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Automation and Industrial Solutions Safety Concept: Distributed Safety
Conventional One standard PLC with distributed I/O (ET200S via PROFIBUS DP) controls the
Safety Technology standard functions of a plant; a safety relay controls the dangerous machine
function.
Functional The dangerous machine function is switched via the two forced contactors K1 and
Control K2, which are controlled in a safety-oriented manner by a safety relay. The safety
relay receives the necessary On/Off control signals for the functional On and Off
via the wiring from a digital standard output of the standard PLC, which for this
purpose analyzes the corresponding signals from the plant (among other things,
those of the operator panel) in the standard program.
Protective FunctionsIn order to protect the operator, the dangerous machine function is equipped with
an Emergency Stop command device and an isolating protective equipment in the
form of a safety door. As soon as a wiring error is determined, the Emergency
Stop is pressed, or, the safety door is opened, the safety relay independent from
the control signals of the standard PLC shuts down the motor via the contactors
K1 and K2 as per Stop-Category 0 according to EN 60204-1.
Before every renewed switch on of the contact, the safety relay checks whether
the contacts of the Emergency Stop and the safety door are closed and the
contactors drop or their feedback contacts are closed.
Wiring The wiring and architecture of the safety functions are implemented according to
EN 61508 in SIL 3 or according to EN 954 in Cat.4: The Emergency Stop
command device and the position switch of the safety door are wired via two-
channels with the safety relay. To control the dangerous machine function, two
contactors connected in series are used whose feedback or mirror contacts return
a feedback signal to the safety relay.
Functional The dangerous machine function is switched via the two forced contactors K1 and
Control K2, that now are no longer controlled in a safety-oriented manner by the safety
relay but rather from the safety program of the F-CPU in conjunction with safety-
related input and output modules.
The conditions for the functional On and Off are still analyzed by the standard
program that informs the safety program through variables (such as memory bits)
when the contactors are to be switched on and switched off.
Protective FunctionsThe previously described protective functions will no longer be handled by the
safety relay but rather by the safety program of the F-CPU and the safety-related
input and output modules (F-DI/DO):
As soon as a wiring error is determined, the Emergency Stop is pressed, or, the
safety door is opened, the safety relay must shut down the motor or the contactors
K1 and K2 as per Stop-Category 0 according to EN 60204-1 independent from
the control signals of the standard program.
The wire monitoring of the safety-related actuators and sensors now occurs
through the F-DI / DO modules.
Wiring The wiring and architecture of the protective functions according to SIL 3 (EN
62061) Cat.4 (EN 954) is unchanged in principle:
The Emergency Off command device and the position switch of the safety door
are still two-channel wired, however, no longer with a safety relay, but rather with
an F-DI module of the safety-related ET200S station.
To switch the dangerous machine function, there are still two contactors used
which are connected in series. Now they are controlled by an F-DO module and
their feedback or mirror contacts are now analyzed by the safety program.
F-DI/DO Standard and safety-related input and output modules (F-DI/DO) can be operated
together in mixed configurations. The F-DI/DO modules required in place of the
safety relay could also be integrated in an already existing ET200S station. All
already used I/O modules including their wiring can continue to be used
unchanged.
If the dangerous function of the plant is implemented in SIL3/Cat.4, then the F-DI
and the F-DO modules must be inserted into a separate potential group or must be
isolated from the standard modules by an additional power module (PM) (see
slide).
PROFIsafe The safety-related communication between F-CPU and the F-DI/DO modules
Communication using PROFIsafe is integrated in the failsafe modules. It is executed automatically
and does not have to be programmed regardless of whether the F-DI/DO
modules are used centrally or distributed via PROFIBUS or PROFINET. Already
configured standard communication remains unaffected by the safety-related
communication via PROFIsafe.
1v1 Evaluation For 1v1 evaluation, there is one sensor/encoder and is connected to the F-DI
module via one channel.
If the sensor/encoder quality is less than that of the required safety class,
the sensor/encoder must be used redundantly and connected via two
channels.
2v2 Evaluation For 2v2 evaluation, two input channels are occupied
through two 1-channel sensors/encoders
or
through one 2-channel sensor/encoder
The input signals are compared for equality (equivalency) or non-equality (non-
equivalency) (-> discrepancy analysis).
F-DI / F-DO Fail-safe The basic difference between fail-safe modules and standard ET 200S modules
Modules is that fail-safe modules are designed internally with two-channels. The two
integrated processors monitor each other and automatically test the input and
output switching and transfer the F-module to a safe state in case of failure.
Fail-safe digital input modules (F-DI) acquire the signal states from safety-related
encoders and send corresponding safety message frame telegrams to the F-CPU.
Fail-safe digital output modules (F-DO) are suitable for safety-related switch-off
operations with short-circuit and cross-circuit monitoring up to the actuator.
The F-CPU communicates with the fail-safe modules over the safety-related bus
profile PROFIsafe.
Power Modules / Power modules are used for the load voltage supply of potential groups.
Potential Groups Potential groups in which F-DI/DO modules are used must be supplied by selected
standard power modules (see slide).
With fail-safe power modules, you can economically implement the safety-related
switching off of the load voltage from standard output modules up to (Cat.3 / SIL2).
A new potential group always begins with a power module.
Standard and safety-related modules can be used
in combination within a potential group for applications up to SIL2 / Cat.3
in separate potential groups for applications SIL3 / Cat.4
CPU Contains If "CPU contains safety program" is not activated, no safety program can be
Safety Program downloaded into the CPU later on! This option is therefore absolutely
necessary to operate the CPU in safety mode.
Process Mode Test functions such as "Monitoring" or "Monitor/control variable" are restricted so
that the set permissible cycle time extension cannot be exceeded. Testing using
breakpoints and step-by-step program execution cannot be performed.
Test Mode All test functions can be used without restrictions, even if they cause greater cycle
time extensions.
Basis for PROFIsafe addresses are assigned automatically and uniquely identify source
PROFIsafe and destination. The "Basis for PROFIsafe addresses" can be set in increments of
Addresses 1000 and is practical if several DP master systems or PROFINET IO systems are
operated in a network.
F-DB / F-FB When compiling the safety program, F-function and F-data blocks are
automatically added to the function and data blocks created by the user. Their
number range can be set here. We recommend that the number range for the
automatically generated F-blocks is defined in the upper end of the range possible
for the respective CPU used (see CPU performance data) so that the lower range
remains free for the user-defined blocks.
Addresses of the The addresses of fail-safe input and output modules can be set freely just as with
Inputs and Outputs standard modules.
The fail-safe input and output modules also occupy, in addition to the pure input
and output user data, additional bytes in the process images for handling the
safety-related PROFIsafe communication. An F-DI module therefore also occupies
bytes in the process image of outputs, an F-DO module also bytes in the process
image of inputs.
F_Source and are the PROFIsafe addresses and are used to uniquely identify the source
F_Destination (F-CPU) and the destination (F-module). The PROFIsafe addresses must be
Address unique in the station and throughout the network. To prevent incorrect parameter
assignment, the F_destination_address is automatically assigned. When the
F_destination_address is changed manually, its station-side uniqueness is
checked automatically, but not its network-wide uniqueness! It is up to the user to
ensure this!
DIP Switch Setting corresponds to the F_destination_address in binary representation. The address
DIP switch setting of the module must match the bit pattern shown here. The
address DIP switch of the F-module must therefore be set PRIOR TO the
installation of the F-module.
F-Monitoring Time is the PROFIsafe monitoring time for the safety-related communication between
(ms) the F-CPU and F-I/O. If the F-I/O does not receive a valid safety message frame
from the F-CPU within a parameterizable monitoring time, the F-module
passivates itself by means of a "communication error".
The F-monitoring time should be long enough so that uncritical message frame
delays are tolerated, but short enough so that in the event of an error the response
is as quick as required by the control process.
You will find more information on determining the F-monitoring time in the chapter
"Configuring the Monitoring Times".
Discrepancy Time The behavior at discrepancy is only relevant during the discrepancy time! If the
discrepancy still exists after the discrepancy time has elapsed, the module
recognizes this as an error and signals (as always in the event of an error) the
value "0" for the affected channel to the F-CPU.
Two module channel response settings are possible during the discrepancy time:
"Supply last valid value"
The last valid value prior to the occurrence of the discrepancy (old value) is made
available to the safety program of the F-CPU as soon as a discrepancy between
the signals of the two affected input channels is determined. This value remains
available until the discrepancy is cleared, or until the discrepancy time has expired
and a discrepancy error is detected. After the discrepancy time has elapsed, if a
discrepancy error is detected, the value '0' is signaled in any case to the safety
program of the CPU!
Attention: Since a discrepancy error is only detected after the discrepancy time
has elapsed, the response time of the controller is prolonged. If, for safety
reasons, very fast responses by the PLC are required, the discrepancy time
should not be set longer than necessary.
"Supply value 0"
Since, with this setting, the "safe" value "0" is signaled to the safety program of the
F-CPU during the discrepancy time, the response time of the PLC is not
prolonged. This is because the value "0" is already the value that is signaled to the
CPU anyway in the event of an error (that is, after the discrepancy time has
elapsed).
Activated In order to avoid errors, outputs that are not used should be deactivated.
Read-back Time is the maximum time after switching off an output that a read-back signal may
still be detected before the error "short-circuit" results in the passivation of the
output channel. The set read-back time must be sufficiently long, especially when
switching capacitative loads, to permit the discharge of the switched capacity
within the read-back time.
The read-back time is also the dark period in switch-off tests. 0-signals are
switched to the output bit while the output is active for checking the actuator wiring.
A sufficiently slow actuator does not respond to the temporary deactivation of the
output and remains switched on.
Diagnostics: If wire break diagnostics is activated, the module passivates itself in the event of a
Wire Break wire break and signals a diagnostic interrupt to the CPU. However, a wire break is
only detected if an output channel is switched on at the moment. The wire break
diagnostic is no safety-related test function.
Hell- / Dark Tests Independent of the wire break diagnostics, the F-DO modules always carry out
(cannot be parameterized!) so-called light and dark period tests internally in which
the respective output channel is briefly (<=1m) switched on or off. The actuators
connected to the fail-safe outputs should therefore be selected sufficiently slow-
acting (possibly use interface relays).
F-DBs Data blocks for storing shared (global) data are also available in the safety
program. Safety-related data blocks (F-DBs) are created/changed and used in the
program in the same manner as standard DBs. Only the number of usable data
types is restricted. Instance data blocks of safety-related FBs (no matter if created
by the user or inserted from the Distributed Safety library) are, as in the standard,
not edited by the user but generated by STEP7.
Shared (global) DB The "shared DB" is a failsafe data block (F-DB) that contains shared data of the
safety program. The "shared DB" is automatically inserted or expanded when the
hardware configuration is saved and compiled. The data of the "shared DB" can be
evaluated both in the safety and in the standard user program.
I/O DB For every F-I/O, an F-I/O DB is automatically generated when the hardware
configuration is compiled. This DB contains variables that describe the state of the
respective module (passivation, depassivation capability, diagnostic data, channel
information etc.).
Run-time Group By integrating the "F-Call" into a time interrupt OB, it is ensured that the safety
program is executed at defined intervals, which is essential for determining the
response times of the safety program and thus for the safety functions in the plant.
F-CALL Each runtime group is represented by an "F-Call", a function (FC) that is inserted
(not programmed!) by the user in the programming language "F-Call" and can be
generated by Distributed Safety. In addition to the system blocks automatically
generated by Distributed Safety (SBs, F-FBs, used for implementing safety
functions, that serve as I/O drivers that contain the diverse redundant logic etc.),
the F-Call block also contains the call of the "program block", which is declared as
such (FC or FB) by the user. Invoking the F-Call is therefore tantamount to calling
a runtime group of the safety program.
Program Block PB The "program block" (PB), created by the user in the form of an F-FC or F-FB
contains the user program. The user can program his control logic directly in this
PB and/or he can use it to invoke other safety-related user or library blocks from
Distributed Safety (F-FCs, F-FBs) for program structuring.
F-Program Block The "F-program block" (F-PB) of a runtime group must be programmed as a
(F-PB) non-parameterizable, F-FC or F-FB. The user can create the safety-related logic
directly in the program block, and/or the block can used for program structuring
where other safety-related user or library blocks are called up within it.
The properties that an F-FC or F-FB are to serve as a "program block" are only
assigned to this block when the runtime group is created. When the safety
program is compiled, the call of the program block is integrated into the F-CALL.
Editor Settings Within F-blocks, the Editor marks all not fail-safe addresses (standard inputs and
outputs, bit memories etc.) in color. In the Editors standard settings, this is the
color yellow. On the other hand, safety-related modules, such as F-CPUs, of all
things, are marked in yellow which very easily leads to confusion.
For that reason, it is recommended that you choose another color other than
yellow in the Editor Settings to identify not fail-safe addresses.
Invoking F-CALL To guarantee that execution of the safety program is carried out continuously at
equal intervals, the safety program or the F-CALL of a runtime group is
programmed in a cyclic interrupt OB (e.g. OB35). The call is programmed just like
it would for a standard block. Other standard blocks, in addition to the F-CALL, can
also be called in this cyclic interrupt OB.
F-Call Block The block that is to be used as F-Call for the runtime group that is newly created in
this dialog can be selected here.
F-Program Block The F-FC or F-FB that is to serve as the program block (PB) in this runtime group
can be selected here. Distributed Safety will integrate the call of the specified F-
program block in the F-Call program when the F-Call is generated.
Safety Mode After a consistent safety program has been downloaded into the CPU and a warm
restart has subsequently been carried out, the safety mode of the CPU is
activated.
Omdat in deze eerste opdracht nog geen failsafe functies gebruikt worden,
hoeven de parameters van de failsafe hardware nog niet ingesteld te
worden.
NB. Bij enkele opstellingen kan deze configuratie iets afwijken van
bovenstaande ivm de toevoeging van de functiemodellen. Neem de exacte
configuratie over van de opstelling.
Stap 2: Zet het vinkje CPU contains safety program aan om de CPU te kunnen
laden met een F-programma.
F parameters Alle instellingen die door Step7 gegenereerd worden zijn grijs en niet aan
te passen.
Bij het compileren zal een extra schermpje met loop-balk te zien zijn
(Initializing safety program) tijdens het genereren van de FBs en DBs
behorende bij de fail-safe-modules.
Deze zullen dan te zien zijn in de Blocks folder van de Manager.
OB35 De F-Call zelf (bv. FC1) wordt cyclisch aangeroepen vanuit OB35.
Hierdoor wordt een constant gedrag van de F applicatie verkregen.
Stap 12: Maak OB35. Maak hier een aanroep naar F-aanroep (FC1, de F-Call) en
sla alles op.
SAFETY_UITGANG_RELAIS (Q16.0) -Q
Stap 14: Omdat na het bevestigen van de NOODSTOP de band NIET direct mag
gaan draaien, gebruiken we de SAFETY_UITGANG_RELAIS (Q16.0) op
de RESET ingang van K1 en K2 om de bandmotor uit te schakelen na het
bedienen van de NOODSTOP. Breidt OB1 uit met bovengenoemde
wijziging.
Save FC10 (F-APPLICATIE) en OB1 en sluit beide bouwstenen.
Stap 16: Test het in- en uitschakelen van de transportband en test de werking van
de NOODSTOP.
Stap 2: Sleep de Call van F_FDBACK (FB216) uit de F-Application Blocks (Library
Distibuted Safety (V1) in netwerk 2 van FC10 en geef deze als instanceDB
DB216.
COMMAND - ON
I 8.3 - FEEDBACK
F00016_4_F_DO_DC24_24_2A.QBAD - QBAD_FIO
I 1.5 - ACK
T#100MS - FDB_TIME
SAFETY_UITGANG_RELAIS (Q16.0) -Q
Stap 3: Test wederom het in- en uitschakelen van de transportband en test de werking van
de NOODSTOP eerst zonder dat een relais blijft kleven. Zet daarna voorzichtig het
oranje lipje van een relais omhoog en test wederom de werking van de
NOODSTOP.