Functional Example AS-FE-I-010-V20-EN SIMATIC Safety Integrated for Factory Automation Distributed use of laser scanner SIMATIC FS600 in category 3 according to EN 954-1: 1996 (with evaluation according to EN 62061 and EN ISO 13849-1: 2006)
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 Entry ID: 21330889 Preliminary remark The Functional Examples dealing with “Safety Integrated” are fully functional and tested automation configurations based on A&D standard products for simple, fast and inexpensive implementation of automation tasks in safety engineering. Each of these Functional Examples covers a frequently occurring subtask of a typical customer problem in safety engineering.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 Entry ID: 21330889 Copyright © Siemens AG 2007 All rights reserved 21330889_as_fe_i_010_v20_en_lscanner.doc Table of Contents 1 Warranty, Liability and Support .................................................................... 4 2 2.1 2.1.1 2.1.2 2.2 Automation Function...................................................................................... 5 Description of the functionality............................................
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 1 Entry ID: 21330889 Warranty, Liability and Support Copyright © Siemens AG 2007 All rights reserved 21330889_as_fe_i_010_v20_en_lscanner.doc We accept no liability for 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 Safety Functional Example shall be excluded.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 2 Automation Function 2.1 Description of the functionality 2.1.1 Foreword Entry ID: 21330889 Application areas The laser scanner SIMATIC FS600 is used for hazard protection. The laser scanner, aligned horizontally in most cases, monitors the presence of persons in the protected zone. Copyright © Siemens AG 2007 All rights reserved 21330889_as_fe_i_010_v20_en_lscanner.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 Entry ID: 21330889 Distributed use of the laser scanner SIMATIC FS600 In the “PROFIBUS“ variant, the SIMATIC FS600 laser scanner can be operated as safe bus component together with non-safe standard components on the same bus (PROFIBUS DP). This is enabled by the PROFIsafe protocol, an expansion of PROFIBUS DP.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 Entry ID: 21330889 Bits of the cyclic input data (F-CPU Õ laser scanner SIMATIC FS600) Copyright © Siemens AG 2007 All rights reserved 21330889_as_fe_i_010_v20_en_lscanner.doc Only the bits required for understanding the entire functionality are explained here. ! WARNING Bit Meaning Bit 7: OSSD The OSSD bit (bit 7) is fail-safe information of the laser scanner SIMATIC FS600.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 Entry ID: 21330889 Detection zones and warning zones When using the laser scanner SIMATIC FS600, you have to define protection and warning zones. A detection zone (SF) and a warning zone (WF) always form a zone pair. Up to 4 zone pairs can be defined; but only one zone pair may be active at any time. Detection zone numbers (bits 0, 1 and 2 of the cyclic output data) let you define the zone pair (1, 2, 3 or 4) to be active.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 2.1.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 Entry ID: 21330889 Parameter set for the laser scanner SIMATIC FS600 Copyright © Siemens AG 2007 All rights reserved 21330889_as_fe_i_010_v20_en_lscanner.doc The parameter set for the laser scanner SIMATIC FS600 contains the configuration data for the safety functional example. How to load the configuration data into the laser scanner SIMATIC FS600 is described in chapter 4.3.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 Entry ID: 21330889 Flowchart Copyright © Siemens AG 2007 All rights reserved 21330889_as_fe_i_010_v20_en_lscanner.doc The flowchart illustrates the function process of the safety functional example. NOTICE In order to meet the requirements of category 3 / SIL 2, it is obligatory for certain actuators (e.g. contactor) to read back the process signal to the actuator. Read-back is not implemented in this safety functional example.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 Entry ID: 21330889 Time sequence The following picture illustrates the relations over time. The names of the signals correspond to those in the STEP7 project. The designations are displayed in the table below. Signal Explanation START Start command for switching the indicator light (actuator) on. STOP Stop command for switching the indicator light (actuator) off.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 Entry ID: 21330889 Explanation of the above times Time Note / Explanation t1 Switching the actuator on: Indicator light goes on (ACTUATOR=“1“). t2 Switching the actuator off: Indicator light goes on (ACTUATOR=“0“). t3 Switching the actuator on: Indicator light goes on (ACTUATOR=“1“).
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 3 Entry ID: 21330889 Required components Hardware components Copyright © Siemens AG 2007 All rights reserved 21330889_as_fe_i_010_v20_en_lscanner.doc Component Type MLFB / Order information No.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 Entry ID: 21330889 Configuration software/tools Component Type MLFB / Order information No. SIMATIC STEP 7 V5.4 + SP1 6ES7810-4CC07-0YA5 1 SIMATIC Distributed Safety V5.4 + SP3 6ES7833-1FC01-0YA5 1 LS4soft V1.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 4.1 Entry ID: 21330889 Overview of the hardware configuration Copyright © Siemens AG 2007 All rights reserved 21330889_as_fe_i_010_v20_en_lscanner.doc The laser scanner SIMATIC FS600 is operated as DP slave on the PROFIBUS DP (with PROFIsafe profile). An F-CPU is used as DP master.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 4.2 Entry ID: 21330889 Wiring of hardware components Requirements: The power supply is supplied with 230V AC. First check the addresses set at the hardware components listed below: Copyright © Siemens AG 2007 All rights reserved 21330889_as_fe_i_010_v20_en_lscanner.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 The wiring of the hardware is illustrated below. In the following table, the hardware components occurring several times are numbered. This ensures that they can be clearly assigned in the subsequent wiring diagram. Copyright © Siemens AG 2007 All rights reserved 21330889_as_fe_i_010_v20_en_lscanner.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 Copyright © Siemens AG 2007 All rights reserved 21330889_as_fe_i_010_v20_en_lscanner.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 Entry ID: 21330889 Connecting the laser scanner SIMATIC FS600 to PROFIBUS In order to integrate the laser scanner SIMATIC FS600 into the PROFIBUS network, you need the device master file (GSD) of the SIMATIC FS600 laser scanner. This file comes with the laser scanner SIMATIC FS600.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 Entry ID: 21330889 The laser scanner SIMATIC FS600 has five male/female connectors (X1 to X5). Connect these male/female connectors as follows: Copyright © Siemens AG 2007 All rights reserved 21330889_as_fe_i_010_v20_en_lscanner.doc Male/female connector Function Note / Explanation X1 Restart button Connect a push button (NO) here. (This is considered in chapter 3 in the “Hardware components” table.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 Note 4.3 Entry ID: 21330889 The cable outlet of the PC adapter at the laser scanner SIMATIC FS600 must face towards the direction of the detection zone. The PC adapter should only be connected in the installation phase or for control purposes. LS4soft configuration and diagnostics software The example below shows how to load the following file containing the parameter set into the laser scanner SIMATIC FS600.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 Copyright © Siemens AG 2007 All rights reserved 21330889_as_fe_i_010_v20_en_lscanner.doc No. Action Entry ID: 21330889 Note 8 Click “Cancel”. You do not generate a new configuration but use the file as_fe_i_010_v10_code_plsc anner.ls. 9 Verify whether the “Display measurement diagram” tab is active. The currently active zone pairs and the associated contours appear.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 Entry ID: 21330889 Changing detection and warning zones If you wish to change detection and warning zones, click the “Define detection/warning zones“ tab. Then set the detection or warning zone you want to edit. Copyright © Siemens AG 2007 All rights reserved 21330889_as_fe_i_010_v20_en_lscanner.doc Working with the wizard A useful wizard is available for “Authorized Users” to parameterize the laser scanner SIMATIC FS600.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 Entry ID: 21330889 The wizard can also be used to specify which zone pairs can be changed over. In the safety functional example, it is allowed to switch from zone pair 1 to 2 and from zone pair 2 to 1. Copyright © Siemens AG 2007 All rights reserved 21330889_as_fe_i_010_v20_en_lscanner.doc 4.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 Entry ID: 21330889 Testing inputs and outputs Prerequisites: No. • The inputs and outputs have the default values specified under “Inputs/outputs used”. • No objects are currently in the detection zone of the laser scanner SIMATIC FS600. Action Response Note A 8.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 Entry ID: 21330889 Testing the LEDs at the laser scanner SIMATIC FS600 The laser scanner SIMATIC FS600 indicates its current status via five LEDs: LED Color 1 Green 2 Function / Meaning Pictogram Sensor function is active, active detection zone is free Warning zone occupied Yellow OSSD outputs switched off 3 Copyright © Siemens AG 2007 All rights reserved 21330889_as_fe_i_010_v20_en_lscanner.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 Entry ID: 21330889 To test the laser scanner SIMATIC FS600, carry out the following actions: No. 1 Copyright © Siemens AG 2007 All rights reserved 21330889_as_fe_i_010_v20_en_lscanner.doc 2 3 Action Make sure that no objects are located in either the warning zone, or the detection zone Place an object into the warning zone of the laser scanner SIMATIC FS600.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 4.5 Entry ID: 21330889 Important hardware component settings The STEP 7 project delivered with this safety functional example contains the hardware configuration and the sample code. Below, several important settings from the hardware configuration of STEP 7 are shown to give you an overview. It is basically possible to change these settings (e.g.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 Entry ID: 21330889 Settings of the CPU 315F-2DP The settings are displayed after double-clicking “CPU 315F-2 DP” (see “Overview picture”). Screenshot Note OB35 is set to 50 ms (default value = 100 ms) Copyright © Siemens AG 2007 All rights reserved 21330889_as_fe_i_010_v20_en_lscanner.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 Screenshot Entry ID: 21330889 Note Copyright © Siemens AG 2007 All rights reserved 21330889_as_fe_i_010_v20_en_lscanner.doc The laser scanner SIMATIC FS600 comes with the “FB LS4” function block. The “FB LS4” is not used in the safety functional example. If you want to use the “FB LS4“ for adjusting the sample code to your requirements, you must ensure to reserve a retentive memory area of at least 34 bytes.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 Entry ID: 21330889 Settings of the failsafe DI (F-DI) The settings are displayed after double-clicking “4/8 F-DI DC24V” (see “Overview picture”). Screenshot Note Parameters / F parameters: DIP switch setting (9…0) This value has to be set on the F module (F-DI). F-monitoring time (ms) The F-monitoring time must be larger than the call time of OB35. Copyright © Siemens AG 2007 All rights reserved 21330889_as_fe_i_010_v20_en_lscanner.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 Entry ID: 21330889 Settings of the fail-safe DO (F-DO) The settings are displayed after double-clicking “4 F-DO DC24V/2A” (Overview picture). Screenshot Note Parameters / F parameters: DIP switch setting (9…0) This value has to be set on the F module (F-DO). F-monitoring time (ms) The F-monitoring time must be larger than the call time of OB35. Copyright © Siemens AG 2007 All rights reserved 21330889_as_fe_i_010_v20_en_lscanner.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 Entry ID: 21330889 Settings of the laser scanner SIMATIC FS600 Copyright © Siemens AG 2007 All rights reserved 21330889_as_fe_i_010_v20_en_lscanner.doc Select the laser scanner SIMATIC FS600 and double-click the line that appears: Then click the PROFIsafe tab. Screenshot Note F_Dest_Add This value derives from the PROPIBUS address (here: 4) plus 500. F_WD_Time The default value of 10 ms is usually too small.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 5 Entry ID: 21330889 Basic Performance Data Load memory and main memory Total Portion of S7 standard blocks Portion of F blocks Load Memory 93.8 Kbytes 47.7 Kbytes 46.1 Kbytes Main Memory 76.3 Kbytes 43.9 Kbytes 32.4 Kbytes Cycle time Time Typical total cycle time (standard program and safety program) Copyright © Siemens AG 2007 All rights reserved 21330889_as_fe_i_010_v20_en_lscanner.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 Entry ID: 21330889 Use of the STEP7 project The STEP 7 project shows how a laser scanner SIMATIC FS600 is used with SIMATIC Safety Integrated. Functionality of the STEP 7 project The following functions are implemented with the STEP 7 project: • Operational start and stop of a “machine” • If the detection zone is violated, the fail-safe S7-CPU (F-CPU) will switch off an actuator (indicator light).
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 6.2 Entry ID: 21330889 Program execution standard program OB1 Network 1 Copyright © Siemens AG 2007 All rights reserved 21330889_as_fe_i_010_v20_en_lscanner.doc Network 1 evaluates the conditions for an operational start or stop of the “machine” (indicator light). Parameter Explanation START Push button (NO) for the start request. STOP Push button (NC) for the stop request INSTANZ_FB3. The “INSTANZ_FB3”.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 Entry ID: 21330889 Network 2 In OB1 the “Proxy-Enable“ bit (Bit 6 of the cyclic output data) is permanently supplied with the value “0“. Network 3 The laser scanner SIMATIC FS600 can be parameterized automatically when it is replaced. This is prepared in network 3 by calling “FB LS4”. But the automatic parameter configuration is not effective since the ProxyEnable bit permanently has the value “0”.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 Entry ID: 21330889 Network 1 FB SET_ACT (FB3, DB3) is called here: Copyright © Siemens AG 2007 All rights reserved 21330889_as_fe_i_010_v20_en_lscanner.doc Parameter Explanation ACK Acknowledgement signal OSSD Safety-relevant output of the laser scanner SIMATIC FS600 COND1 Start condition, defined in OB1.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 Entry ID: 21330889 The following table describes the parameters. Parameter Explanation SEN_FIELD1 Position switch 1 (NC) “1“ signal: Switch not applied. SEN_FIELD2 Position switch 2 (NC) “1“ signal: Switch not applied.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 Entry ID: 21330889 FB FIELD_PAIR_SWITCHING (FB4, DB4) The following table describes the parameters.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 Entry ID: 21330889 Expansion of the safety functional example Program sequences are prepared in the sample code that allow using the zone pairs 3 and 4. Please proceed as follows: • Parameterize the zone pairs 3 and 4 using the LS4soft configuration and diagnostics software. • Replace the memory bits (dummies) with sensors (e.g. position switches).
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 Entry ID: 21330889 Network 5 and network 6 A zone pair will always become active in the safety functional example if the following conditions are met simultaneously: • the associated position switch (NC) switches (“0“ signal) • the other position switch (NC) and the memory bits (dummies) all have the “1“ signal. Copyright © Siemens AG 2007 All rights reserved 21330889_as_fe_i_010_v20_en_lscanner.doc During changeover (e.g.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 Entry ID: 21330889 This condition can be a potential hazard depending on the application, for instance, if the sensor responsible for the changeover does not respond. In the safety functional example this condition is detected and compared with a parameterized time. If this condition continues to be true after this time has elapsed, this will be interpreted as an error and the #ERR_SW_TIME bit will be set (see network 5).
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 ! Entry ID: 21330889 The time to be set at parameter PT of the FB F_TON depends on the application. Generally, this time should be as small as possible. For times larger than 1 sec additional safety measures should be considered. WARNING Network 6: Copyright © Siemens AG 2007 All rights reserved 21330889_as_fe_i_010_v20_en_lscanner.doc For a set #ERR_SW_TIME bit, the bits 0, 1 and 2 of the cyclic output data are reset.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 6.4 Entry ID: 21330889 Operating instructions Prerequisites: • Hardware configuration and sample code of the STEP 7 project are available in the S7-CPU • The laser scanner SIMATIC FS600 has been parameterized. • Zone pair 1 has been set (via the two positioning switches) • The PC adapter has not been connected • Zone pair 1 is active • No objects are currently in the detection zone of the laser scanner SIMATIC FS600.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 Entry ID: 21330889 7 Evaluation acc. to EN 62061 and EN ISO 13849-1: 2006 7.1 Information about the standards The following safety functional example gives an overview of EN 62061: • http://support.automation.siemens.com/WW/view/en/23996473 For an overview of the EN ISO13849: 2006, see the following book: • 7.2 Funktionale Sicherheit von Maschinen und Anlagen. Umsetzung der europäischen Maschinenrichtlinie in der Praxis.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 8 Safety Function 1 8.1 Mapping of the safety function Entry ID: 21330889 The following illustration shows the mapping of the safety function to the safety functional example: „Evaluate“ Copyright © Siemens AG 2007 All rights reserved 21330889_as_fe_i_010_v20_en_lscanner.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 8.2 Assessment of "Detect" 8.2.1 Evaluation according to EN 62061 Entry ID: 21330889 Result: Result Explanation SILCL 2 PFHD 8.96 * 10-8 8.2.2 Information of the manufacturer SIEMENS AG Evaluation according to EN ISO 13849-1: 2006 Result: Copyright © Siemens AG 2007 All rights reserved 21330889_as_fe_i_010_v20_en_lscanner.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 8.3 Assessment of "Evaluate" 8.3.1 Evaluation according to EN 62061 Entry ID: 21330889 Result: Result Explanation SILCL 3 Information of the manufacturer SIEMENS AG PFHD 1.7 * 10-9 The values for the calculation can be found in the following table. Values for calculating the PFHD: Copyright © Siemens AG 2007 All rights reserved 21330889_as_fe_i_010_v20_en_lscanner.doc Parameter Component Value Definition 5.
Distributed Use of SIMATIC FS600 Laser Scanner in Category 3 / SIL 2 9 Entry ID: 21330889 History Version Date Differences V1.0 02 / 2005 First edition V2.0 10 / 2007 Updating the contents regarding: • Hardware and software • Performance data • Screenshots Copyright © Siemens AG 2007 All rights reserved 21330889_as_fe_i_010_v20_en_lscanner.
