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kapitel 4
4.1
Introduction
4.2
SIMATIC S7-400F/FH
4.3
SIMATIC S7-300F
4.1 Introduction
4/2
Communications
The safety-related and standard communications between the central
controller (CPU) and I/O are established
via PROFIBUS DP. The PROFIsafe
profile is characterized by the fact that
the safety functions are implemented
in the safe end terminals, using standard PROFIBUS functions.
The net data of the safety function
and the safety measures are in a
standard data telegram. No additional
hardware components are required.
Standard communications and safetyrelated communications therefore
use the same hardware platform:
The automation and safety technology
grow close together.
PROFIsafe is transferred independently of the data transfer medium, e.g.
using copper or fiber-optic cables.
Totally Integrated Automation
The safety technology (Safety Integrated) is a component of Totally Integrated Automation fully integrated with
the safety and standard automation
(SIMATIC S7).
Where today, standard automation
(classic PLCs) and safety automation
(electromechanical systems) are
separate, with these systems, both
of these environments are merging
to form a unified, integrated overall
system.
4
Advantages
Significantly faster
mounting/installation
/ commissioning
Low configuring
and engineering costs
Siimipler service/
maintenance and
configuring changes
S7-400F/FH
S7-300F
4/3
4.2.1 Introduction
Fig. 4/1
Fail-safe S7-400F
4/4
4.2.2 Hardware
The hardware of the S7-400F/FH is
based on the CPUs of the fault-tolerance, redundant SIMATIC S7-400H
which is supplemented by an F library.
This F library contains pre-configured
basic function blocks which have been
approved by the German Inspectorate
(TV) as well as a parameterization
tool for the fail-safe I/O modules. In
order to be able to run the S7-400F/
FH, the F Copy License needs to
be loaded into the CPU.
4
4.2.3 Programming
Fig.4/2
Graphic configuring of the S7-400/FH
using the CFC Engineering Tool
4.2.4 Configuration
4/5
S7-400F programmable
controller
Fail-safe
signal modules
Fig. 4/3
SIMATIC S7-400F with single-channel, single-sided I/O
Redundant
DP master systems
S7-400FH programmable
controller
Single-channel, switched
distributed I/O ET 200M
with 2 x IM 153-2
Fail-safe
signal modules
Redundant
PROFIBUS DP
Fig. 4/4
SIMATIC S7-400FH with single-channel switched I/O
Fig. 4/5
SIMATIC S7-400FH with redundant, switched I/O
4/6
Redundant
DP master systems
S7-400FH programmable
controller
Redundant, switched
distributed I/O 2 x ET 200M
each with 2 x IM 153-2
Redundant
fail-safe
signal modules
Redundant
PROFIBUS DP
4
4.2.5 Technical data
CPU
CPU 417-4H
CPU 414-4H
2 Mbyte each
8 Mbyte each
Integral
expandable FEPROM
expandable RAM
FBs/FCs, max.
6144/6144
2048/2048
8191
4095
16/16 Kbyte
8/8 Kbyte
of which, distributed
MPI/DP interface
DP interface
2/2 Kbyte
8/8 Kbyte
2/2 Kbyte
6/6 Kbyte
Main memory
Integral (program/data)
Expandable (program/data)
Load memory
16/16 Kbyte
8/8 Kbyte
Default setting
1024/1024 byte
256/256 byte
Digital channels
131072/131072
65536/65536
of which, centralized
131072/131072
65536/65536
Analog channels
8192/8192
4096/4096
of which, centralized
8192/8192
4096/4096
1st interface
MPI
DP master
DP slave
Default setting
Isolated
yes
yes
no
MPI
yes
2nd interface
DP master
DP slave
Point-to-point
Default setting
Isolated
yes
no
no
DP master
yes
Programming languages
STEP7 V5, from SP1 (LAD, FBD, STL); SCL, CFC, GRAPH, HiGraph
6ES7417-4H...
6ES7414-4H...
4/7
24 (single-channel), 12 (two-channel)
Input voltage
24 V DC
Alarms
Diagnostics alarm
6ES7326-1BK...
10
Output voltage
24 V DC
Alarms
Diagnostics alarm
2 A per channel
6ES7326-1BF...
8 (single-channel)
4 (two-channel)
Input voltage
Alarms
Diagnostics alarm
2 A per channel
6ES7326-1RF...
Alarms
Diagnostics alarm
Integration time
20/16.66 ms
Resolution
13 bits + size
6ES7326-1HE...
F Tool
Requirements
6ES7833-1CC...
4/8
4.3.1 Introduction
The fail-safe control system comprises
fail-safe controllers and fail-safe distributed I/O modules. All of these components communicate through
PROFIBUS DP with the PROFIsafe
profile. The system is programmed
using LAD and FBD.
The new solution with SIMATIC S7300F and fail-safe SIMATIC ET 200S
PROFIsafe signal modules or fail-safe
ET 200M signal modules has been
specifically developed for distributed
safety-related applications in the production environment. Thanks to the
finely scalable F I/O modules, safety
technology only has to be used where
it is actually required. Even third-party
systems can be easily connected.
This solution replaces traditional
electromechanical components and
distinguishes itself as a result of the
following properties and features:
Freely programmable safe linking
of sensors with actuators
Selective safe shutdown of actuators
Mixed configuration of F (fail-safe)
modules and standard modules in
one station
Fig. 4/6
SIMATIC S7-300F with fail-safe distributed ET 200S remote PROFIsafe I/Os
4/9
ET 200M with
standard I/O
Operator Panel
PROFIBUS/PROFIsafe
ET 200M
with F I/O
Laser scanner
Fig. 4/7
Example of a configuration (F I/O is yellow, standard I/O is blue)
Structure
4/10
Light curtain
PROFIsafe
Communication between I/O modules
and the CPU takes place exclusively
via PROFIBUS DP. Data is encapsulated in accordance with the PROFIsafe
profile, so that it can be transmitted
via the standard fieldbus without
being corrupted by any standard
devices connected to the bus.
Diagnostics and messaging concept
The S7-300F offers the same diagnostic and messaging functions as a
standard SIMATIC PLC. None of the
devices are subject to diagnostic
restrictions.
4
4.3.3 Fail-safe I/O
ET 200S / ET 200M
ET 200S and ET 200M F modules
include fail-safe input and output modules as well as fail-safe motor starters:
Fail-safe input modules detect
information from sensors.
Fail-safe output modules control
actuators.
Fail-safe motor starters control
and monitor drives.
All F modules can diagnose internal
and external errors and are configured
with internal redundancy. They have
dedicated self-test functions and meet
the relevant safety requirements.
I/O modules are available in the
ET 200S / ET 200M packaging design.
The ET 200S electronic modules are
30 mm wide and are marked with a
yellow labeling strip and have two
internal channels. They can be withdrawn and plugged-in during live
operation.
The following fail-safe ET 200S
modules are available:
4/8 F-DI 24 V DC, fail-safe digital
input with 4 inputs, 2-channel, SIL 3
sensors (Cat. 4) or 8 inputs, 1-channel, SIL 2 sensors (Cat. 3) for 24 V
4/11
4.3.4 Programming
The Distributed Safety software
package is indispensable when programming. It includes all of the functionality which you require when
engineering your application. The STEP
7 languages LAD and FBD are used to
program the safety-related programs
for the CPU 315F. It is important to
note that this restricts the scope of
functions in terms of operations and
data types. A safety-oriented program
is generated using a special input during compilation. In addition to the failsafe program, a standard program,
which is not subject to any restrictions, can also run in parallel on the
CPU (co-existence).
An additional integral component of
this software package is the F library
with pre-configured programming
examples with safety functions which
have been approved by the German
Inspectorate (TV). The user may
modify these programming examples;
however, these modifications must be
re-certified.
Programming example
The example opposite shows how
stop functions can be set-up to take
immediate effect (Category 0) or to
take effect after a delay (Category 1).
The acknowledge button serves as
the start input.
Fig. 4/8
Programming using the function block diagram (FBD)
Stop 1
Start
Immediate_Stop
Stop
Fig. 4/9
Emergency Stop programming example
=
R
Time 1
4/12
5
&
&
T1
4
4.3.5 ET 200S
fail-safe motor starter
The new fail-safe motor starter is
based, regarding the performance
features, on the High Feature motor
starter.
Emergency Stop
Fig. 4/10
Direct control of motor starters through ET 200S PROFIsafe
4/13
Fig. 4/11
Fail-safe motor starters with safety relays (var. 1) or AS-i Safety at Work (var. 2)
4/14
4
4.3.6 Technical data
170 Kbyte *)
64 Kbyte up to 4 Mbyte
>= 0.1 ms
400 ms
Bit memories/timers/counters
1000/1000
248/124
MPI interface
PROFIBUS DP interface
Dimensions (W x H x D)
40 x 125 x 130 mm
6 ES7315-6F..-
*) In comparison with a standard program, the number of fail-safe operations is limited due to
the fail-safe-specific overheads; depending on the type of programming, approx. 34 K fail-safe
operations are possible.
Fail-safe
ET 200S modules
Digital input
4/8 F-DI
Digital output
4 F-DO
Number of inputs/outputs
4 at 24 V/2 A
Input/output voltage
24 V DC
24 V DC
24 V DC
6ES7138-4FA..-
6ES7138-4FB..-
6ES7138-4CF..-
Fail-safe
ET 200M modules
Digital input
SM 326 F
Digital output
SM 326 F
Ex-input module
SM 326 NAMUR
Number of inputs/
24 (1-channel)
12 (2-channel)
10
8 (1-channel)
4 (2-channel)
6 (2-channel)
Input/outputvoltage
24 V DC
24 V DC
Interrupts
Diagnostics interrupt
Diagnostics interrupt
Diagnostics interrupt
Input/output current
4-20 mA
6ES7326-1BK..-
6ES7326-2BF..-
6ES7326-1RF..-
6ES7326-1HE..-
Diagnostics interrupt
4/15
7.5 kW
16 A
Short-circuit-breaking capacity
50 kA at 400 V
Coding
Diagnostics
Tripping class
Coordination type
2 (16 A)
3RK1301-0.B13-.AA2
3RK1903-3A..
5A
Order No..
3RK1903-3BA00
4 NO
Diagnostics
Switching capacity
1.5 A / 24 V
Order No.
3RK1903-3CA00
Self-diagnostics
Power failure
3RK1903-3DA00
Engineering Tools
Distributed Safety software package
Order No.
6ES7883-1FC00-0YX0
4/17