Applications & Tools. Entering limit values for safely limited speed (SLS) into a SINAMICS S120 via PROFIsafe with PROFINET SINAMICS S120

Transcription

1 lcover sheet Entering limit values for safely limited speed (SLS) into a SINAMICS S120 via PROFIsafe with PROFINET SINAMICS S120 Application example February 2014 Applications & Tools Answers for industry.

2 Siemens Industry Online Support This article is taken from Siemens Industry Online Support. The following link takes you directly to the download page for this document: Caution: The functions and solutions described in this article are limited primarily to the implementation of the automation task. Please also note that in case of networking your plant area with other parts of the plant, the company network or the Internet, appropriate protective measures within the framework of industrial security must be adopted. For more information, see the entry ID Version 1.0, Entry ID:

3 s Task 1 Solution 2 Basic principles 3 SINAMICS S120 Safety Integrated Entering limit values for safely limited speed (SLS) into a SINAMICS S120 via PROFIsafe with PROFINET Configuration and project engineering 4 Installation 5 Commissioning the application 6 Operating the application 7 References 8 Contact persons 9 History 10 Version 1.0, Entry ID:

4 Table of contents Warranty and liability Note The application examples in this document are not binding and do not claim to be complete regarding the configuration, equipping, and any eventuality. The application examples do not represent specific customer solutions, but are only intended to provide support for typical applications. You are responsible for the proper operation of the described products. These application examples do not relieve you of your responsibility regarding the safe handling when using, installing, operating, and maintaining the equipment. By using these application examples, you agree that Siemens cannot be made liable for possible damage beyond the mentioned liability clause. We reserve the right to make changes to these application examples at any time and without prior notice. If there are any differences between the suggestions made in these application examples and other Siemens publications, such as catalogs, the contents of the other document(s) take priority. We give no guarantee for the information contained in this document. We accept no liability for any damage or loss caused by the examples, information, programs, planning data or performance data described in these application examples, irrespective of the legal basis for claims arising from such damage or loss, unless liability is mandatory. For example, according to the product liability law, in cases of malfeasance, gross negligence, due to endangerment of life, the body or health, due to assumption of a guarantee for a product's characteristics of state, due to malicious concealment of a defect or due to violation of basic contractual obligations. However, claims for indemnification based on breach of contract shall be limited to liability for damages to the contract-specific, foreseeable damages, provided there is no mandatory liability for intent, acts of gross negligence, harm to the life, body and health of human beings. Any change to the burden of proof to your disadvantage is not covered hereby. Any form of duplication of these application examples or excerpts hereof is not permitted without the express consent of Siemens Industry Sector. 4 Version 1.0, Entry ID:

5 Table of contents Table of contents Warranty and liability Task Overview Solution Overview of the overall solution Description of the core functionality Hardware and software components used Basic principles PROFIsafe communication Configuration and project engineering Passwords Preparation Hardware configuration Configuring the basic drive functions PROFIsafe configuration to control the safety functions integrated in the drive Parameterizing the safety functions integrated in the drive Configuring the F-CPU Acceptance test Installation Commissioning the application Preconditions Preparation Commissioning Operating the application Overview Description of function References Related documents Internet links Contact persons History Version 1.0, Entry ID:

6 1 Task 1 Task 1.1 Overview Introduction The following safety functions according to DIN EN are currently integrated in SINAMICS S120 drives: Table 1-1: SINAMICS S120 safety functions according to DIN EN Name Function Description STO Safe Torque Off SS1 Safe Stop 1 SBC Safe Brake Control SS2 Safe Stop 2 SOS SLS SSM SDI SLP Safe Operating Stop Safely Limited Speed Safe Speed Monitor Safe Direction Safely Limited Position Safe disconnection of the torque-generating power supply to the motor. The switching on inhibited function prevents the drive unit from being switched on again. (Category 0 stop function according to EN ) The drive is quickly and safely stopped along the OFF3 ramp and is safely monitored. Transition to STO after a delay time has expired or the shutdown speed has been reached. (Category 1 stop function according to EN ) SBC is only used when there is a motor brake and the motor brake is connected to the power connector via the outputs. SBC always responds in conjunction with STO or when internal safety monitoring functions respond with safe pulse cancellation. The drive is quickly and safely stopped along the OFF3 ramp and is safely monitored. Transition to SOS after a delay time has expired; the drive remains in closed-loop control. (Category 2 stop function according to EN ) Not available for safety functions without encoder. This function serves to safely monitor the standstill position of a drive; the drive remains in closed-loop control. Not available for safety functions without encoder. The drive speed is safely monitored. Parameterizable shutdown response when the limit value is violated. Safely displays when the speed falls below a speed limit (n < nx). The direction of motion (positive and negative directions) is safely monitored. Parameterizable shutdown response when moving in the direction that has not been enabled. The positioning range of a drive is safely monitored; corresponds to safety-relevant software limit switches. Parameterizable shutdown response when position limits are violated. Not available for safety functions without encoder. 6 Version 1.0, Entry ID:

7 1 Task In addition to the functions defined in standard DIN EN , the following safety functions are also available in SINAMICS S120. Table 1-2: SINAMICS S120 safety functions not specified by DIN EN Name Function Description SP SBT Safe Position Safe Brake Test The safety-relevant position values of the SINAMICS S120 are transferred to a higher-level fail-safe control system (F-CPU) using a PROFIsafe telegram For safety functions without encoder, these are only available with some restrictions. Using this function, the holding torque of up to 2 (holding) brakes can be tested. In conjunction with the SBC function, a safety-relevant brake can be implemented. Not available for safety functions without encoder. The implementation of safety concepts is facilitated significantly through the use of drive-integrated safety engineering and its use also simplifies the verification of the required safety category for a machine. The user is also supported by the Safety Evaluation Tool. In the current example, a SIMATIC F-CPU uses the PROFIsafe telegram with PROFINET to control the safety functions. The SLS limit value input is implemented using telegram 901 via the F-CPU. Version 1.0, Entry ID:

8 1 Task Overview of the automation task The following diagram provides an overview of the automation task. Figure 1-1: Concept of the safety functions The following safety functions are used as basis for further consideration. Table 1-3: Safety functions of the application example Safety function Description Response SF1 SF2 Actuating the Emergency Stop button When the protective door is open, it is not permissible that the drive exceeds the velocity/speed configured by the user. (high limit value) STO: Safe shutdown of the drive torque. SLS: Monitoring of the drive speed. 8 Version 1.0, Entry ID:

9 1 Task Safety function Description Response SF3 When the light barrier is interrupted, it is not permissible that the drive exceeds the velocity/speed configured by the user. (low limit value) SLS: Monitoring of the drive speed. Description of the automation task In this example, STO and SLS are to be controlled via PROFIsafe with PROFINET. PROFIsafe telegram 901 is also used to transfer limit values for the safely limited speed (SLS) to the drive. The following conditions must be met in order that the drive can operate with any speed: Protective door -S2 is closed, light barrier -S3 is not interrupted, and therefore provides a HIGH signal at the output. However, if a protective door low signal is transferred, then SLS becomes active and the SLS limit value is set by the F-CPU to 100% of the limit value saved in the drive. If the light barrier -S3 supplies a low signal, then SLS also becomes active; however the F-CPU reduces the limit value saved in the drive to 40%. If both sensors supply a low signal, then the SLS limit value is reduced to 40%. In both cases, SLS level 1 is active; however, only the signal state of light barrier -S3 defines as to whether the limit value is reduced. Version 1.0, Entry ID:

10 2 Solution 2 Solution 2.1 Overview of the overall solution Schematic The following schematic diagram shows the most important components of the solution: Figure 2-1: Relative components of the safety functions Controlling safety functions STO and SLS via PROFIsafe with PROFINET for a SINAMICS S120 drive line-up is demonstrated using this application example. PROFIsafe telegram 901 can be used to control the safety function and also enter a safety-relevant speed limit. The drive line-up in the booksize format comprises an infeed and a Double Motor Module (DMM). A CU320-2 Control Unit is used to control the motor. The extended setpoint channel is used to enter a speed setpoint. The servomotor is controlled using the Double Motor Module. A Smart Line Module (SLM) is used as infeed. The safety-related signals are sensed using fail-safe inputs of the F-CPU and evaluated in the F-CPU. The safety functions integrated in the drive are controlled via the fail-safe PROFIsafe communication. A variable SLS limit is entered depending on the states of the signals of the protective door and the light barrier. The F-CPU evaluates the signals, and 10 Version 1.0, Entry ID:

11 2 Solution depending on the signal state of the protective door (-S2) and the light barrier (-S3), transfers the override value (100 or 40%) for SLS level 1. The F-CPU is the F host as well as also the PROFINET controller. Design This application example is based on the SINAMICS S120 training case (6ZB BA00) and the SAFETY training case. Advantages The application described here offers you the following advantages: Simple control of the safety functions integrated in the drive. Simple design using standard technology. The existing system can be quickly and simply expanded. Space-saving and favorably-priced design using integrated safety functions additional hardware is not required. Complex safety concepts can be implemented on this basis. Limitations Knowledge required This application does not contain a description of the safety functions of the SINAMICS S120, the general drive functions of the SINAMICS S120, the hardware interfaces of the CU320-2 It is assumed that readers have basic knowledge of these topics. Information on these topics can be found in the documents in the references. It is assumed that readers have basic knowledge about engineering SINAMICS S120 drives with the STARTER or SIMOTION SCOUT and STEP7 engineering software. Version 1.0, Entry ID:

12 2 Solution 2.2 Description of the core functionality Overview and description of the hardware used Figure 2-2: Hardware components used Sequence of the core functionality Switches -S1 to -S4 are located on a switchbox that belongs to the SAFETY training case. The STO function is initiated using -S1. The SLS safety function is controlled using switch -S2 or -S3. Using switch -S2, a high SLS limit value is entered, and using switch -S3, a low SLS limit value is entered; switch -S3 has a higher priority. Pushbutton -S4 is used for fail-safe acknowledgment. Switches -S5 to -S8 are located on a switchbox that belongs to the SINAMICS training case. Switch -S5 is used to switch on and switch off the drive. You can toggle between different speed setpoints using switches -S6 and -S7. Switch -S8 is used to initiate a test stop of the safety functions. The remaining switches are not used in this application example. Note In this application example, only the upper (red) drive of the two-axis demonstration case is used. The DRIVE-CLiQ connection to the encoder of the lower motor (gray cable) should be withdrawn. Topology alarm A1416 is output if this is not done. 12 Version 1.0, Entry ID:

13 2 Solution 2.3 Hardware and software components used Hardware components The application was created with the following components: Table 2-1: Hardware components Component Qty MLFB/ ordering data Note SAFETY training case 1 SINAMICS S120 training case 1 6ZB BA00 CU320-2 PN 1 6SL3040-1MA01-0AA0 Compact Flash Card 1 6SL3054-0ED00-1BA0 CBE20 1 6SL3055-0AA00-2EB0 As an alternative, a CU320-2 DP can also be used. Only necessary when using a CU320-2 DP. Table 2-2: SAFETY training case (essential components) Component Type MLFB/ ordering data Qty Manufacturer SITOP power supply SITOP SMART 120W 6EP AA01 1 Siemens SIMATIC S7-300 CPU SIMATIC S7 fail-safe input module SIMATIC S7 fail-safe output module SINAMICS fail-safe Terminal Module Drive-CLiQ Toggle switches -S2 and -S3 Emergency Stop button -S1 Pushbutton -S4 Load resistors R1 R8 CPU 315F-2 PN/DP SIMATIC MMC, 512KB SM 326 F-DI 24 SM 326 F-DO 8 6ES FH13-0AB0 6ES LJ20-0AA0 6ES BK01-0AB0 6ES BF40-0AB0 1 Siemens 1 Siemens 1 Siemens 1 Siemens TM54F 6SL3055-0AA00-3BA0 1 Siemens Cable, gray metal connector Toggle switch 0-I, latching, 16 mm, black Holder with solder pins Mushroom pushbutton, red, 16 mm Holder with solder pins Pushbutton, flat, 16 mm, white Holder with lamp socket and lamp 1kOhm 1W 6FX2002-1DC00-1AC0 1 Siemens 3SB2000-2AB01 2 Siemens 3SB2908-0AB 2 Siemens 3SB2000-1AC01 1 Siemens 3SB2908-0AB 1 Siemens 3SB2000-0AG01 1 Siemens 3SB2455-1B 1 Siemens Type PO595-0 style 0207 Power metal oxide film resistors 1 Yageo Europe Version 1.0, Entry ID:

14 2 Solution Component Type MLFB/ ordering data Qty Manufacturer Terminals for the load resistors (R1 R8) Load resistor R9 Terminals for load resistor (R9) ST 2.5-QUATTRO-TG P-CO component connector SMA0207 1K2 1% TK TERMINALS_ACCES SORY_EMPTY_CON NECTOR_TYPE1_G RAY TERMINAL_4- WIRE_GRAY RES_MET_FLM_1K2 _+- 1%_600mW_+50ppm _0207 Phoenix Contact Phoenix Contact 1 Beyschlag WAGO WAGO Note The application example was tested with the hardware components listed here. Alternatively, other components with the same function may be used. In such a case, a different parameter assignment and different wiring of the components may be required. The components marked in yellow are not relevant for this function example. Standard software components Table 2-3: Engineering software Component Qty. Order number Version STEP 7 1 6ES7810-4CC10-0YA7 V5.5 SP2 HF1 S7 Distributed Safety Programming S7 F configuration pack 1 1 6ES7833-1FC02-0YA5 V5.4 SP5 V5.5 SP10 STARTER 1 6SL3072-0AA00-0AG0 V Sample files and projects The list below contains all the files and projects used in this example. Table 2-4: Documents and files MC_FE_I_019_V10.zip Component _MC_FE_I_019_V10_en.pdf Note This zipped file contains the project. This document 14 Version 1.0, Entry ID:

15 3 Basic principles 3 Basic principles 3.1 PROFIsafe communication Every drive with configured PROFIsafe slot in the drive device represents an F device with a fail-safe communication to the F host via PROFINET. A suitable PROFIsafe telegram (PROFIsafe slot) is created for each drive. SIEMENS telegram 901 is used in this example. Telegram 901 transfers the S_STW2 (safety control word 2), the variable SLS limit (S_SLS_LIMIT_A), the S_ZSW2 (safety status word 2), the active SLS value of level 1 (S_SLS_LIMIT_A_ACTIVE), a counter value (S_CYCLE_COUNT) and the safe position value in the 16-bit format (S_XIST16) as user data. It is structured as follows: Table 3-1: Structure of PROFIsafe telegram 901 Output data Input data PZD1 S_STW2 S_ZSW2 PZD2 PZD3 S_SLS_LIMIT_A S_SLS_LIMIT_A_ACTIVE PZD4 - S_CYCLCE_COUNT PZD5 - S_XIST16 The SLS limit value input is transferred using S_SLS_LIMIT_A (PZD3). S_SLS_LIMIT_A PZD3 in telegrams 901 and 902, output signals SLS limit value input Value range ; % Version 1.0, Entry ID:

16 4 Configuration and project engineering In this chapter, you get to know how the individual components must be parameterized. STARTER is used as the engineering software for SINAMICS S120. How the software project belonging to this application example was set-up is described step-by-step in the following sections. Note The screenshots were generated with the "English" language setting. Display differences can occur for other language settings. 4.1 Passwords NOTICE For reasons of simplicity, a common safety password is used for the program and hardware on the SIMATIC components in the project. Safety password for F-CPU: 0 Safety password for SINAMICS: 1 Such simple passwords must not be used in a real application as they do not provide adequate protection against authorized personnel accessing the configuration. 16 Version 1.0, Entry ID:

17 4.2 Preparation Before configuration can be started, the PROFINET interface of the computer being used must be suitably set. Table 4-1: Setting the PG/PC interface 1. To start, please open the SIMATIC Manager. 2. Then create a new project by pressing the "New" button. 3. The PG/PC interface is now set up. To do this, please press the "Set PG/PC button in the "Options" menu. Version 1.0, Entry ID:

18 Here, select the hardware which you wish to use to establish an online connection. 4. In this example, it involves the USB Ethernet adapter "ASIX AX88179 USB 3.0". Open the properties window using the "Properties" button. 5. In the subsequent window, please click on the "Network properties" button. 6. Select the network connection being used and open the status window by double-clicking on the corresponding network. 18 Version 1.0, Entry ID:

19 7. Now click the "Properties" button. 8. Now select the menu item "Internet Protocol (TCP/IP)" and press the "Properties" button. Version 1.0, Entry ID:

20 Now set a fixed IP address. 9. The following setting is used in this example: IP address: Subnet mask: Confirm your entry with "OK." 10. In order to assign the devices the required IP addresses and device names, under "PLC", select the "Edit Ethernet Node" item. 20 Version 1.0, Entry ID:

21 11. Then click the "Browse" button. 12. All of the nodes/participants that can be reached are listed. First select "S7-300" station and then press "OK". Version 1.0, Entry ID:

22 In this example, the S7-300 station was assigned the following configuration: IP address: Subnet mask: Now acknowledge the entries that you have made with "Assign IP Configuration", and close the window with "Close". 14. Note: The "Assign Name" button can be used to assign a specific name to a node/participant. The "pn-io" default value is kept unchanged for this particular example. The CU320-2 is assigned an IP address in the following. To do this, select the Control Unit from the nodes/participants that can be reached and press "OK". 22 Version 1.0, Entry ID:

23 In this example, the CU320-2 station was assigned the following configuration: IP address: Subnet mask: Now acknowledge the entries that you have made with "Assign IP Configuration", and close the window with "Close". Note: The "Assign Name" button can be used to assign a specific name to a node/participant. The "s120xcu320x2xpn" default value is kept unchanged for this particular example. Version 1.0, Entry ID:

24 4.3 Hardware configuration Table 4-2: Hardware configuration In the next step, now insert a SIMATIC 300 station into the project. 1. To do this, click on the "Insert" menu item. In the following submenu select the entry "Station" followed by "2 SIMATIC 300 Station". 2. Now open the window to configure the hardware being used. This is realized by doubleclicking on the "Hardware" entry, for example. 24 Version 1.0, Entry ID:

25 First insert a rack in the "HW Config" window. 3. Then please select the F-CPU being used and insert this. To do this you can drag the corresponding F-CPU and drop it into the rack (profile rail). In this example the following F-CPU is used: "CPU 315F-2 PN/DP". Once this has been done, then the adjacent window is displayed. 4. Here, please check that the IP address of the CPU lies within the address range of the PC/PG interface, and press the "New" button to create a new subnet (PROFINET). Press the "OK" button to create a new subnet. 5. Then select the subnet that has been created and exit the mask with "OK". Version 1.0, Entry ID:

26 6. Now make the basic settings, with which the safety mode of the F-CPU being used is activated. To do this, open the properties window (by double-clicking on the F- CPU). Here, go to the "Protection" tab. Activate the safety mode by setting a checkmark for "CPU contains safety program". 7. As protection level, select level 1, and activate passwordprotected access. Assign a password for the safety program. 0 is used as password in this particular example. Click "OK" to confirm the data that have been entered. Now insert the F-DI module of the safety demonstration case by dragging and dropping. 8. In this example an "FDI24xDC24V" module is used. Then open the properties of the module by double-clicking on the module. 26 Version 1.0, Entry ID:

27 Check the address settings for the input and output range of the data. 9. In this example, the following applies: Input address: 0..9 Output address: In the property window of the FDI module, make the following adaptations under the "Parameters" tab. Select "Safety mode". Select "Passivate the channel". Set the checkmark for "Diagnostic interrupt" Version 1.0, Entry ID:

28 11. Make the settings for the F-DIs, which are highlighted in the adjacent screenshot. Please note, that for all of the other channels, the checkmark is removed for "Activated", as only channels 0, 1, 2, 3 are used. 12. Now insert the F-DO module of the safety demonstration case by dragging and dropping. An "FDO8xDC24V/2A" module is used in this example. Then open the properties of the module by double-clicking on the module. 28 Version 1.0, Entry ID:

29 Check the address settings for the input and output range of the data. 13. In this example, the following applies: Input address: Output address: Now make the settings as shown in the adjacent screenshot. To do this, go to the "Parameters" tab. It should be noted that only channel 7 is activated. The checkmark for "Activated" should be removed for all other channels. For channel 7, also remove the checkmark for "Diagnostics: wire break". 15. Now insert SINAMICS S120 into the hardware configuration. In the catalog select a SINAMICS S120 with CU320-2 PN and drag the component with version V4.6 and drop at the PROFINET connection that has been created (Ethernet 1). Version 1.0, Entry ID:

30 The following window is opened after insertion. Here, please select the subnet on which the SINAMICS S120 is to be operated. 16. In this example, this is the "Ethernet 1" network. Also check the automatically created address. In the example, the CU320-2 PN is assigned address Close the screen form using the "OK" button Here, save and compile the hardware configuration. Then please open "NetPro" to insert the PG/PC into the configuration. From the catalog, select the PG/PC object, and drag it to the work area. Open it by double-clicking on the properties window symbol. 19. Select the "Interfaces" tab, and press the "New" button to configure a network interface.. An "Industrial Ethernet" interface is required for the example. Click "OK" to confirm the selection. 30 Version 1.0, Entry ID:

31 Select the newly created interface, and press the "Properties" button to open the window that is displayed. 20. Remove the checkmark for "Set MAC address / use ISO protocol" and set the same network address and subnet mask that you assigned when setting the PC/PG interface in Section 4.2. In the example, the following IP address and subnet mask are used: Click "OK" to confirm what has been entered. 21. Now change to the "Assignment" tab to assign the interface of the hardware being used. To do this, select the corresponding interface (in the example: TCP/IP -> ASIX AX88179 ) and press "Assign". 22. The assigned interface is now displayed in the "Assigned" window. Please ensure that the checkmark for "S7ONLINE Access" is set. Click "OK" to confirm what has been entered. Version 1.0, Entry ID:

32 The computer is now inserted with an active connection shown in yellow. 23. Please save and compile the changes that have been made. Then close "NetPro" and return to HW Config. 24. Save and compile the settings in HW Config again. Then load the configuration into the F-CPU. 32 Version 1.0, Entry ID:

33 4.4 Configuring the basic drive functions All of the SINAMICS S120 drive lineup settings required to move the axis are explained in this section. The configuration of the safety functions is described in a separate section. Table 4-3: Configuring the basic drive functions Open STARTER from the existing S7 project. You can do this by doubleclicking on "Commissioning". Now go online and start the automatic drive configuration. You can go online by pressing the "Connect to selected target devices" button. In the project navigator then select the entry "Automatic Configuration". Version 1.0, Entry ID:

34 3. Then press the "Configure" button. The DRIVE-CLiQ nodes are then read out Select the "Servo" control mode. Then press the "Create" button. Go offline after the automatic configuration has been completed. 34 Version 1.0, Entry ID:

35 6. In this application example, only the upper (red) motor is used. As a consequence, the lower (blue) motor should be deleted from the application. To do this, right click on the "SERVO_03" button, and press the "Delete" button. 7. The drive has to be postconfigured in the next step. Open the drive configuration by double-clicking on the drive, in this particular case "SERVO_02". Then press the "Configure DDS" button. Version 1.0, Entry ID:

36 The extended setpoint channel is used to specify the speed of the drive. Therefore, enable the "Extended setpoint channel" function. 8. Complete your entries by pressing "Next". Note: In the following, only those screen forms are described in which a change is required. 9. A signal for "Infeed in operation" (p0864) must be configured. Here, fixed binector 1 is used in the example. Note: In a real application, fixed binector 1 should not be used as signal for the "Infeed in operation" (p0864). 36 Version 1.0, Entry ID:

37 Since a motor with DRIVE-CLiQ interface is used, this should be read out. To do this, activate the "Read out motor again" checkbox. 10. Press the "Next" button to acknowledge the entries that you have made. Continue with the post configuration until it has been completed. After the post configuration has been completed, in the project navigator, select the menu item "Telegram configuration". 11. Version 1.0, Entry ID:

38 12. In the following screen form, please select "Standard Telegram 1" for the drive. 13. Then return to "Free telegram configuring with BICO ; as a consequence, the links of the "Standard Telegram 1" are kept. These can be subsequently adapted for the example Now save the changes that have been made. Then go online and download the project to the target device. The speed controller should be set as follows, as in the following the "Safely Limited Speed" (SLS) is parameterized. A speed controller that has been sent too weak can result in alarm C01714/C30714 "Safely Limited Speed exceeded"! To do this, change to the "Speed controller" screen form, and set the following values: P gain (p1460): 0.3 Nms/wheel Reset time (p1462): 5.0 ms 16. In order to switch the drive on with switch -S5, the appropriate digital input is interconnected to the ON/OFF1 enable. To do this, click "Control Logic" below the drive object. Digital input DI 0 (r722.0) is then connected to parameter p Version 1.0, Entry ID:

39 The required speed setpoints are entered in the following screen form. To do this, click on "Setpoint channel > Fixed setpoints". Binary logic (bit 0-3) can be implemented here which allows a switchover to various speed setpoints. The following interconnections have been made: Bit 0: Bit 1: Control Unit DI1 (r722.1), (switch -S6) Bit 2: Control Unit DI2 (r722.2), (switch -S7) The following fixed values were entered: Fixed value 1: 250 rpm Fixed value 3: 500 rpm Fixed value 5: 1000 rpm Fixed value 7: 1000 rpm Fixed setpoint active p1024 still has to be interconnected with p1070[0] main setpoint. From the project navigator, open the screen form "Ramp-function generator" to set the OFF3 ramp-down time. 18. Then click on the button with the red frame. Version 1.0, Entry ID:

40 The OFF3 ramp-down time is used for braking when SS1/SS2 is selected. Set parameter (p1135) to 0.5 seconds. 19. For this example, this means that when SS1/SS2 is selected the drive operating at maximum speed (p1082) comes to a standstill in 0.5 seconds. In this example, when an SLS speed limit is exceeded, SS2 becomes active When using a Single Line Module for 1AC 230V (provided in the training cases), now adapt the DC link parameters. To do this, open the expert list and make the adjacent parameter changes. Changes to the specified values can only be made online. Note: As the SLM 5 kw has no DRIVE-CLiQ interfaces, it is not necessary to parameterize the infeed. Then save the configuration, copy from RAM to ROM and load the configuration into the PG/PC. Now go offline again to continue the configuration. p0210: 345V p1248[0]: 240V p1244[0]: 401V See also FAQ ID: Version 1.0, Entry ID:

41 4.5 PROFIsafe configuration to control the safety functions integrated in the drive Table 4-4: PROFIsafe configuration 1. In the project navigator now change to the menu item "Telegram configuration". Then add a PROFIsafe slot by pressing the "Add PROFIsafe" button. 2. Now change the telegram to "PROFIsafe standard telegram 901". Then transfer the telegram configuration to HW Config. You do this by pressing the "Set up addresses" button. 3. Now change to the hardware configuration in SIMATIC Manager. The telegram selected was entered automatically into HW Config. The allocated address can be changed here. Open the PROFIsafe properties by double-clicking on "PROFIsafe telegram 901". Version 1.0, Entry ID:

42 Additional settings can be made under the "PROFIsafe tab. In STARTER, the value of "F_Dest_Add" should be entered in the hexadecimal format for the drive. 4. "C6hex" or "198dec" were used in this particular example. Note: The watchdog time ("F_WD_Time" = 150msec) should not be an integer multiple of the OB 35 cycle. In the example, the OB35 cycle is 100msec Close the screen form by pressing the "OK" button. Now save and compile the HW configuration. Then load the HW Config to the target system. 42 Version 1.0, Entry ID:

43 4.6 Parameterizing the safety functions integrated in the drive Table 4-5: Parameterizing the safety functions integrated in the drive 1. Now go online with STARTER again. Download the project and copy RAM to ROM. 2. In the project navigator then change to the "Safety Integrated" safety functions. Here, please press the "Change settings" button. 3. Please select the extended safety functions via PROFIsafe. (Extended functions via PROFIsafe) Then enable the safety functions. 4. To do this, set the "Safety functions" to "Enable". Then press the "Configuration" button Version 1.0, Entry ID:

44 Then select DI3 (r722.3) as signal source for the test stop of the safety functions. 5. This means that the test stop can be controlled using switch - S8. Now press the "PROFIsafe configuration" button. In the PROFIsafe configuration, enter the PROFIsafe address that you defined in HW Config Address "C6hex" is used in this example. Then check that the PROFIsafe telegram of "Telegram configuration" matches the "Safety parameterization". Close the window by clicking "Close". Please press the "Safe stop functions (SS1, SS2, SOS, SAM)" button to configure the SS2 safety function, which becomes active when the SLS limit value is exceeded. 44 Version 1.0, Entry ID:

45 In screen form SS2, please also change the value of the delay time "Delay time SS2/STOP C - > SOS active" to 500ms. 8. This stop response becomes active when the SLS limit is exceeded. Close the screen form using "Close". 9. To be able to parameterize the SLS safety function, please press the "Safely limited speed (SLS)" button in the "Safety Integrated" screen form. For SLS level 1, please set the value to 7500mm/min; in this example this corresponds to a speed of 750 rpm. 10. Please select "STOP C" as stop response. Now change the value of the delay time "Delay time between sel. SLS -> SLS active to 500ms. Finally, set the selection for "SLS limit via PROFIsafe" to "Enable" and close the screen form with "Close". Version 1.0, Entry ID:

46 11. The parameters must now be copied. To do this please press the "Copy parameters" button. Then click on the "Activate settings" button. 12. You are subsequently prompted to change the password. The default password is "0". Change the password to "1". 13. Data is copied from RAM to ROM when pressing the "Yes" button. 14. Then go offline Now please carry out a power on reset of the drive. Then go online again, load the project into the PG/PC and save it. POWER OFF/ON 46 Version 1.0, Entry ID:

47 4.7 Configuring the F-CPU A standard program is not required for this application example, as the drives are exclusively controlled via BICO interconnections in SINAMICS. For most applications in practice, a program which is independent of the safety program is expected here, which is based on a standard telegram. In this example, in OB1 only the required enables are defined in the control word. In this example, the safety program in the F-CPU is processed in fail-safe function block FB1. A simplified program sequence has been selected to illustrate how the functions work. Complex safety logic and boundary conditions for creating the safety program are covered in the Distributed Safety manuals. NOTICE The safety program for this function example has been consciously made as simple as possible, and coordinated to run on the safety demonstration case. It is not permissible that the program is used in this form for a real application. You start with the F call block. This is required to call the safety program. For this purpose, a function (in this case, FC1) must be inserted in the block folder in the F call programming language. Cyclic interrupt OB35 is required to cyclically call the safety program. In this example, the actual safety program is executed in a function block (here, FB1), this means that only FB1 must now be inserted using the F-LAD or F-FBD programming language. Table 4-6: Configuring the F-CPU 1. OB1 Permanently writing all enables to the control word Address 256 was specified by the telegram configuration. Corresponds to the start address of "Standard telegram 1". The address can be taken from HW Config or the telegram configuration of the drive. (see Table 4-5, No. 2. and No. 3) Version 1.0, Entry ID:

48 2. Now insert an additional function. This function is called using what is known as the F call block with the safety program. This is simply created. No changes can be made in this block. Please assign the "FC1" name and as programming language, select "F-CALL". Click "OK" to confirm what has been entered. 3. OB35 Subsequently insert an organization block. Assign the "OB35" name, and select "STL" as programming language. Open the OB35 and insert a network, in which the safety program is called using the "CALL FC 1" command. Then save the block. 48 Version 1.0, Entry ID:

49 4. FB1 In this example, the actual safety program is created in an FB function block. Please insert such a block into the block folder. Then assign the "FB1" name, and as programming language select "F-FDB" (=F-FUP). Network 1: The automatic acknowledgment is activated in this network. Network 2: Safety function STO is controlled using switch -S1. Network 3: In this network, all of the safety functions on the drive that are not required are permanently deselected. This applies to SS1, SS2, SOS, SLP and SDI+/-. Network 4: Safety function SLS is controlled using switch -S2 or -S3. Version 1.0, Entry ID:

50 5. Network 5: Pushbutton -S4 is used to control the acknowledgment bit of the PROFIsafe telegram. Networks 6 and 7: In this network, SLS speed level 1 is permanently selected on the PROFIsafe STW. Network 8: SLP position range 0 is permanently selected Network 9: Here, using the position of switch -S3, a decision is made as to which SLS override is set. If the switch is not actuated (high signal), then the SLS override is set to 100% (=32767). In this case, networks 10 and 11 are skipped. If the switch is actuated (low signal), then the SLS override is set to 40% (=13107). Network 10: Here, the default value for the SLS override is set to 40%. The network is calculated until the jump condition in network 9 is not fulfilled. Network 11: As a consequence, network 12 is skipped (jump to the "end" label). This prevents the override from being reduced to 40% if the condition in network 9 is not fulfilled. 50 Version 1.0, Entry ID:

51 6. Network 12: A jump is made to this network (or to the "SLS" label) if the condition from network 9 is fulfilled. Here, the override (AW 19) is set to a value of (=100%). Network 13: A jump is made to the "end" label from network 11. As a network may not contain just one label, the link between the SSM signal and signal lamp -L4 was shifted into this network. The signal lamp (=Q10.7) contained in pushbutton -S4 is controlled if the SSM function signals a HIGH signal. 7. FC1 Network 14: Pushbutton -S4 is used to reintegrate the drive. (acknowledge safety alarms) Open the "FC1" function. In the adjacent screenshot, safety program (FB1) is assigned to the FC1 and the associated I-DB defined. Select "DB1" as I-DB. Then acknowledge with "OK". Version 1.0, Entry ID:

52 8. The safety program should then be generated and downloaded into the CPU. To do this, please press the "Compile" button followed by "Download". In addition, the standard blocks must be loaded to the F-CPU. Note We recommend that blocks OB82 and OB86 are also integrated in order to tolerate the failure of the I/O (e.g. the drives for a power on reset) without the F- CPU going into the STOP operating state. 4.8 Acceptance test To verify safety-relevant parameter assignments/configurations, when the machine is first commissioned, and also when safety-relevant parameters are changed, an acceptance test must be performed. The acceptance test must be appropriately documented. The acceptance reports must be appropriately stored and archived. This involves specifications laid down in the machinery directive. The acceptance test must be carried out after parameterization has been completed and a power on reset. You can find information about the acceptance test, the acceptance report and an example of a corresponding acceptance report in the "Function Manual SINAMICS S120 Safety Integrated" (FHS) /1/ in the Chapter Acceptance test and acceptance report. A script has been generated to simplify handling the acceptance test; this script is available at no charge in the PRODIS entry (link only available in the SIEMENS Intranet) that can be downloaded by authorized personnel. This script conveniently guides the user step by step through the acceptance test. 52 Version 1.0, Entry ID:

53 5 Installation 5 Installation Hardware installation The following diagrams show the hardware configuration of the application. Figure 5-1: Overview of the test setup (schematic) Version 1.0, Entry ID:

54 5 Installation Figure 5-2: Wiring the F-DIs/F-DOs SAFETY demonstration case Note In this application example, only the upper (red) drive of the two-axis demonstration case is used. The DRIVE-CLiQ connection to the encoder of the lower motor (gray cable) should be withdrawn. Topology alarm A1416 is output if this is not done. 54 Version 1.0, Entry ID:

55 6 Commissioning the application 6 Commissioning the application Until now, the configuration of the application example has been described step-by-step. The following steps must be observed if the project example is to be loaded directly to the hardware. First, all components (S7-F-CPU and SINAMICS S120) should be generally reset or reset to factory settings. 6.1 Preconditions Preconditions for operation The SIMATIC components have been mounted and connected with one another. The PROFIsafe addresses of the fail-safe input and output modules must have been set by means of the DIL switch; see Table 4-2 (lines 10 and 14) from Section 4.3. All components have been connected as specified in Chapter Preparation The motor has been connected to the Motor Module using a power cable. The Motor Module is correctly connected with the infeed (DC link and 24 V DC control voltage). The infeed is connected to the line supply. The components are supplied with 24 V DC. (see Chapter 4.2 Preparation) Version 1.0, Entry ID:

56 6 Commissioning the application 6.3 Commissioning Table 6-1: Commissioning the sample project 1. To start, please open the SIMATIC Manager. 2. Please unzip the project supplied into any directory and then open it. In the SIMATIC Manager, click on "File" followed by "Retrieve". 3. Once the project has been opened, please open the HW config, and carry out a download. 4. Please load the safety program as next step. Depending on the particular setting, the standard blocks are also loaded. If this is not the case, then manually load the blocks into the F-CPU. 56 Version 1.0, Entry ID:

57 6 Commissioning the application 5. Now open the integrated STARTER project. To do this, double-click on "Commissioning". 6. Then establish an online connection and carry out a download. 7. When using the extended safety functions, the hardware replacement must be acknowledged after the download. To do this, please press the "Acknowledge hardware replacement" button. 8. Then copy from RAM to ROM. Then go offline. 9. Now carry out a power-on reset. POWER OFF/ON 10. To complete commissioning, go back online, load the configuration into the PG and save it. Version 1.0, Entry ID:

58 7 Operating the application 7 Operating the application 7.1 Overview Figure 7-1: Overview diagram showing how to operate the application Switches -S1 to -S4 are located on a switchbox that belongs to the SAFETY training case. Switches -S5 to -S8 are located on a switchbox that belongs to the SINAMICS training case. 7.2 Description of function Switching on/switching off The drive is switched on (OFF1) using switch -S5 and a speed setpoint of 250 rpm entered. Speed levels The speed setpoint is increased to 500 rpm by pressing switch -S6. A speed setpoint of 1000 rpm can be entered by pressing switch -S7. 58 Version 1.0, Entry ID:

59 7 Operating the application Emergency Stop Protective door If, while the motor is rotating, switch -S1 is actuated, then safety function STO is activated. After selecting STO, the converter safely switches off the torque of the connected motor. Switch -S2 simulates a protective door. As long as switch -S2 is not actuated (highlevel), the protective door is closed. In this particular case, the drive can be operated at any speed (precondition, -S3 is not actuated. If switch -S2 is actuated (low signal), then this corresponds to the protective door being opened. Safety function SLS with SLS level 1 is selected. After a configurable time has elapsed, the speed is safely monitored against a limit value (in this case, 750 rpm). For an active SLS level, the corresponding stop response STOP C is initiated when this limit value is exceeded. This means that the drive is braked along the OFF3 ramp, and after a configurable delay time has elapsed, standstill (zero speed) is monitored using the SOS safety function. In this particular case, the drive remains in the closed-loop controlled mode. Safety messages C01714 and C30714 are output. Light barrier Switch -S3 simulates a light barrier. As long as switch -S3 is not actuated (highlevel), the light barrier is not interrupted. In this particular case, the drive can be operated at any speed (precondition, -S2 is not actuated. If switch -S3 is actuated (low signal), then this corresponds to the light barrier being interrupted. Safety function SLS with SLS level 1 is selected. However, here the limit value of SLS level 1 is reduced by the F-CPU to 40%. After a configurable time has elapsed, the speed is safely monitored against a limit value (in this case, 300 rpm). For an active SLS level, the corresponding stop response STOP C is initiated when this limit value is exceeded. This means that the drive is braked along the OFF3 ramp, and after a configurable delay time has elapsed, standstill (zero speed) is monitored using the SOS safety function. In this particular case, the drive remains in the closed-loop controlled mode. Safety messages C01714 and C30714 are output. Switch -S3 always has priority over -S2, i.e. when switches -S2 and -S3 are simultaneously actuated, the SLS speed is limited to 300 rpm. Reintegrating/acknowledging safety faults The drives have to be reintegrated after power OFF/ON. All of the safety fault messages are acknowledged by pressing -S4, and signal lamp -S4 is turned on. The signal lamp goes dark if the specified SSM limit is exceeded. Test stop A test stop can be carried out using button -S8. Version 1.0, Entry ID:

60 7 Operating the application Table 7-1: Overview of the SAFETY training case switch functions Switch Function -S1 STO activation -S2 Select SLS with a speed limit of 750 rpm. -S3 Select SLS with a speed limit of 300 rpm. -S4 Depassivation and fail-safe acknowledgment Table 7-2: Overview of the switch functions at the SINAMICS training case Switch Digital input Description -S5 DI 0 Switch on/switch off drive (ON/OFF1) with speed setpoint: 250 rpm -S6 DI 1 Speed setpoint: 500 rpm -S7 DI 2 Speed setpoint: 1000 rpm -S8 DI 3 Test stop selection 60 Version 1.0, Entry ID:

61 8 References 8 References 8.1 Related documents This list does not claim to be complete and only provides a selection of suitable references. Table 8-1: Related documents Topic /1/ SINAMICS S120 Safety Integrated /2/ SINAMICS S120 List Manual /3/ SINAMICS S120 Manual 1 /4/ SINAMICS S120 Manual 2 /5/ SINAMICS S120 Function Manual /6/ SINAMICS S120 Commissioning manual /7/ STEP7 SIMATIC S7-300/400 /8/ STEP7 SIMATIC S7-300/400 /9/ STEP7 SIMATIC S7-300 Title SINAMICS S120 Safety Integrated Function Manual 01/2013 Edition MLFB: 6SL3097-4AR00-0AP4 SINAMICS S120/S150 List Manual 01/2013 Edition MLFB: 6SL3097-4AP00-0AP4 SINAMICS S120 Control Units and additional system components Manual Edition 01/2013 MLFB: 6SL3097-4AH00-0AP3 SINAMICS S120 Manual for Booksize Power Units 01/2013 Edition MLFB: 6SL3097-4AC00-0AP5 SINAMICS S120 Function Manual 01/2013 Edition MLFB: 6SF3097-4AB00-0AP3 SINAMICS S120 Commissioning Manual 01/2013 Edition MLFB: 6SF3097-4AF00-0AP3 Automation with STEP 7 in STL and SCL Author: Hans Berger Publicis MCD Verlag ISBN: Automation with STEP 7 in LAD and FBD Author: Hans Berger Publicis MCD Verlag ISBN: Automation with SIMATIC S7-300 in the TIA Portal Author: Hans Berger Publicis MCD Verlag ISBN: Version 1.0, Entry ID:

62 8 References 8.2 Internet links This list does not claim to be complete and only provides a selection of suitable information. Table 8-2: Internet links Topic \1\ Reference to the article \2\ Siemens Industry Online Support Title Version 1.0, Entry ID:

63 9 Contact persons 9 Contact persons Siemens AG Industry Sector I DT MC PMA APC Frauenauracher Strasse 80 D Erlangen, Germany safety.team.motioncontrol.i-dt@siemens.com Version 1.0, Entry ID:

64 10 History 10 History Table 10-1: History Version Date Revision V1.0 02/2014 First Edition 64 Version 1.0, Entry ID: