 0: Fault Positive edge required after triggerin g the safety function to reintegra te F-I/O Chapter Chapter VS: value status Chapter delaytimeunlock TIME Choose a time which is long enough Table Outputs of FB F16FDoorSIL3PLe Description Symbol Data type Convention Output signal from the F-DQ to the electric actuator Magnet in the position switch signalplesil3quality BOOL 1: F-DQ output set fdoorcoil BOOL 0: Guard locking active Actuator on F-DQ Entry ID: , V1.2, 12/

134 Description Symbol Data type Convention Release safety door Acknowledgment for safety door releasefdoor BOOL 1: With regard to safety door, start is possible (safety door closed) ackreqfdoor BOOL 1: Acknowledgment required Information of the F-library blocks. Can be read out, for example, in the standard user program. Configuration and parameterization The STEP 7 hardware configuration (HW Config) has already been prepared for commissioning FB F16FDoorSIL3PLe. Customizations are possible. The associated HW Config can be found in the provided block library. WARNING Inappropriate values for safety-related settings may result in the safety function not being triggered in the event of danger. Please keep this in mind if, due to your requirements, you want to change the settings shown here. For more information on the hardware configuration in this user scenario, please refer to chapter Configuration and parameterization The STEP 7 hardware configuration (HW Config) has already been prepared for commissioning FB F16FDoorSIL3PLe. Customizations are possible. The associated HW Config can be found in the provided block library. WARNING Inappropriate values for safety-related settings may result in the safety function not being triggered in the event of danger. Please keep this in mind if, due to your requirements, you want to change the settings shown here. For more information on the hardware configuration in this user scenario, please refer to chapter Entry ID: , V1.2, 12/

135 Operation of the user scenario For demonstration purposes, this document shows different user scenarios. These scenarios can also be used as verification steps for validation. For information on installing the user scenario, please refer to chapter Requirements: No faults Safety door closed Table Start actuator No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start Guard locking is activated, then signalplesil3quality = 1 4 Press stop signalplesil3quality = 0; then the timer for the delayed release of the safety door starts. 5 Wait until the timer expires. When the timer has expired, the safety door can be opened. Table Safety function: Safety door fault No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start Guard locking is activated, then signalplesil3quality = 1 4 Turn the hinge switch until it outputs 0 signal. signalplesil3quality = 0; then the timer for the delayed release of the safety door starts. 5 Wait until the timer expires. When the timer has expired, the safety door can be opened. 6 Close the safety door 7 Start again with no. 1 Entry ID: , V1.2, 12/

136 6.18 User Scenario 17: Safety Door with Guard Locking at PL d/sil 2, Electric Actuator You are using a drive as an actuator. Please also follow the information in chapter Safety function This user scenario has the following safety functions: Safety function with regard to the position of the safety door (interlocking) Opening the safety door during operation safely shuts down the actuator. Safety function with regard to guard locking After shutdown of the actuator, the safety door may only be opened when the actuator no longer constitutes a hazard. Under Normative assessment of guard locking, chapter addresses the situation where there is a safety function with regard to guard locking Hardware and software components Hardware components You need the hardware and software components listed below. Table Hardware Component No. Article number CPU 1215FC DC/DC/RLY SM 1226 F- DI8/16x24VDC SM 1226 F-DQ 4x24VDC Enclosed pushbutton (NO) Enclosed pushbutton (NC) Position switch with solenoid interlocking (spring-locked) 1 6ES7215-1HF40-0XB0 1 6ES7226-6BA32-0XB0 1 6ES DA32-0XB0 2 3SB3801-0DD3 1 3SB3801-0DB3 1 3SE5322-0SD21 Hinge switch 1 3SE5132-0LU21 Actuator for position switch 1 3SE5000-0AV0 Entry ID: , V1.2, 12/

137 Software components Table Software Component No. Article number STEP 7 Basic 1 6ES7822-0AA03-0YA5 Or STEP 7 Professional STEP 7 Safety Basic V13 SP1 1 6ES7833-1FB13-0YA5 Or STEP 7 Safety Advanced Wiring The figure below shows the wiring of the hardware components. Figure 6-69 Safety door with guard locking PL d/sil 2 wiring 24V DC M stop start ack.0.1 L+.2 M L1 M L+.3 emagnet Vs signalpldsil2quality fdoorcoil.0 Vs2 hingedswitch sepact For the actuator signals, please refer to chapter Entry ID: , V1.2, 12/

138 In the safety program, the signals of the position switch are defined as follows: sepact (monitoring of the actuator position) sepact (monitoring of the locking device position) fdoorcoil (control of guard locking) The following figure shows the wiring on the position switch and therefore complements the above connection diagram. Figure 6-70 Internal terminals of the position switch with solenoid interlocking sepact (F-DI) CH + (F-DQ) emagnet (Standard-DI) Vs1 (F-DI) L+ (F-CPU) CH (F-DQ) Brief description of the core functionality The following flowchart provides a concise description of the core functionality. Before starting the scenario for the first time, open and close the safety door once. Then acknowledge with ACK=1. Entry ID: , V1.2, 12/

139 Figure 6-71 Safety door with guard locking core functionality Start Safety door closed? Yes No Stop request? Yes Actuators stop No Previous stop was operational stop? No Yes Timer starts Acknowledge Unlock No timer expired? Yes Start conditions are complied Safety door interlocking is released Actuators on WARNING In this example for electric actuators, the safety door s guard locking is deactivated when the timer has expired. For moving parts, a hazard cannot be automatically ruled out when the timer has expired. Make sure that the safety door s guard locking is deactivated only when a hazard no longer exists. Entry ID: , V1.2, 12/

140 Description of the user block FB F17FDoorSIL2PLd Figure 6-72 User block FB F17FDoorSIL2PLd NOTICE For F-blocks, the enable input (EN) must not be wired. This example assumes that you are using a hinge switch (hingedswitch) as a second channel. However, it is not mandatory to use a hinge switch. The required dual-channel redundancy can also be implemented with a different switch. WARNING Death or severe personal injury may result if you select a delaytimeunlock time that is too short. Customize these times to your requirements, for example to the slow-down time of a hazardous machine, to release the safety door when the delaytimeunlock time has expired. Parameter description The following section describes the inputs and outputs of FB F17FDoorSIL2PLd. NO: normally open (contact); NC: normally closed (contact) Entry ID: , V1.2, 12/

141 Table Inputs of FB F17FDoorSIL2PLd Description Symbol Data type Convention Acknowledgment ack BOOL NO 1: Acknowledgment Start request start BOOL NO 1: Start request Stop request stop BOOL NC 0: Stop request Monitoring of magnet in position switch emagnet BOOL NC 0: Magnet in position switch energized 1: Magnet in position switch deenergized Position switch sepact BOOL NC 1: Actuator inserted (safety door closed) Hinge switch hingedswitch BOOL NC 1: Unoperated (safety door closed) Position switch value status sepactvs BOOL Hinge switch value status hingedswitchvs BOOL Value status of output signalpldsil2quality Value status of output fdoorcoil In the position switch: Time between the response of the magnet and the monitoring contact Time delay after shutdown of the actuators to release the safety door. signalpldsil2qualityvs fdoorcoilvs feedbacktime BOOL BOOL TIME 0: Fault Positive edge required after triggerin g the safety function to reintegra te F-I/O Chapter Chapter VS: value status Chapter delaytimeunlock TIME Choose a time which is long enough Table Outputs of FB F17FDoorSIL2PLd Description Symbol Data type Convention Output signal from the F-DQ to the electric actuator Magnet in the position switch signalpldsil2quality BOOL 1: F-DQ output set fdoorcoil BOOL 0: Guard locking active Actuator on F-DQ Entry ID: , V1.2, 12/

142 Description Symbol Data type Convention Release safety door Acknowledgment for safety door releasefdoor BOOL 1: With regard to safety door, start is possible (safety door closed) ackreqfdoor BOOL 1: Acknowledgment required Information of the F-library blocks. Can be read out, for example, in the standard user program Configuration and parameterization The STEP 7 hardware configuration (HW Config) has already been prepared for commissioning FB F17FDoorSIL2PLd. Customizations are possible. The associated HW Config can be found in the provided block library. WARNING Inappropriate values for safety-related settings may result in the safety function not being triggered in the event of danger. Please keep this in mind if, due to your requirements, you want to change the settings shown here. For more information on the hardware configuration in this user scenario, please refer to chapter Operation of the user scenario For demonstration purposes, this document shows different user scenarios. These scenarios can also be used as verification steps for validation. For information on installing the user scenario, please refer to chapter Requirements: No faults Safety door closed Entry ID: , V1.2, 12/

143 Table Start actuator No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start Guard locking is activated, then signalpldsil2quality = 1 4 Press stop signalpldsil2quality = 0; then the timer for the delayed release of the safety door starts. 5 Wait until the timer expires. When the timer has expired, the safety door can be opened. Table Safety function: Safety door fault No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start Guard locking is activated, then signalpldsil2quality = 1 4 Turn the hinge switch until it outputs 0 signal. signalpldsil2quality = 0; then the timer for the delayed release of the safety door starts. 5 Wait until the timer expires. When the timer has expired, the safety door can be opened. 6 Close the safety door 7 Start again with no. 1 Entry ID: , V1.2, 12/

144 6.19 User Scenario 18: Safety Door with Guard Locking at PL c/sil 1, Electric Actuator Safety function This user scenario has the following safety functions: Safety function with regard to the position of the safety door (interlocking) Opening the safety door during operation safely shuts down the actuator. Safety function with regard to guard locking After shutdown of the actuator, the safety door may only be opened when the actuator no longer constitutes a hazard. Under Normative assessment of guard locking, chapter addresses the situation where there is a safety function with regard to guard locking Hardware and software components Hardware components You need the hardware and software components listed below. Table Hardware Component No. Article number CPU 1215FC DC/DC/RLY SM 1226 F- DI8/16x24VDC SM 1226 F-DQ 4x24VDC Enclosed pushbutton (NO) Enclosed pushbutton (NC) Position switch with solenoid interlocking (spring-locked) Actuator for position switch Software components Table Software 1 6ES7215-1HF40-0XB0 1 6ES7226-6BA32-0XB0 1 6ES DA32-0XB0 2 3SB3801-0DD3 1 3SB3801-0DB3 1 3SE5322-0SD21 1 3SE5000-0AV0 Component No. Article number STEP 7 Basic 1 6ES7822-0AA03-0YA5 Or STEP 7 Professional STEP 7 Safety Basic V13 SP1 1 6ES7833-1FB13-0YA5 Or STEP 7 Safety Advanced Entry ID: , V1.2, 12/

145 Wiring The figure below shows the wiring of the hardware components. Figure 6-73 Safety door with guard locking SIL 1/PL d wiring 24V DC M stop start ack L+ M L1 M L+.3 emagnet Vs signalplcsil1quality fdoorcoil sepact For the actuator signals, please refer to chapter In the safety program, the signals of the position switch are defined as follows: sepact (monitoring of the actuator position) sepact (monitoring of the locking device position) fdoorcoil (control of guard locking) Entry ID: , V1.2, 12/

146 The following figure shows the wiring on the position switch and therefore complements the above connection diagram. Figure 6-74 Internal terminals of the position switch with solenoid interlocking sepact (F-DI) CH + (F-DQ) emagnet (Standard-DI) Vs1 (F-DI) L+ (F-CPU) CH (F-DQ) Entry ID: , V1.2, 12/

147 Brief description of the core functionality The following flowchart provides a concise description of the core functionality. Before starting the scenario for the first time, open and close the safety door once. Then acknowledge with ACK=1. Figure 6-75 Safety door with guard locking core functionality Start Safety door closed? Yes No No Stop request? Yes Actuator stops Previous stop was operational stop? No Acknowledge Yes Timer starts Unlock No timer expired? Yes Start conditions are complied Safety door interlocking is released Actuator on Entry ID: , V1.2, 12/

148 WARNING In this example for electric actuators, the safety door s guard locking is deactivated when the timer has expired. For moving parts, a hazard cannot be automatically ruled out when the timer has expired. Make sure that the safety door s guard locking is deactivated only when a hazard no longer exists Description of the user block FB F18FDoorSIL1PLc Figure 6-76 F-user block FB F18FDoorSIL1PLc NOTICE For F-blocks, the enable input (EN) must not be wired. WARNING Death or severe personal injury may result if you select a delaytimeunlock time that is too short. Customize these times to your requirements, for example to the slow-down time of a hazardous machine, to release the safety door when the delaytimeunlock time has expired. Parameter description The following section describes the inputs and outputs of FB F18FDoorSIL1PLc. NO: normally open (contact); NC: normally closed (contact) Entry ID: , V1.2, 12/

149 Table Inputs of FB F18FDoorSIL1PLc Description Symbol Data type Convention Acknowledgment ack BOOL NO 1: Acknowledgment Start request start BOOL NO 1: Start request Stop request stop BOOL NC 0: Stop request Monitoring of magnet in position switch emagnet BOOL NC 0: Magnet in position switch energized 1: Magnet in position switch deenergized Position switch sepact BOOL NC 1: Actuator inserted (safety door closed) Positive edge required after triggering the safety function to reintegrat e F-I/O Chapter Chapter Position switch value status sepactvs BOOL 0: Fault Value status of output signalplcsil1quality signalplcsil1qualityvs BOOL VS: value status Chapter Time delay after shutdown of the actuators to release the safety door. delaytimeunlock TIME Choose a time which is long enough Table Outputs of FB F18FDoorSIL1PLc Description Symbol Data type Convention Output signal from the F-DQ to the electric actuator Magnet in the position switch Release safety door Acknowledgment for safety door signalplcsil1quality BOOL 1: F-DQ output set fdoorcoil BOOL 0: Guard locking active releasefdoor BOOL 1: With regard to safety door, start is possible (safety door closed) ackreqfdoor BOOL 1: Acknowledgment required Actuator on F-DQ Information of the F-library blocks. Can be read out, for example, in the standard user program. Entry ID: , V1.2, 12/

150 Configuration and parameterization The STEP 7 hardware configuration (HW Config) has already been prepared for commissioning FB F18FDoorSIL1PLc. Customizations are possible. The associated HW Config can be found in the provided block library. WARNING Inappropriate values for safety-related settings may result in the safety function not being triggered in the event of danger. Please keep this in mind if, due to your requirements, you want to change the settings shown here. For more information on the hardware configuration in this user scenario, please refer to chapter Operation of the user scenario For demonstration purposes, this document shows different user scenarios. These scenarios can also be used as verification steps for validation. For information on installing the user scenario, please refer to chapter Requirements: No faults Table Start actuator Safety door closed No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start Guard locking is activated, then signalplcsil1quality = 1 4 Press stop signalplcsil1quality = 0; then the timer for the delayed release of the safety door starts. 5 Wait until the timer expires. When the timer has expired, the safety door can be opened. Entry ID: , V1.2, 12/

151 6.20 User Scenario 19: Emergency Stop + Safety Door without Guard Locking at PL e/sil 3, Electromechanical Actuator Safety function This user scenario has the following safety functions: Pressing the emergency stop button safely shuts down the actuator. Opening the safety door during operation safely shuts down the actuator Hardware and software components You need the hardware and software components listed below. Hardware components Table Hardware Component No. Article number CPU 1215FC DC/DC/RLY SM 1226 F- DI8/16x24VDC SM 1226 F-DQ 4x24VDC Enclosed pushbutton (NO) Enclosed pushbutton (NC) Emergency stop pushbutton (NC/NC) Position switch without tumbler Actuator for position switch 1 6ES7215-1HF40-0XB0 1 6ES7226-6BA32-0XB0 1 6ES DA32-0XB0 2 3SB3801-0DD3 1 3SB3801-0DB3 1 3SB3801-0EG3 2 3SE5132-1QV20 2 3SE5000-0AV0 Contactors 2 3RT2015-2BB42 Software components Table Software Component No. Article number STEP 7 Basic 1 6ES7822-0AA03-0YA5 Or STEP 7 Professional STEP 7 Safety Basic V13 SP1 1 6ES7833-1FB13-0YA5 Or STEP 7 Safety Advanced Entry ID: , V1.2, 12/

152 Wiring The figure below shows the wiring of the hardware components. Figure 6-77 Emergency stop and safety door without guard locking PL e/sil 3 wiring 24V DC M stop start ack L1 M K2 K1 L+.3.4 L+ M Vs1.1 K1 0+ K Vs2 estop posswitch2 Vs1 posswitch1.0 In the F-program, the NC auxiliary contacts of the contactors K1 and K2 are termed feedback1 and feedback2. Entry ID: , V1.2, 12/

153 Brief description of the core functionality The following flowchart provides a concise description of the core functionality. Figure 6-78 Emergency stop + safety door without guard locking core functionality Start No Safety door closed and e-stop released? Yes Stop request? Yes Actuator is switched off No Previous stop was operational stop? No Yes Acknowledge Start conditions are complied Actuators on Entry ID: , V1.2, 12/

154 Description of the user block FB F19EStopFDoorSIL3PLe Figure 6-79 User block FB F19EStopFDoorSIL3PLe NOTICE For F-blocks, the enable input (EN) must not be wired. Parameter description The following section describes the inputs and outputs of FB F19EStopFDoorSIL3PLe. NO: normally open (contact); NC: normally closed (contact) Table Inputs of FB F19EStopFDoorSIL3PLe Description Symbol Data type Convention Acknowledgment ack BOOL NO 1: Acknowledgment Start request start BOOL NO 1: Start request Stop request stop BOOL NC 0: Stop request Readback signal from auxiliary contact of contactor K1 Readback signal from auxiliary contact of contactor K2 readbackk1 readbackk2 BOOL BOOL Emergency stop estop BOOL NC/NC NC 0: Contactor has picked up Positive edge required after triggering a safety function to reintegrate F-I/O Entry ID: , V1.2, 12/

155 pushbutton Description Symbol Data type Convention 0: Emergency stop triggered Position switch 1 posswitch1 BOOL NC 1: Actuator inserted (safety door closed) Position switch 2 posswitch2 BOOL NC 1: Actuator inserted (safety door closed) Position switch 1 value status Position switch 2 value status posswitch1vs posswitch2vs BOOL BOOL Value status of output K1K2 K1K2VS BOOL Time between the control command and the response of the contactors feedbacktime TIME 0: Fault VS: value status Chapter Table Outputs of FB F19EStopFDoorSIL3PLe Description Symbol Data type Convention Contactors K1/K2 K1K2 BOOL 1: Control command for the contactors Release safety door Release emergency stop Acknowledgment for safety door Acknowledgment required releasefdoor BOOL 1: With regard to safety door, start is possible (safety door closed) releaseestop BOOL 1: Emergency stop released and acknowledged ackreqfdoor BOOL 1: Acknowledgment ackreqestop BOOL required Actuator on F-DQ Information of the F-library blocks. Can be read out, for example, in the standard user program. Entry ID: , V1.2, 12/

156 Configuration and parameterization The STEP 7 hardware configuration (HW Config) has already been prepared for commissioning FB F19EStopFDoorSIL3PLe. Customizations are possible. The associated HW Config can be found in the provided block library. WARNING Inappropriate values for safety-related settings may result in the safety function not being triggered in the event of danger. Please keep this in mind if, due to your requirements, you want to change the settings shown here. For more information on the hardware configuration in this user scenario, please refer to chapter Operation of the user scenario For demonstration purposes, this document shows different user scenarios. These scenarios can also be used as verification steps for validation. For information on installing the user scenario, please refer to chapter Requirements: No faults Emergency stop released Safety door closed Table Start actuator No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start K1K2 picks up 4 Press stop K1K2 drops out Entry ID: , V1.2, 12/

157 Table Safety function: Safe shutdown when the safety door is opened No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start K1K2 picks up 4 Open the safety door K1K2 drops out 5 Close the safety door 6 Start again with no. 2 Table Safety function: Trigger emergency stop No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Acknowledgment mandatory when starting the scenario for the first time 3 Press start K1K2 picks up 4 Press the emergency stop (estop) K1K2 drops out 5 Release the emergency stop (estop) 6 Press start K1K2 does not pick up (acknowledgment required) 7 Start again with no. 2 Table Trigger readback error No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Acknowledgment mandatory when starting the scenario for the first time 3 Press start K1K2 picks up 4 Make sure that K1 or K2 does not drop out when shutting down Simulated welding of the contactor 5 Press stop Readback error is detected 6 Let the contactor drop out 7 Press start K1K2 does not pick up (acknowledgment required) 8 Start with no. 2 Entry ID: , V1.2, 12/

158 6.21 User Scenario 20: Emergency Stop + Safety Door without Guard Locking at PL d/sil 2, Electromechanical Actuator Safety function This user scenario has the following safety functions: Pressing the emergency stop button safely shuts down the actuator. Opening the safety door during operation safely shuts down the actuator Hardware and software components You need the hardware and software components listed below. Hardware components Table Hardware Component No. Article number CPU 1215FC DC/DC/RLY SM 1226 F- DI8/16x24VDC SM 1226 F-DQ 4x24VDC Enclosed pushbutton (NO) Enclosed pushbutton (NC) Emergency stop pushbutton (NC/NC) Position switch without tumbler Actuator for position switch 1 6ES7215-1HF40-0XB0 1 6ES7226-6BA32-0XB0 1 6ES DA32-0XB0 2 3SB3801-0DD3 1 3SB3801-0DB3 1 3SB3801-0EG3 2 3SE5132-1QV20 2 3SE5000-0AV0 Contactors 2 3RT2015-2BB42 Software components Table Software Component No. Article number STEP 7 Basic 1 6ES7822-0AA03-0YA5 Or STEP 7 Professional STEP 7 Safety Basic V13 SP1 1 6ES7833-1FB13-0YA5 Or STEP 7 Safety Advanced Entry ID: , V1.2, 12/

159 Wiring The figure below shows the wiring of the hardware components. Figure 6-80 Emergency stop and safety door without guard locking PL d/sil 2 wiring 24V DC M stop start ack L1 M K2 K1 L+.3.4 L+ M Vs1.1 K1 0+ K Vs2 estop posswitch2 Vs1 posswitch1.0 In the F-program, the NC auxiliary contacts of the contactors K1 and K2 are termed feedback1 and feedback2. Entry ID: , V1.2, 12/

160 Brief description of the core functionality The following flowchart provides a concise description of the core functionality. Figure 6-81 Emergency stop + safety door without guard locking core functionality Start No Safety door closed and e-stop released? Yes Stop request? Yes Actuator is switched off No Previous stop was operational stop? No Yes Acknowledge Start conditions are complied Actuators on Entry ID: , V1.2, 12/

161 Description of the user block FB F20EStopFDoorSIL2PLd Figure 6-82 User block FB F20EStopFDoorSIL2PLd NOTICE For F-blocks, the enable input (EN) must not be wired. Parameter description The following section describes the inputs and outputs of FB F20EStopFDoorSIL2PLd. NO: normally open (contact); NC: normally closed (contact) Table Inputs of FB F20EStopFDoorSIL2PLd Description Symbol Data type Convention Acknowledgment ack BOOL NO 1: Acknowledgment Start request start BOOL NO 1: Start request Stop request stop BOOL NC 0: Stop request Readback signal from auxiliary contact of contactor K1 Readback signal from auxiliary contact of contactor K2 readbackk1 readbackk2 BOOL BOOL NC 0: Contactor has picked up Positive edge required after triggering the safety function to reintegrate F-I/O Entry ID: , V1.2, 12/

162 Description Symbol Data type Convention Emergency stop pushbutton estop BOOL NC/NC 0: Emergency stop triggered Position switch 1 posswitch1 BOOL NC 1: Actuator inserted (safety door closed) Position switch 2 posswitch2 BOOL NC 1: Actuator inserted (safety door closed) Position switch 1 value status Position switch 2 value status posswitch1vs posswitch2vs BOOL BOOL Value status of output K1K2 K1K2VS BOOL Time between the control command and the response of the contactors feedbacktime TIME 0: Fault VS: value status Chapter Table Outputs of FB F20EStopFDoorSIL2PLd Description Symbol Data type Convention Contactors K1/K2 K1K2 BOOL 1: Control command for the contactors Release safety door Release emergency stop Acknowledgment for safety door Acknowledgment required releasefdoor BOOL 1: With regard to safety door, start is possible (safety door closed) releaseestop BOOL 1: Emergency stop released and acknowledged ackreqfdoor BOOL 1: Acknowledgment ackreqestop BOOL required Actuator on F-DQ Information of the F-library blocks. Can be read out, for example, in the standard user program. Entry ID: , V1.2, 12/

163 Configuration and parameterization The STEP 7 hardware configuration (HW Config) has already been prepared for commissioning FB F20EStopFDoorSIL2PLd. Customizations are possible. The associated HW Config can be found in the provided block library. WARNING Inappropriate values for safety-related settings may result in the safety function not being triggered in the event of danger. Please keep this in mind if, due to your requirements, you want to change the settings shown here. For more information on the hardware configuration in this user scenario, please refer to chapter Operation of the user scenario For demonstration purposes, this document shows different user scenarios. These scenarios can also be used as verification steps for validation. For information on installing the user scenario, please refer to chapter Requirements: No faults Emergency stop released Safety door closed Table Start actuator No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start K1K2 picks up 4 Press stop K1K2 drops out Entry ID: , V1.2, 12/

164 Table Safety function: Safe shutdown when the safety door is opened No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start K1K2 picks up 4 Open the safety door K1K2 drops out 5 Close the safety door 6 Start again with no. 2 Table Safety function: Trigger emergency stop No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Acknowledgment mandatory when starting the scenario for the first time 3 Press start K1K2 picks up 4 Press the emergency stop (estop) K1K2 drops out 5 Release the emergency stop (estop) 6 Press start K1K2 does not pick up (acknowledgment required) 7 Start again with no. 2 Table Trigger readback error No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Acknowledgment mandatory when starting the scenario for the first time 3 Press start K1K2 picks up 4 Make sure that K1 or K2 does not drop out when shutting down Simulated welding of the contactor 5 Press stop Readback error is detected 6 Let the contactor drop out 7 Press start K1K2 does not pick up (acknowledgment required) 8 Start with no. 2 Entry ID: , V1.2, 12/

165 6.22 User Scenario 21: Emergency Stop + Safety Door without Guard Locking at PL c/sil 1, Electromechanical Actuator Safety function This user scenario has the following safety functions: Pressing the emergency stop button safely shuts down the actuator. Opening the safety door during operation safely shuts down the actuator Hardware and software components You need the hardware and software components listed below. Hardware components Table Hardware Component No. Article number CPU 1215FC DC/DC/RLY SM 1226 F- DI8/16x24VDC SM 1226 F-DQ 4x24VDC Enclosed pushbutton (NO) Enclosed pushbutton (NC) Emergency stop pushbutton (NC) Position switch without tumbler Actuator for position switch 1 6ES7215-1HF40-0XB0 1 6ES7226-6BA32-0XB0 1 6ES DA32-0XB0 2 3SB3801-0DD3 1 3SB3801-0DB3 1 3SB3801-0DG3 1 3SE5132-1QV20 1 3SE5000-0AV0 Contactors 1 3RT2015-2BB42 Software components Table Software Component No. Article number STEP 7 Basic 1 6ES7822-0AA03-0YA5 Or STEP 7 Professional STEP 7 Safety Basic V13 SP1 1 6ES7833-1FB13-0YA5 Or STEP 7 Safety Advanced Entry ID: , V1.2, 12/

166 Wiring The figure below shows the wiring of the hardware components. Figure 6-83 Emergency stop and safety door without guard locking PL c/sil 1 wiring 24V DC M stop start ack L1 M K1 L+.3 L+ M Vs1.1 K estop Vs1 posswitch1 In the F-program, the auxiliary contact of contactor K1 is termed feedback. Due to the use of the FB FDBACK F-library block, it is useful to monitor readback. Basically, monitoring the readback signals is not required for PL c/sil 1. Entry ID: , V1.2, 12/

167 Brief description of the core functionality The following flowchart provides a concise description of the core functionality. Figure 6-84 Emergency stop + safety door without guard locking core functionality Start No Safety door closed and e-stop released? Yes Stop request? Yes Actuator is switched off No Previous stop was operational stop? No Yes Acknowledge Start conditions are complied Actuator on Entry ID: , V1.2, 12/

168 Description of the user block FB F21EStopFDoorSIL1PLc Figure 6-85 User block FB F21EStopFDoorSIL1PLc NOTICE For F-blocks, the enable input (EN) must not be wired. Parameter description The following section describes the inputs and outputs of FB F21EStopFDoorSIL1PLc. NO: normally open (contact); NC: normally closed (contact) Table Inputs of FB F21EStopFDoorSIL1PLc Description Symbol Data type Convention Acknowledgment ack BOOL NO 1: Acknowledgment Start request start BOOL NO 1: Start request Stop request stop BOOL NC 0: Stop request Readback signal from auxiliary contact of contactor K1 Emergency stop pushbutton readbackk1 BOOL NC 0: Contactor has picked up estop BOOL NC 0: Emergency stop triggered Positive edge required after triggering the safety function to reintegrate F-I/O Entry ID: , V1.2, 12/

169 Description Symbol Data type Convention Position switch posswitch BOOL NC 1: Actuator inserted (safety door closed) Position switch value status posswitchvs BOOL 0: Fault Value status of output K1 K1VS BOOL VS: value status Chapter Time between the control command and the response of the contactor feedbacktime TIME Table Outputs of FB F21EStopFDoorSIL1PLc Description Symbol Data type Convention Contactors K1/K2 K1K2 BOOL 1: Control command for the contactors Release safety door Release emergency stop Acknowledgment for safety door Acknowledgment required releasefdoor BOOL 1: With regard to safety door, start is possible (safety door closed) releaseestop BOOL 1: Emergency stop released and acknowledged ackreqfdoor BOOL 1: Acknowledgment ackreqestop BOOL required Actuator on F-DQ Information of the F-library blocks. Can be read out, for example, in the standard user program Configuration and parameterization The STEP 7 hardware configuration (HW Config) has already been prepared for commissioning FB F21EStopFDoorSIL1PLc. Customizations are possible. The associated HW Config can be found in the provided block library. WARNING Inappropriate values for safety-related settings may result in the safety function not being triggered in the event of danger. Please keep this in mind if, due to your requirements, you want to change the settings shown here. For more information on the hardware configuration in this user scenario, please refer to chapter Operation of the user scenario For demonstration purposes, this document shows different user scenarios. These scenarios can also be used as verification steps for validation. Entry ID: , V1.2, 12/

170 For information on installing the user scenario, please refer to chapter Requirements: No faults Emergency stop released Safety door closed Table Start actuator No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start K1 picks up 4 Press stop K1 drops out Table Safety function: Trigger emergency stop No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Acknowledgment mandatory when starting the scenario for the first time 3 Press start K1 picks up 4 Press the emergency stop (estop) K1 drops out 5 Release the emergency stop (estop) 6 Press start K1 does not pick up (acknowledgment required) 7 Start again with no. 2 Table Safety function: Safe shutdown when the safety door is opened No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start K1 picks up 4 Open the safety door K1 drops out 5 Close the safety door 6 Start again with no. 2 Entry ID: , V1.2, 12/

171 Table Trigger readback error No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start K1 picks up 4 Make sure that K1 does not drop out when shutting down Simulated welding of the contactor 5 Press stop Readback error is detected 6 Let the contactor drop out 7 Press start K1 does not pick up (acknowledgment required) 8 Start again with no User Scenario 22: Emergency Stop and Safety Door without Guard Locking at PL e/sil 3, Electric Actuator Safety function This user scenario has the following safety functions: Pressing the emergency stop button safely shuts down the actuator. Opening the safety door during operation safely shuts down the actuator Hardware and software components Hardware components You need the hardware and software components listed below. Table Hardware Component No. Article number CPU 1215FC DC/DC/RLY SM 1226 F- DI8/16x24VDC SM 1226 F-DQ 4x24VDC Enclosed pushbutton (NO) Enclosed pushbutton (NC) Emergency stop pushbutton (NC/NC) Position switch without tumbler 1 6ES7215-1HF40-0XB0 1 6ES7226-6BA32-0XB0 1 6ES DA32-0XB0 2 3SB3801-0DD3 1 3SB3801-0DB3 1 3SB3801-0EG3 2 3SE5132-1QV20 Entry ID: , V1.2, 12/

172 Component No. Article number Actuator for position switch 2 3SE5000-0AV0 Software components Table Software Component No. Article number STEP 7 Basic 1 6ES7822-0AA03-0YA5 Or STEP 7 Professional STEP 7 Safety Basic V13 SP1 1 6ES7833-1FB13-0YA5 Or STEP 7 Safety Advanced Entry ID: , V1.2, 12/

173 Wiring The figure below shows the wiring of the hardware components. Figure 6-86 Emergency stop and safety door without guard locking PL e/sil 3 wiring 24V DC M stop start ack L1 M L+ L+ M Vs signalplesil3quality Vs2 estop posswitch2 Vs1 posswitch1.0 For the actuator signals, please refer to chapter Entry ID: , V1.2, 12/

174 Brief description of the core functionality The following flowchart provides a concise description of the core functionality. Figure 6-87 Emergency stop + safety door without guard locking core functionality Start No Safety door closed and e-stop released? Yes Stop request? Yes Actuator is switched off No Previous stop was operational stop? No Yes Acknowledge Start conditions are complied Actuators on Entry ID: , V1.2, 12/

175 Description of the user block FB F22EStopFDoorSIL3PLe Figure 6-88 User block FB F22EStopFDoorSIL3PLe NOTICE For F-blocks, the enable input (EN) must not be wired. Parameter description The following section describes the inputs and outputs of FB F22EStopFDoorSIL3PLe. NO: normally open (contact); NC: normally closed (contact) Table Inputs of FB F22EStopFDoorSIL3PLe Description Symbol Data type Convention Acknowledgment ack BOOL NO 1: Acknowledgment Start request start BOOL NO 1: Start request Stop request stop BOOL NC 0: Stop request Emergency stop pushbutton estop BOOL NC/NC 0: Emergency stop triggered Position switch 1 posswitch1 BOOL NC 1: Actuator inserted (safety Positive edge required after triggering the safety function to reintegrate F-I/O Entry ID: , V1.2, 12/

176 Description Symbol Data type Convention door closed) Position switch 2 posswitch2 BOOL NC 1: Actuator inserted (safety door closed) Position switch 1 value status Position switch 2 value status Value status of output signalplesil3quality posswitch1vs BOOL 0: Fault posswitch2vs signalplesil3qualityvs BOOL BOOL VS: value status Chapter Table Outputs of FB F22EStopFDoorSIL3PLe Description Symbol Data type Convention Output signal from the F-DQ to the electric actuator Release safety door Release emergency stop Acknowledgment for safety door Acknowledgment required signalplesil3quality BOOL 1: F-DQ output set releasefdoor BOOL 1: With regard to safety door, start is possible (safety door closed) releaseestop BOOL 1: Emergency stop released and acknowledged ackreqfdoor BOOL 1: Acknowledgment ackreqestop BOOL required Information of the F-library blocks. Can be read out, for example, in the standard user program Configuration and parameterization The STEP 7 hardware configuration (HW Config) has already been prepared for commissioning FB F22EStopFDoorSIL3PLe. Customizations are possible. The associated HW Config can be found in the provided block library. WARNING Inappropriate values for safety-related settings may result in the safety function not being triggered in the event of danger. Please keep this in mind if, due to your requirements, you want to change the settings shown here. For more information on the hardware configuration in this user scenario, please refer to chapter Entry ID: , V1.2, 12/

177 Operation of the user scenario For demonstration purposes, this document shows different user scenarios. These scenarios can also be used as verification steps for validation. For information on installing the user scenario, please refer to chapter Requirements: No faults Emergency stop released Safety door closed Table Start actuator No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start signalplesil3quality = 1 4 Press stop signalplesil3quality = 0 Table Safety function: Trigger emergency stop No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start signalplesil3quality = 1 4 Press the emergency stop (estop) signalplesil3quality = 0 5 Release the emergency stop (estop) 6 Press start signalplesil3quality = 0 (acknowledgment required) 7 Start again with no. 2 Table Safety function: Safe shutdown when the safety door is opened No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. Entry ID: , V1.2, 12/

178 No. Action Comment 3 Press start signalplesil3quality = 1 4 Open the safety door signalplesil3quality = 0 5 Close the safety door 6 Start again with no User Scenario 23: Emergency Stop + Safety Door without Guard Locking at PL d/sil 2, Electric Actuator You are using a drive as an actuator. Please also follow the information in chapter Safety function This user scenario has the following safety functions: Pressing the emergency stop button safely shuts down the actuator. Opening the safety door during operation safely shuts down the actuator Hardware and software components Hardware components You need the hardware and software components listed below. Table Hardware Component No. Article number CPU 1215FC DC/DC/RLY SM 1226 F- DI8/16x24VDC SM 1226 F-DQ 4x24VDC Enclosed pushbutton (NO) Enclosed pushbutton (NC) Emergency stop pushbutton (NC/NC) Position switch without tumbler Actuator for position switch 1 6ES7215-1HF40-0XB0 1 6ES7226-6BA32-0XB0 1 6ES DA32-0XB0 2 3SB3801-0DD3 1 3SB3801-0DB3 1 3SB3801-0EG3 2 3SE5132-1QV20 2 3SE5000-0AV0 Entry ID: , V1.2, 12/

179 Software components Wiring Table Software Component No. Article number STEP 7 Basic 1 6ES7822-0AA03-0YA5 Or STEP 7 Professional STEP 7 Safety Basic V13 SP1 1 6ES7833-1FB13-0YA5 Or STEP 7 Safety Advanced The figure below shows the wiring of the hardware components. Figure 6-89 Emergency stop and safety door without guard locking PL d/sil 2 wiring 24V DC M stop start ack L1 M L+ L+ M Vs signalpldsil2quality Vs2 estop posswitch2 Vs1 posswitch1.0 Entry ID: , V1.2, 12/

180 For the actuator signals, please refer to chapter Brief description of the core functionality The following flowchart provides a concise description of the core functionality. Figure 6-90 Emergency stop + safety door without guard locking core functionality Start No Safety door closed and e-stop released? Yes Stop request? Yes Actuator is switched off No Previous stop was operational stop? Yes No Acknowledge Start conditions are complied Actuators on Entry ID: , V1.2, 12/

181 Description of the user block FB F23EStopFDoorSIL2PLd Figure 6-91 User block FB F23EStopFDoorSIL2PLd NOTICE For F-blocks, the enable input (EN) must not be wired. Parameter description The following section describes the inputs and outputs of FB F23EStopFDoorSIL2PLd. NO: normally open (contact); NC: normally closed (contact) Table Inputs of FB F23EStopFDoorSIL2PLd Description Symbol Data type Convention Acknowledgment ack BOOL NO 1: Acknowledgment Start request start BOOL NO 1: Start request Stop request stop BOOL NC 0: Stop request Emergency stop pushbutton estop BOOL NC/NC 0: Emergency stop triggered Position switch 1 posswitch1 BOOL NC 1: Actuator inserted (safety Positive edge required after triggering the safety function to reintegrate F-I/O Entry ID: , V1.2, 12/

182 Description Symbol Data type Convention door closed) Position switch 2 posswitch2 BOOL NC 1: Actuator inserted (safety door closed) Position switch 1 value status Position switch 2 value status Value status of output signalpldsil2quality posswitch1vs posswitch2vs signalpldsil2qualityvs BOOL BOOL BOOL 0: Fault VS: value status Chapter Table Outputs of FB F23EStopFDoorSIL2PLd Description Symbol Data type Convention Output signal from the F-DQ to the electric actuator Release safety door Release emergency stop Acknowledgment for safety door Acknowledgment required signalpldsil2quality BOOL 1: F-DQ output set releasefdoor BOOL 1: With regard to safety door, start is possible (safety door closed) releaseestop BOOL 1: Emergency stop released and acknowledged ackreqfdoor BOOL 1: Acknowledgment ackreqestop BOOL required Information of the F-library blocks. Can be read out, for example, in the standard user program Configuration and parameterization The STEP 7 hardware configuration (HW Config) has already been prepared for commissioning FB F23EStopFDoorSIL2PLd. Customizations are possible. The associated HW Config can be found in the provided block library. WARNING Inappropriate values for safety-related settings may result in the safety function not being triggered in the event of danger. Please keep this in mind if, due to your requirements, you want to change the settings shown here. For more information on the hardware configuration in this user scenario, please refer to chapter Entry ID: , V1.2, 12/

183 Operation of the user scenario For demonstration purposes, this document shows different user scenarios. These scenarios can also be used as verification steps for validation. For information on installing the user scenario, please refer to chapter Requirements: No faults Emergency stop released Safety door closed Table Start actuator No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start signalpldsil2quality = 1 4 Press stop signalpldsil2quality = 0 Table Safety function: Trigger emergency stop No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start signalpldsil2quality = 1 4 Press the emergency stop (estop) signalpldsil2quality = 0 5 Release the emergency stop (estop) 6 Press start signalpldsil2quality = 0 (acknowledgment required) 7 Start again with no. 2 Table Safety function: Safe shutdown when the safety door is opened No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. Entry ID: , V1.2, 12/

184 No. Action Comment 3 Press start signalpldsil2quality = 1 4 Open the safety door signalpldsil2quality = 0 5 Close the safety door 6 Start again with no User Scenario 24: Emergency Stop + Safety Door without Guard Locking at PL c/sil 1, Electric Actuator Safety function This user scenario has the following safety functions: Pressing the emergency stop button safely shuts down the actuator. Opening the safety door during operation safely shuts down the actuator Hardware and software components Hardware components You need the hardware and software components listed below. Table Hardware Component No. Article number CPU 1215FC DC/DC/RLY SM 1226 F- DI8/16x24VDC SM 1226 F-DQ 4x24VDC Enclosed pushbutton (NO) Enclosed pushbutton (NC) Emergency stop pushbutton (NC) Position switch without tumbler Actuator for position switch Software components Table Software 1 6ES7215-1HF40-0XB0 1 6ES7226-6BA32-0XB0 1 6ES DA32-0XB0 2 3SB3801-0DD3 1 3SB3801-0DB3 1 3SB3801-0DG3 1 3SE5132-1QV20 1 3SE5000-0AV0 Component No. Article number STEP 7 Basic 1 6ES7822-0AA03-0YA5 Or STEP 7 Professional STEP 7 Safety Basic V13 SP1 1 6ES7833-1FB13-0YA5 Or STEP 7 Safety Advanced Entry ID: , V1.2, 12/

185 Wiring The figure below shows the wiring of the hardware components. Figure 6-92 Emergency stop and safety door without guard locking PL c/sil 1 wiring 24V DC M stop start ack L1 M L+ L+ M Vs signalplcsil1quality 0-.0 estop Vs1 posswitch1 For the actuator signals, please refer to chapter Entry ID: , V1.2, 12/

186 Brief description of the core functionality The following flowchart provides a concise description of the core functionality. Figure 6-93 Emergency stop + safety door without guard locking core functionality Start No Safety door closed and e-stop released? Yes Stop request? Yes Actuator is switched off No Previous stop was operational stop? No Yes Acknowledge Start conditions are complied Actuator on Entry ID: , V1.2, 12/

187 Description of the user block FB F24EStopFDoorSIL1PLc Figure 6-94 User block FB F24EStopFDoorSIL1PLc NOTICE For F-blocks, the enable input (EN) must not be wired. Parameter description The following section describes the inputs and outputs of FB F24EStopFDoorSIL1PLc. NO: normally open (contact); NC: normally closed (contact) Table Inputs of FB F24EStopFDoorSIL1PLc Description Symbol Data type Convention Acknowledgment ack BOOL NO 1: Acknowledgment Start request start BOOL NO 1: Start request Stop request stop BOOL NC 0: Stop request Emergency stop pushbutton estop BOOL NC 0: Emergency stop triggered Position switch posswitch BOOL NC 1: Actuator inserted (safety door closed) Positive edge required after triggering the safety function to reintegrate F-I/O Entry ID: , V1.2, 12/

188 Description Symbol Data type Convention Position switch value status Value status of output signalplcsil1quality posswitchvs BOOL 0: Fault signalplcsil1qualityvs BOOL VS: value status Chapter Table Outputs of FB F24EStopFDoorSIL1PLc Description Symbol Data type Convention Output signal from the F-DQ to the electric actuator Release safety door Release emergency stop Acknowledgment for safety door Acknowledgment required signalplcsil1quality BOOL 1: F-DQ output set releasefdoor BOOL 1: With regard to safety door, start is possible (safety door closed) releaseestop BOOL 1: Emergency stop released and acknowledged ackreqfdoor BOOL 1: Acknowledgment ackreqestop BOOL required Information of the F-library blocks. Can be read out, for example, in the standard user program Configuration and parameterization The STEP 7 hardware configuration (HW Config) has already been prepared for commissioning FB F24EStopFDoorSIL1PLc. Customizations are possible. The associated HW Config can be found in the provided block library. WARNING Inappropriate values for safety-related settings may result in the safety function not being triggered in the event of danger. Please keep this in mind if, due to your requirements, you want to change the settings shown here. For more information on the hardware configuration in this user scenario, please refer to chapter Entry ID: , V1.2, 12/

189 Operation of the user scenario For demonstration purposes, this document shows different user scenarios. These scenarios can also be used as verification steps for validation. For information on installing the user scenario, please refer to chapter Requirements: No faults Emergency stop released Safety door closed Table Start actuator No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start signalplcsil1quality = 1 4 Press stop signalplcsil1quality = 0 Table Safety function: Trigger emergency stop No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start signalplcsil1quality = 1 4 Press the emergency stop (estop) signalplcsil1quality = 0 5 Release the emergency stop (estop) 6 Press start signalplcsil1quality = 0 (acknowledgment required) 7 Start again with no. 2 Table Safety function: Safe shutdown when the safety door is opened No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. Entry ID: , V1.2, 12/

190 No. Action Comment 3 Press start signalplcsil1quality = 1 4 Open the safety door signalplcsil1quality = 0 5 Close the safety door 6 Start again with no User Scenario 25: Emergency Stop + Safety Door with Guard Locking at PL e/sil 3, Electromechanical Actuator Safety function This user scenario has the following safety functions: Pressing the emergency stop button safely shuts down the actuator. Safety function with regard to the position of the safety door (interlocking) Opening the safety door during operation safely shuts down the actuator. Safety function with regard to guard locking After shutdown of the actuator, the safety door may only be opened when the actuator no longer constitutes a hazard. Under Normative assessment of guard locking, chapter addresses the situation where there is a safety function with regard to guard locking Hardware and software components Hardware components You need the hardware and software components listed below. Table Hardware Component No. Article number CPU 1215FC DC/DC/RLY SM 1226 F- DI8/16x24VDC SM 1226 F-DQ 4x24VDC Enclosed pushbutton (NO) Enclosed pushbutton (NC) Emergency stop pushbutton (NC/NC) Position switch with solenoid interlocking (spring-locked) 1 6ES7215-1HF40-0XB0 1 6ES7226-6BA32-0XB0 1 6ES DA32-0XB0 2 3SB3801-0DD3 1 3SB3801-0DB3 1 3SB3801-0EG3 1 3SE5322-0SD21 Entry ID: , V1.2, 12/

191 Component No. Article number Hinge switch 1 3SE5132-0LU21 Actuator for position switch Software components 1 3SE5000-0AV0 Contactors 2 3RT2015-2BB42 Table Software Component No. Article number STEP 7 Basic 1 6ES7822-0AA03-0YA5 Or STEP 7 Professional STEP 7 Safety Basic V13 SP1 1 6ES7833-1FB13-0YA5 Or STEP 7 Safety Advanced Entry ID: , V1.2, 12/

192 Wiring The figure below shows the wiring of the hardware components. Figure 6-95 Emergency stop + safety door with guard locking PL e/sil 3 wiring 24V DC M stop start ack L+.4 M L1 M K2.3 K1 0+ Vs1 L+.0 K1 K2.5 emagnet fdoorcoil.1 Vs2 hingedswitch sepact.0 estop In the F-program, the NC auxiliary contacts of the contactors K1 and K2 are termed feedback1 and feedback2. Entry ID: , V1.2, 12/

193 In the safety program, the signals of the position switch are defined as follows: sepact (monitoring of the actuator position) sepact (monitoring of the locking device position) fdoorcoil (control of guard locking) The following figure shows the wiring on the position switch and therefore complements the above connection diagram. Figure 6-96 Internal terminals of the position switch with solenoid interlocking sepact (F-DI) CH + (F-DQ) emagnet (Standard-DI) Vs1 (F-DI) L+ (F-CPU) CH (F-DQ) Entry ID: , V1.2, 12/

194 Brief description of the core functionality The following flowchart provides a concise description of the core functionality. Before starting the scenario for the first time, open and close the safety door once. Then acknowledge with ack=1. Figure 6-97 Emergency stop + safety door with guard locking core functionality Start No Safety door closed and e-stop released? Yes No Stop request? Yes Actuators stop Previous stop was operational stop? No Yes Timer starts Acknowledge Unlock No timer expired? Yes Start conditions are complied Safety door interlocking is released Actuators on Entry ID: , V1.2, 12/

195 WARNING In this example for electromechanical actuators, the safety door s guard locking is deactivated when the timer has expired. For moving parts, a hazard cannot be automatically ruled out when the timer has expired. Make sure that the safety door s guard locking is deactivated only when a hazard no longer exists Description of the user block FB F25EStopFDoorSIL3PLe Figure 6-98 User block FB F25EStopFDoorSIL3PLe NOTICE For F-blocks, the enable input (EN) must not be wired. This example assumes that you are using a hinge switch (hingedswitch) as a second channel. However, it is not mandatory to use a hinge switch. The required dual-channel redundancy can also be implemented with a different switch. WARNING Death or severe personal injury may result if you select a delaytimeunlock time that is too short. Customize these times to your requirements, for example to the slow-down time of a hazardous machine, to release the safety door when the delaytimeunlock time has expired. Entry ID: , V1.2, 12/

196 Parameter description The following section describes the inputs and outputs of FB F25EStopFDoorSIL3PLe. NO: normally open (contact); NC: normally closed (contact) Table Inputs of FB F25EStopFDoorSIL3PLe Description Symbol Data type Convention Acknowledgment ack BOOL NO 1: Acknowledgment Start request start BOOL NO 1: Start request Stop request stop BOOL NC 0: Stop request Monitoring of magnet in position switch Readback signal from auxiliary contact of contactor K1 Readback signal from auxiliary contact of contactor K2 emagnet BOOL NC 0: Magnet in position switch energized 1: Magnet in position switch de-energized readbackk1 readbackk2 BOOL BOOL NC 0: Contactor has picked up Emergency stop pushbutton estop BOOL NC/NC 0: Emergency stop triggered Positive edge required after triggering the safety function to reintegrate F-I/O Chapter Position switch sepact BOOL NC 1: Actuator inserted (safety door closed) Chapter Hinge switch hingedswitch BOOL NC 1: Unoperated (safety door closed) Position switch value status sepactvs BOOL Hinge switch value status hingedswitchvs BOOL Value status of output K1K2 K1K2_VS BOOL Value status of output fdoorcoil Time between the control command and the response of the contactors fdoorcoil_vs feedbacktime BOOL TIME 0: Fault VS: value status Chapter Entry ID: , V1.2, 12/

197 Description Symbol Data type Convention Time delay after shutdown of the actuators to release the safety door. delaytimeunlock TIME When the time has elapsed, the door will be released. Choose a time which is long enough Table Outputs of FB F25EStopFDoorSIL3PLe Description Symbol Data type Convention Contactors K1/K2 K1K2 BOOL 1: Control command for the contactors Magnet in the position switch Release safety door Release emergency stop Acknowledgment for safety door Acknowledgment required fdoorcoil BOOL 0: Guard locking active releasefdoor BOOL 1: With regard to safety door, start is possible (safety door closed) releaseestop BOOL 1: Emergency stop released and acknowledged ackreqfdoor BOOL 1: Acknowledgment AckReqEStop BOOL required Actuator on F-DQ Information of the F-library blocks. Can be read out, for example, in the standard user program Configuration and parameterization The STEP 7 hardware configuration (HW Config) has already been prepared for commissioning FB F32F25EStopFDoorSIL3PLe. Customizations are possible. The associated HW Config can be found in the provided block library. WARNING Inappropriate values for safety-related settings may result in the safety function not being triggered in the event of danger. Please keep this in mind if, due to your requirements, you want to change the settings shown here. For more information on the hardware configuration in this user scenario, please refer to chapter Entry ID: , V1.2, 12/

198 Implementation of the safety functions in the F-program In this chapter, you will find information on the structure of the F-program that is (in parts) also applicable to the other user scenarios. Release The application will only be released when the F-library blocks for the safety door (FB SFDOOR) and the emergency stop (FB ESTOP1), for their part, give the release (Q=1). Figure 6-99 Release of safety door and emergency stop For each release, Q=1 is required Switching the actuator The actuator can only be switched on when the safety door provides feedback that the safety door was interlocked. This information is provided via the emagnet variable that correlates with the magnet in the position switch (see also Safety door signals in chapter 6.1.2). Entry ID: , V1.2, 12/

199 Figure Switching the actuator Contactor auxiliary contacts must correlate with the actuator signal Missing release of safety door or e-stop or operational stop switches off the actuator Feedback from the magnet in the position switch as a switch-on condition Guard locking The guard locking also uses FB FDBACK. This is where the correlation of the signals of the emagnet monitoring contact and of the magnet in the position switch is monitored. Figure Activating and monitoring the interlocking WARNING Death or severe personal injury may result if the actuator starts before the safety door is interlocked. For the following reason, this risk does not exist in the user scenarios described in this document: The guard locking, incl. monitoring, was programmed in a network following the switching of the actuator. This means that the actuator only starts one program cycle after the safety door has been interlocked (switch-on condition due to emagnet). Entry ID: , V1.2, 12/

200 Operation of the user scenario For demonstration purposes, this document shows different user scenarios. These scenarios can also be used as verification steps for validation. For information on installing the user scenario, please refer to chapter Requirements: No faults Emergency stop released Safety door closed Table Start actuator No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start Guard locking is activated, then K1K2 picks up 4 Press stop K1K2 drops out; then the timer for the delayed release of the safety door starts. 5 Wait until the timer expires. When the timer has expired, the safety door can be opened. Table Safety function: Trigger emergency stop No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start K1K2 picks up 4 Press the emergency stop (estop) K1K2 drops out 5 Release the emergency stop (estop) 6 Press start K1K2 does not pick up (acknowledgment required) 7 Wait until the timer expires. 8 Start again with no. 2 Entry ID: , V1.2, 12/

201 Table Safety function: Safety door fault No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start Guard locking is activated, then K1K2 picks up 4 Turn the hinge switch until it outputs 0 signal. K1K2 drops out; then the timer for the delayed release of the safety door starts. 5 Wait until the timer expires. When the timer has expired, the safety door can be opened. 6 Close the safety door 7 Start again with no. 1 Table Trigger readback error No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Acknowledgment mandatory when starting the scenario for the first time 3 Press start K1K2 picks up 4 Make sure that K1 or K2 does not drop out when shutting down Simulated welding of the contactor 5 Press stop Readback error is detected 6 Let the contactor drop out 7 Press start K1K2 does not pick up (acknowledgment required) 8 Start with no. 2 Entry ID: , V1.2, 12/

202 6.27 User Scenario 26: Emergency Stop + Safety Door with Guard Locking at PL d/sil 2, Electromechanical Actuator Safety function This user scenario has the following safety functions: Pressing the emergency stop button safely shuts down the actuator. Safety function with regard to the position of the safety door (interlocking) Opening the safety door during operation safely shuts down the actuator. Safety function with regard to guard locking After shutdown of the actuator, the safety door may only be opened when the actuator no longer constitutes a hazard. Under Normative assessment of guard locking, chapter addresses the situation where there is a safety function with regard to guard locking Hardware and software components Hardware components You need the hardware and software components listed below. Table Hardware Component No. Article number CPU 1215FC DC/DC/RLY SM 1226 F- DI8/16x24VDC SM 1226 F-DQ 4x24VDC Enclosed pushbutton (NO) Enclosed pushbutton (NC) Emergency stop pushbutton (NC/NC) Position switch with solenoid interlocking (spring-locked) 1 6ES7215-1HF40-0XB0 1 6ES7226-6BA32-0XB0 1 6ES DA32-0XB0 2 3SB3801-0DD3 1 3SB3801-0DB3 1 3SB3801-0EG3 1 3SE5322-0SD21 Hinge switch 1 3SE5132-0LU21 Actuator for position switch 1 3SE5000-0AV0 Contactors 2 3RT2015-2BB42 Entry ID: , V1.2, 12/

203 Software components Table Software Component No. Article number STEP 7 Basic 1 6ES7822-0AA03-0YA5 Or STEP 7 Professional STEP 7 Safety Basic V13 SP1 1 6ES7833-1FB13-0YA5 Or STEP 7 Safety Advanced Entry ID: , V1.2, 12/

204 Wiring The figure below shows the wiring of the hardware components. Figure Emergency stop + safety door with guard locking PL d/sil 2 wiring 24V DC M stop start ack L+.4 M L1 M K2.3 K1 0+ Vs1 L+.0 K1 K2.5 emagnet fdoorcoil.1 Vs2 hingedswitch sepact.0 estop In the F-program, the NC auxiliary contacts of the contactors K1 and K2 are termed feedback1 and feedback2. Entry ID: , V1.2, 12/

205 In the safety program, the signals of the position switch are defined as follows: sepact (monitoring of the actuator position) sepact (monitoring of the locking device position) fdoorcoil (control of guard locking) The following figure shows the wiring on the position switch and therefore complements the above connection diagram. Figure Internal terminals of the position switch with solenoid interlocking sepact (F-DI) CH + (F-DQ) emagnet (Standard-DI) Vs1 (F-DI) L+ (F-CPU) CH (F-DQ) Brief description of the core functionality The following flowchart provides a concise description of the core functionality. Before starting the scenario for the first time, open and close the safety door once. Then acknowledge with ack=1. Entry ID: , V1.2, 12/

206 Figure Emergency stop + safety door with guard locking core functionality Start No Safety door closed and e-stop released? Yes Stop request? Yes Actuators stop No Previous stop was operational stop? No Yes Timer starts Acknowledge Unlock No timer expired? Yes Start conditions are complied Safety door interlocking is released Actuators on WARNING In this example for electromechanical actuators, the safety door s guard locking is deactivated when the timer has expired. For moving parts, a hazard cannot be automatically ruled out when the timer has expired. Make sure that the safety door s guard locking is deactivated only when a hazard no longer exists. Entry ID: , V1.2, 12/

207 Description of the user block FB F26EStopFDoorSIL2PLd Figure User block FB F26EStopFDoorSIL2PLd NOTICE For F-blocks, the enable input (EN) must not be wired. This example assumes that you are using a hinge switch (hingedswitch) as a second channel. However, it is not mandatory to use a hinge switch. The required dual-channel redundancy can also be implemented with a different switch. WARNING Death or severe personal injury may result if you select a delaytimeunlock time that is too short. Customize these times to your requirements, for example to the slow-down time of a hazardous machine, to release the safety door when the delaytimeunlock time has expired. Parameter description The following section describes the inputs and outputs of FB F26EStopFDoorSIL2PLd. NO: normally open (contact); NC: normally closed (contact) Entry ID: , V1.2, 12/

208 Table Inputs of FB F26EStopFDoorSIL2PLd Description Symbol Data type Convention Acknowledgment ack BOOL NO 1: Acknowledgment Start request start BOOL NO 1: Start request Stop request stop BOOL NC 0: Stop request Monitoring of magnet in position switch Readback signal from auxiliary contact of contactor K1 Readback signal from auxiliary contact of contactor K2 emagnet BOOL NC 0: Magnet in position switch energized 1: Magnet in position switch de-energized readbackk1 readbackk2 BOOL BOOL NC 0: Contactor has picked up Emergency stop pushbutton estop BOOL NC/NC 0: Emergency stop triggered Position switch sepact BOOL NC 1: Actuator inserted (safety door closed) Hinge switch hingedswitch BOOL NC 1: Unoperated (safety door closed) Position switch value status sepactvs BOOL Hinge switch value status hingedswitchvs BOOL Value status of output K1K2 K1K2_VS BOOL Value status of output fdoorcoil Time between the control command and the response of the contactors Time delay after shutdown of the actuators to release the safety door. fdoorcoil_vs feedbacktime BOOL TIME 0: Fault delaytimeunlock TIME When the time has elapsed, the door will be released. Positive edge required after triggering the safety function to reintegrate F-I/O Chapter Chapter VS: value status Chapter Choose a time which is long enough Entry ID: , V1.2, 12/

209 Table Outputs of FB F26EStopFDoorSIL2PLd Description Symbol Data type Convention Contactors K1/K2 K1K2 BOOL 1: Control command for the contactors Magnet in the position switch Release safety door Release emergency stop Acknowledgment for safety door Acknowledgment required fdoorcoil BOOL 0: Guard locking active releasefdoor BOOL 1: With regard to safety door, start is possible (safety door closed) releaseestop BOOL 1: Emergency stop released and acknowledged ackreqfdoor BOOL 1: Acknowledgment AckReqEStop BOOL required Actuator on F-DQ Information of the F-library blocks. Can be read out, for example, in the standard user program Configuration and parameterization The STEP 7 hardware configuration (HW Config) has already been prepared for commissioning FB F26EStopFDoorSIL2PLd. Customizations are possible. The associated HW Config can be found in the provided block library. WARNING Inappropriate values for safety-related settings may result in the safety function not being triggered in the event of danger. Please keep this in mind if, due to your requirements, you want to change the settings shown here. For more information on the hardware configuration in this user scenario, please refer to chapter Entry ID: , V1.2, 12/

210 Operation of the user scenario For demonstration purposes, this document shows different user scenarios. These scenarios can also be used as verification steps for validation. For information on installing the user scenario, please refer to chapter Requirements: No faults Emergency stop released Safety door closed Table Start actuator No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start Guard locking is activated, then K1K2 picks up 4 Press stop K1K2 drops out; then the timer for the delayed release of the safety door starts. 5 Wait until the timer expires. When the timer has expired, the safety door can be opened. Table Safety function: Trigger emergency stop No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start K1K2 picks up 4 Press the emergency stop (estop) K1K2 drops out 5 Release the emergency stop (estop) 6 Press start K1K2 does not pick up (acknowledgment required) 7 Wait until the timer expires. 8 Start again with no. 2 Entry ID: , V1.2, 12/

211 Table Safety function: Safety door fault No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start Guard locking is activated, then K1K2 picks up 4 Turn the hinge switch until it outputs 0 signal. K1K2 drops out; then the timer for the delayed release of the safety door starts. 5 Wait until the timer expires. When the timer has expired, the safety door can be opened. 6 Close the safety door 7 Start again with no. 1 Table Trigger readback error No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Acknowledgment mandatory when starting the scenario for the first time 3 Press start K1K2 picks up 4 Make sure that K1 or K2 does not drop out when shutting down Simulated welding of the contactor 5 Press stop Readback error is detected 6 Let the contactor drop out 7 Press start K1K2 does not pick up (acknowledgment required) 8 Start with no. 2 Entry ID: , V1.2, 12/

212 6.28 User Scenario 27: Emergency Stop + Safety Door with Guard Locking at PL c/sil 1, Electromechanical Actuator Safety function This user scenario has the following safety functions: Pressing the emergency stop button safely shuts down the actuator. Safety function with regard to the position of the safety door (interlocking) Opening the safety door during operation safely shuts down the actuator. Safety function with regard to guard locking After shutdown of the actuator, the safety door may only be opened when the actuator no longer constitutes a hazard. Under Normative assessment of guard locking, chapter addresses the situation where there is a safety function with regard to guard locking Hardware and software components Hardware components You need the hardware and software components listed below. Table Hardware Component No. Article number CPU 1215FC DC/DC/RLY SM 1226 F- DI8/16x24VDC SM 1226 F-DQ 4x24VDC Enclosed pushbutton (NO) Enclosed pushbutton (NC) Emergency stop pushbutton (NC) Position switch with solenoid interlocking (spring-locked) Actuator for position switch 1 6ES7215-1HF40-0XB0 1 6ES7226-6BA32-0XB0 1 6ES DA32-0XB0 2 3SB3801-0DD3 1 3SB3801-0DB3 1 3SB3801-0DG3 1 3SE5322-0SD21 1 3SE5000-0AV0 Contactors 1 3RT2015-2BB42 Entry ID: , V1.2, 12/

213 Software components Table Software Component No. Article number STEP 7 Basic 1 6ES7822-0AA03-0YA5 Or STEP 7 Professional STEP 7 Safety Basic V13 SP1 1 6ES7833-1FB13-0YA5 Or STEP 7 Safety Advanced Entry ID: , V1.2, 12/

214 Wiring The figure below shows the wiring of the hardware components. Figure Emergency stop + safety door with guard locking PL c/sil 1 wiring 24V DC M stop start ack L+ M L1 M L+ K1.3.4 emagnet.1.0 Vs1 0+ K fdoorcoil.1 sepact.0 estop In the F-program, the NC auxiliary contacts of the contactors K1 and K2 are termed feedback1 and feedback2. Entry ID: , V1.2, 12/

215 Due to the use of the FB FDBACK F-library block, it is useful to monitor readback. Basically, monitoring the readback signals is not required for PL c/sil 1. In the safety program, the signals of the position switch are defined as follows: sepact (monitoring of the actuator position) sepact (monitoring of the locking device position) fdoorcoil (control of guard locking) The following figure shows the wiring on the position switch and therefore complements the above connection diagram. Figure Internal terminals of the position switch with solenoid interlocking sepact (F-DI) CH + (F-DQ) emagnet (Standard-DI) Vs1 (F-DI) L+ (F-CPU) CH (F-DQ) Entry ID: , V1.2, 12/

216 Brief description of the core functionality The following flowchart provides a concise description of the core functionality. Before starting the scenario for the first time, open and close the safety door once. Then acknowledge with ack=1. Figure Emergency stop + safety door with guard locking core functionality Start No Safety door closed and e-stop released? Yes No Stop request? Yes Actuator stops Previous stop was operational stop? No Yes Timer starts Acknowledge Unlock No timer expired? Yes Start conditions are complied Safety door interlocking is released Actuator on Entry ID: , V1.2, 12/

217 WARNING In this example for electromechanical actuators, the safety door s guard locking is deactivated when the timer has expired. For moving parts, a hazard cannot be automatically ruled out when the timer has expired. Make sure that the safety door s guard locking is deactivated only when a hazard no longer exists Description of the user block FB F27EStopFDoorSIL1PLc Figure User block FB F27EStopFDoorSIL1PLc NOTICE For F-blocks, the enable input (EN) must not be wired. WARNING Death or severe personal injury may result if you select a delaytimeunlock time that is too short. Customize these times to your requirements, for example to the slow-down time of a hazardous machine, to release the safety door when the delaytimeunlock time has expired. Parameter description The following section describes the inputs and outputs of FB F27EStopFDoorSIL1PLc. NO: normally open (contact); NC: normally closed (contact) Entry ID: , V1.2, 12/

218 Table Inputs of FB F27EStopFDoorSIL1PLc Description Symbol Data type Convention Acknowledgment ack BOOL NO 1: Acknowledgment Start request start BOOL NO 1: Start request Stop request stop BOOL NC 0: Stop request Monitoring of magnet in position switch Readback signal from auxiliary contact of contactor K1 emagnet BOOL NC 0: Magnet in position switch energized 1: Magnet in position switch de-energized readbackk1 BOOL NC 0: Contactor has picked up Emergency stop pushbutton estop BOOL NC/NC 0: Emergency stop triggered Position switch sepact BOOL NC 1: Actuator inserted (safety door closed) Position switch value status sepactvs BOOL 0: Fault Value status of output K1 K1_VS BOOL Positive edge required after triggering the safety function to reintegrate F-I/O Chapter Chapter VS: value status Chapter Time between the control command and the response of the contactor feedbacktime TIME Time delay after shutdown of the actuators to release the safety door. delaytimeunlock TIME When the time has elapsed, the door will be released. Choose a time which is long enough Table Outputs of FB F27EStopFDoorSIL1PLc Description Symbol Data type Convention Contactor K1 K1 BOOL 1: Actuator switched (contactor has picked up) Magnet in the position switch Release safety door fdoorcoil BOOL 0: Guard locking active releasefdoor BOOL 1: With regard to safety door, start is possible (safety door closed) Release releaseestop BOOL 1: Emergency stop released and Actuator on F-DQ Information of the F-library blocks. Can be read out, for example, in the standard user program. Entry ID: , V1.2, 12/

219 Description Symbol Data type Convention emergency stop Acknowledgment for safety door Acknowledgment required acknowledged ackreqfdoor BOOL 1: Acknowledgment AckReqEStop BOOL required Configuration and parameterization The STEP 7 hardware configuration (HW Config) has already been prepared for commissioning FB F27EStopFDoorSIL1PLc. Customizations are possible. The associated HW Config can be found in the provided block library. WARNING Inappropriate values for safety-related settings may result in the safety function not being triggered in the event of danger. Please keep this in mind if, due to your requirements, you want to change the settings shown here. For more information on the hardware configuration in this user scenario, please refer to chapter Operation of the user scenario For demonstration purposes, this document shows different user scenarios. These scenarios can also be used as verification steps for validation. For information on installing the user scenario, please refer to chapter Entry ID: , V1.2, 12/

220 Requirements: No faults Emergency stop released Safety door closed Table Start actuator No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start Guard locking is activated, then K1 picks up 4 Press stop K1 drops out; then the timer for the delayed release of the safety door starts. 5 Wait until the timer expires. When the timer has expired, the safety door can be opened. Table Safety function: Trigger emergency stop No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start K1 picks up 4 Press the emergency stop (estop) K1 drops out 5 Release the emergency stop (estop) 6 Press start K1 does not pick up (acknowledgment required) 7 Start again with no. 2 Table Trigger readback error No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start K1 picks up 4 Make sure that K1 does not drop out when shutting down Simulated welding of the contactor 5 Press stop Readback error is detected 6 Let the contactor drop out 7 Press start K1 does not pick up (acknowledgment Entry ID: , V1.2, 12/

221 No. Action Comment 8 Start with no. 2 required) 6.29 User Scenario 28: Emergency Stop and Safety Door with Guard Locking at PL e/sil 3, Electric Actuator Safety function This user scenario has the following safety functions: Pressing the emergency stop button safely shuts down the actuator. Safety function with regard to the position of the safety door (interlocking) Opening the safety door during operation safely shuts down the actuator. Safety function with regard to guard locking After shutdown of the actuator, the safety door may only be opened when the actuator no longer constitutes a hazard. Under Normative assessment of guard locking, chapter addresses the situation where there is a safety function with regard to guard locking Hardware and software components Hardware components You need the hardware and software components listed below. Table Hardware Component No. Article number CPU 1215FC DC/DC/RLY SM 1226 F- DI8/16x24VDC SM 1226 F-DQ 4x24VDC Enclosed pushbutton (NO) Enclosed pushbutton (NC) Emergency stop pushbutton (NC/NC) Position switch with solenoid interlocking (spring-locked) 1 6ES7215-1HF40-0XB0 1 6ES7226-6BA32-0XB0 1 6ES DA32-0XB0 2 3SB3801-0DD3 1 3SB3801-0DB3 1 3SB3801-0EG3 1 3SE5322-0SD21 Hinge switch 1 3SE5132-0LU21 Actuator for position 1 3SE5000-0AV0 Entry ID: , V1.2, 12/

222 switch Software components Component No. Article number Table Software Component No. Article number STEP 7 Basic 1 6ES7822-0AA03-0YA5 Or STEP 7 Professional STEP 7 Safety Basic V13 SP1 1 6ES7833-1FB13-0YA5 Or STEP 7 Safety Advanced Entry ID: , V1.2, 12/

223 Wiring The figure below shows the wiring of the hardware components. Figure Emergency stop + safety door with guard locking PL e/sil 3 wiring 24V DC M stop start ack L+ M L1 Vs1 M L+.3 emagnet SignalPLeSIL3Quality fdoorcoil.1 Vs2 hingedswitch.0 sepact estop In the F-program, the NC auxiliary contacts of the contactors K1 and K2 are termed feedback1 and feedback2. Entry ID: , V1.2, 12/

224 In the safety program, the signals of the position switch are defined as follows: sepact (monitoring of the actuator position) sepact (monitoring of the locking device position) fdoorcoil (control of guard locking) The following figure shows the wiring on the position switch and therefore complements the above connection diagram. Figure Internal terminals of the position switch with solenoid interlocking sepact (F-DI) CH + (F-DQ) emagnet (Standard-DI) Vs1 (F-DI) L+ (F-CPU) CH (F-DQ) Entry ID: , V1.2, 12/

225 Brief description of the core functionality The following flowchart provides a concise description of the core functionality. Before starting the scenario for the first time, open and close the safety door once. Then acknowledge with ack=1. Figure Emergency stop + safety door with guard locking core functionality Start No Safety door closed and e-stop released? Yes No Stop request? Yes Actuators stop Previous stop was operational stop? No Acknowledge Yes Timer starts Unlock No timer expired? Yes Start conditions are complied Safety door interlocking is released Actuators on Entry ID: , V1.2, 12/

226 WARNING In this example for electric actuators, the safety door s guard locking is deactivated when the timer has expired. For moving parts, a hazard cannot be automatically ruled out when the timer has expired. Make sure that the safety door s guard locking is deactivated only when a hazard no longer exists Description of the user block FB F28EStopFDoorSIL3PLe Figure User block FB F28EStopFDoorSIL3PLe NOTICE For F-blocks, the enable input (EN) must not be wired. This example assumes that you are using a hinge switch (hingedswitch) as a second channel. However, it is not mandatory to use a hinge switch. The required dual-channel redundancy can also be implemented with a different switch. WARNING Death or severe personal injury may result if you select a delaytimeunlock time that is too short. Customize these times to your requirements, for example to the slow-down time of a hazardous machine, to release the safety door when the delaytimeunlock time has expired. Entry ID: , V1.2, 12/

227 Parameter description The following section describes the inputs and outputs of FB F28EStopFDoorSIL3PLe. NO: normally open (contact); NC: normally closed (contact) Table Inputs of FB F28EStopFDoorSIL3PLe Description Symbol Data type Convention Acknowledgment ack BOOL NO 1: Acknowledgment Start request start BOOL NO 1: Start request Stop request stop BOOL NC 0: Stop request Monitoring of magnet in position switch Emergency stop pushbutton emagnet BOOL NC 0: Magnet in position switch energized 1: Magnet in position switch deenergized estop BOOL NC/NC 0: Emergency stop triggered Position switch sepact BOOL NC 1: Actuator inserted (safety door closed) Hinge switch hingedswitch BOOL NC 1: Unoperated (safety door closed) Position switch value status sepactvs BOOL Hinge switch value status hingedswitchvs BOOL Value status of output signalplesil3quality Value status of output fdoorcoil In the position switch: Time between the response of the magnet and the monitoring contact signalplesil3quality_vs fdoorcoil_vs feedbacktime BOOL BOOL TIME 0: Fault Positive edge required after triggerin g the safety function to reintegr ate F-I/O Chapter Chapter VS: value status Chapter Entry ID: , V1.2, 12/

228 Description Symbol Data type Convention Time delay after shutdown of the actuators to release the safety door. delaytimeunlock TIME When the time has elapsed, the door will be released. Choose a time which is long enough Table Outputs of FB F28EStopFDoorSIL3PLe Description Symbol Data type Convention Channel 1: Output signal from the F-DQ to the electric actuator Magnet in the position switch Release safety door Release emergency stop Acknowledgment for safety door Acknowledgment required signalplesil3quality BOOL 1: F-DQ output set fdoorcoil BOOL 0: Guard locking active releasefdoor BOOL 1: With regard to safety door, start is possible (safety door closed) releaseestop BOOL 1: Emergency stop released and acknowledged ackreqfdoor BOOL 1: Acknowledgment AckReqEStop BOOL required Information of the F-library blocks. Can be read out, for example, in the standard user program Configuration and parameterization The STEP 7 hardware configuration (HW Config) has already been prepared for commissioning FB F28EStopFDoorSIL3PLe. Customizations are possible. The associated HW Config can be found in the provided block library. WARNING Inappropriate values for safety-related settings may result in the safety function not being triggered in the event of danger. Please keep this in mind if, due to your requirements, you want to change the settings shown here. For more information on the hardware configuration in this user scenario, please refer to chapter Entry ID: , V1.2, 12/

229 Operation of the user scenario For demonstration purposes, this document shows different user scenarios. These scenarios can also be used as verification steps for validation. For information on installing the user scenario, please refer to chapter Requirements: No faults Emergency stop released Safety door closed Table Start actuator No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start Guard locking is activated, then signalplesil3quality=1 4 Press stop signalplesil3quality = 0; then the timer for the delayed release of the safety door starts. 5 Wait until the timer expires. When the timer has expired, the safety door can be opened. Table Safety function: Trigger emergency stop No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start signalplesil3quality=1 4 Press the emergency stop (estop) signalplesil3quality=0 5 Release the emergency stop (estop) 6 Press start signalplesil3quality=0 (acknowledgment required) 7 Wait until the timer expires. 8 Start again with no. 2 Entry ID: , V1.2, 12/

230 Table Safety function: Safety door fault No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start Guard locking is activated, then signalplesil3quality=1 4 Turn the hinge switch until it outputs 0 signal. signalplesil3quality = 0; then the timer for the delayed release of the safety door starts. 5 Wait until the timer expires. When the timer has expired, the safety door can be opened. 6 Close the safety door 7 Start again with no User Scenario 29: Emergency Stop + Safety Door with Guard Locking at PL d/sil 2, Electric Actuator You are using a drive as an actuator. Please also follow the information in chapter Safety function This user scenario has the following safety functions: Pressing the emergency stop button safely shuts down the actuator. Safety function with regard to the position of the safety door (interlocking) Opening the safety door during operation safely shuts down the actuator. Safety function with regard to guard locking After shutdown of the actuator, the safety door may only be opened when the actuator no longer constitutes a hazard. Under Normative assessment of guard locking, chapter addresses the situation where there is a safety function with regard to guard locking. Entry ID: , V1.2, 12/

231 Hardware and software components You need the hardware and software components listed below. Hardware components Table Hardware Component No. Article number CPU 1215FC DC/DC/RLY SM 1226 F- DI8/16x24VDC SM 1226 F-DQ 4x24VDC Enclosed pushbutton (NO) Enclosed pushbutton (NC) Emergency stop pushbutton (NC/NC) Position switch with solenoid interlocking (spring-locked) 1 6ES7215-1HF40-0XB0 1 6ES7226-6BA32-0XB0 1 6ES DA32-0XB0 2 3SB3801-0DD3 1 3SB3801-0DB3 1 3SB3801-0EG3 1 3SE5322-0SD21 Hinge switch 1 3SE5132-0LU21 Actuator for position switch 1 3SE5000-0AV0 Software components Table Software Component No. Article number STEP 7 Basic 1 6ES7822-0AA03-0YA5 Or STEP 7 Professional STEP 7 Safety Basic V13 SP1 1 6ES7833-1FB13-0YA5 Or STEP 7 Safety Advanced Entry ID: , V1.2, 12/

232 Wiring The figure below shows the wiring of the hardware components. Figure Emergency stop + safety door with guard locking PL d/sil 2 wiring 24V DC M stop start ack L+ M L1 Vs1 M L+.3 emagnet signalpldsil2quality fdoorcoil.1 Vs2 hingedswitch.0 sepact estop In the F-program, the NC auxiliary contacts of the contactors K1 and K2 are termed feedback1 and feedback2. Entry ID: , V1.2, 12/

233 In the safety program, the signals of the position switch are defined as follows: sepact (monitoring of the actuator position) sepact (monitoring of the locking device position) fdoorcoil (control of guard locking) The following figure shows the wiring on the position switch and therefore complements the above connection diagram. Figure Internal terminals of the position switch with solenoid interlocking sepact (F-DI) CH + (F-DQ) emagnet (Standard-DI) Vs1 (F-DI) L+ (F-CPU) CH (F-DQ) Brief description of the core functionality The following flowchart provides a concise description of the core functionality. Before starting the scenario for the first time, open and close the safety door once. Then acknowledge with ack=1. Entry ID: , V1.2, 12/

234 Figure Emergency stop + safety door with guard locking core functionality Start No Safety door closed and e-stop released? Yes Stop request? Yes Actuators stop No Previous stop was operational stop? No Yes Timer starts Acknowledge Unlock No timer expired? Yes Start conditions are complied Safety door interlocking is released Actuators on WARNING In this example for electric actuators, the safety door s guard locking is deactivated when the timer has expired. For moving parts, a hazard cannot be automatically ruled out when the timer has expired. Make sure that the safety door s guard locking is deactivated only when a hazard no longer exists. Entry ID: , V1.2, 12/

235 Description of the user block FB F29EStopFDoorSIL2PLd Figure User block FB F29EStopFDoorSIL2PLd NOTICE For F-blocks, the enable input (EN) must not be wired. This example assumes that you are using a hinge switch (hingedswitch) as a second channel. However, it is not mandatory to use a hinge switch. The required dual-channel redundancy can also be implemented with a different switch. WARNING Death or severe personal injury may result if you select a delaytimeunlock time that is too short. Customize these times to your requirements, for example to the slow-down time of a hazardous machine, to release the safety door when the delaytimeunlock time has expired. Parameter description The following section describes the inputs and outputs of FB F29EStopFDoorSIL2PLd. NO: normally open (contact); NC: normally closed (contact) Entry ID: , V1.2, 12/

236 Table Inputs of FB F29EStopFDoorSIL2PLd Description Symbol Data type Convention Acknowledgment ack BOOL NO 1: Acknowledgment Start request start BOOL NO 1: Start request Stop request stop BOOL NC 0: Stop request Monitoring of magnet in position switch Emergency stop pushbutton emagnet BOOL NC 0: Magnet in position switch energized 1: Magnet in position switch deenergized estop BOOL NC/NC 0: Emergency stop triggered Position switch sepact BOOL NC 1: Actuator inserted (safety door closed) Hinge switch hingedswitch BOOL NC 1: Unoperated (safety door closed) Position switch value status sepactvs BOOL Hinge switch value status hingedswitchvs BOOL Value status of output signalpldsil2quality Value status of output fdoorcoil In the position switch: Time between the response of the magnet and the monitoring contact Time delay after shutdown of the actuators to release the safety door. signalpldsil2quality_vs fdoorcoil_vs feedbacktime BOOL BOOL TIME 0: Fault delaytimeunlock TIME When the time has elapsed, the door will be released. Positive edge required after triggerin g the safety function to reintegr ate F-I/O Chapter Chapter VS: value status Chapter Choose a time which is long enough Entry ID: , V1.2, 12/

237 Table Outputs of FB F29EStopFDoorSIL2PLd Description Symbol Data type Convention Output signal from the F-DQ to the electric actuator Magnet in the position switch Release safety door Release emergency stop Acknowledgment for safety door Acknowledgment required signalpldsil2quality BOOL 1: F-DQ output set fdoorcoil BOOL 0: Guard locking active releasefdoor BOOL 1: With regard to safety door, start is possible (safety door closed) releaseestop BOOL 1: Emergency stop released and acknowledged ackreqfdoor BOOL 1: Acknowledgment AckReqEStop BOOL required Information of the F-library blocks. Can be read out, for example, in the standard user program Configuration and parameterization The STEP 7 hardware configuration (HW Config) has already been prepared for commissioning FB F29EStopFDoorSIL2PLd. Customizations are possible. The associated HW Config can be found in the provided block library. WARNING Inappropriate values for safety-related settings may result in the safety function not being triggered in the event of danger. Please keep this in mind if, due to your requirements, you want to change the settings shown here. For more information on the hardware configuration in this user scenario, please refer to chapter Entry ID: , V1.2, 12/

238 Operation of the user scenario For demonstration purposes, this document shows different user scenarios. These scenarios can also be used as verification steps for validation. For information on installing the user scenario, please refer to chapter Requirements: No faults Emergency stop released Safety door closed Table Start actuator No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start Guard locking is activated, then signalpldsil2quality = 1 4 Press stop signalpldsil2quality=0; then the timer for the delayed release of the safety door starts. 5 Wait until the timer expires. When the timer has expired, the safety door can be opened. Table Safety function: Trigger emergency stop No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start signalpldsil2quality=1 4 Press the emergency stop (estop) signalpldsil2quality=0 5 Release the emergency stop (estop) 6 Press start signalpldsil2quality=0; (acknowledgment required) 7 Wait until the timer expires. 8 Start again with no. 2 Entry ID: , V1.2, 12/

239 Table Safety function: Safety door fault No. Action Comment 1 Open and close the safety door When starting the scenario for the first time or in the event of a safety door fault, open and close the door completely. 2 Press ack Required when starting the scenario for the first time and after each opening of the safety door. 3 Press start Guard locking is activated, then signalpldsil2quality = 1 4 Turn the hinge switch until it outputs 0 signal. signalpldsil2quality=0; then the timer for the delayed release of the safety door starts. 5 Wait until the timer expires. When the timer has expired, the safety door can be opened. 6 Close the safety door 7 Start again with no. 1 Entry ID: , V1.2, 12/

240 6.31 User Scenario 30: Emergency Stop + Safety Door with Guard Locking at PL c/sil 1, Electric Actuator Safety function This user scenario has the following safety functions: Pressing the emergency stop button safely shuts down the actuator. Safety function with regard to the position of the safety door (interlocking) Opening the safety door during operation safely shuts down the actuator. Safety function with regard to guard locking After shutdown of the actuator, the safety door may only be opened when the actuator no longer constitutes a hazard. Under Normative assessment of guard locking, chapter addresses the situation where there is a safety function with regard to guard locking Hardware and software components Hardware components You need the hardware and software components listed below. Table Hardware Component No. Article number CPU 1215FC DC/DC/RLY SM 1226 F- DI8/16x24VDC SM 1226 F-DQ 4x24VDC Enclosed pushbutton (NO) Enclosed pushbutton (NC) Emergency stop pushbutton (NC) Position switch with solenoid interlocking (spring-locked) Actuator for position switch 1 6ES7215-1HF40-0XB0 1 6ES7226-6BA32-0XB0 1 6ES DA32-0XB0 2 3SB3801-0DD3 1 3SB3801-0DB3 1 3SB3801-0DG3 1 3SE5322-0SD21 1 3SE5000-0AV0 Entry ID: , V1.2, 12/

241 Software components Table Software Component No. Article number STEP 7 Basic 1 6ES7822-0AA03-0YA5 Or STEP 7 Professional STEP 7 Safety Basic V13 SP1 1 6ES7833-1FB13-0YA5 Or STEP 7 Safety Advanced Entry ID: , V1.2, 12/

242 Wiring The figure below shows the wiring of the hardware components. Figure Emergency stop + safety door with guard locking PL c/sil 1 wiring 24V DC M stop start ack L+ M L1 Vs1 M L+.3 emagnet signalplcsil1quality fdoorcoil sepact.0 estop Vs1 In the F-program, the NC auxiliary contacts of the contactors K1 and K2 are termed feedback1 and feedback2. Entry ID: , V1.2, 12/

243 In the safety program, the signals of the position switch are defined as follows: sepact (monitoring of the actuator position) sepact (monitoring of the locking device position) fdoorcoil (control of guard locking) The following figure shows the wiring on the position switch and therefore complements the above connection diagram. Figure Internal terminals of the position switch with solenoid interlocking sepact (F-DI) CH + (F-DQ) emagnet (Standard-DI) Vs1 (F-DI) L+ (F-CPU) CH (F-DQ) Entry ID: , V1.2, 12/

244 Brief description of the core functionality The following flowchart provides a concise description of the core functionality. Before starting the scenario for the first time, open and close the safety door once. Then acknowledge with ack=1. Figure Emergency stop + safety door with guard locking core functionality Start No Safety door closed and e-stop released? Yes No Stop request? Yes Actuator stops Previous stop was operational stop? No Acknowledge Yes Timer starts Unlock No timer expired? Yes Start conditions are complied Safety door interlocking is released Actuators on Entry ID: , V1.2, 12/

245 WARNING In this example for electric actuators, the safety door s guard locking is deactivated when the timer has expired. For moving parts, a hazard cannot be automatically ruled out when the timer has expired. Make sure that the safety door s guard locking is deactivated only when a hazard no longer exists Description of the user block FB F30EStopFDoorSIL1PLc Figure User block FB F30EStopFDoorSIL1PLc NOTICE For F-blocks, the enable input (EN) must not be wired. WARNING Death or severe personal injury may result if you select a delaytimeunlock time that is too short. Customize these times to your requirements, for example to the slow-down time of a hazardous machine, to release the safety door when the delaytimeunlock time has expired. Parameter description The following section describes the inputs and outputs of FB F30EStopFDoorSIL1PLc. NO: normally open (contact); NC: normally closed (contact) Entry ID: , V1.2, 12/