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ABB FSPS-21, User Manual

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Verification and validation

Contents of this chapter

This chapter describes verification and validation of the implemented safety functionality.

Verification and validation produce documented proof of the compliance of the implementation
with specified safety requirements.

For more information, see

Technical guide No. 10 - Functional safety

(3AUA0000048753

[English]).

Verifying the achieved SIL/PL level

Verification of the functional safety system demonstrates and ensures that the implemented
safety system meets the requirements specified for the system in the safety requirements
specification phase.

The most convenient way to verify the required SIL/PL level reached with the implemented
system is to use a specific safety calculator software.

Safety validation

￭

Validation procedure

It is always the responsibility of the machine builder to ensure that the functionality of all the
required safety functions has been appropriately verified and validated.

WARNING!

Until all the safety functionality is validated, the system must not be considered
safe.

The acceptance test must be performed to each safety function.

16

Verification and validation 173

Summary of Contents for FSPS-21

Page 1: ... OPTIONS FOR ABB DRIVES FSPS 21 safety functions fieldbus module User s manual ...

Page 2: ......

Page 3: ...nctions fieldbus module User s manual Table of contents 1 Safety instructions 8 Mechanical installation 9 Electrical installation 17 Start up 2019 ABB Oy All Rights Reserved 3AXD50000158638 Rev A EN EFFECTIVE 2019 02 01 ...

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Page 5: ...ertificates 19 Related manuals 3 Safety system information and considerations 21 Contents of this chapter 21 Applying FSPS 21 safety functions 21 Meeting the requirements of the Machinery Directive 22 Responsibilities 22 Intentional misuse 22 Safety related parts 22 Limitations of Safe torque off STO function 22 Overall system stopping performance 4 Overview of the FSPS 21 module and the Ethernet ...

Page 6: ...C compatibility 8 Mechanical installation 35 Contents of this chapter 35 Necessary tools and instructions 35 Unpacking and examining the delivery 36 Installing the module 9 Electrical installation 39 Contents of this chapter 39 Necessary tools and instructions 39 General cabling instructions 39 Connecting the FSPS 21 to the Ethernet network and to the STO of the drive 40 Terminals 10 Installation ...

Page 7: ...ncy Protocol MRP with TIA14 68 Shared Device 68 Configuring Shared Device for ABB PLC with Automation builder 68 Configuring drive control PLC 69 Configuring safety PLC 70 Configuring Shared Device for Siemens PLC with TIA portal 70 Configuring drive control PLC 71 Configuring safety PLC 71 Using MRP and Shared Device in the same network 13 PROFINET IO Communication profiles 73 Contents of this ch...

Page 8: ... element 101 Example 2b Writing 2 drive parameters multi parameter 103 Example 3 Reading a PROFIdrive parameter 104 Example 4 Configuring the process data written to the drive 106 Example 5 Determining the source of the process data read from the drive 107 Diagnostic and alarm mechanism 107 Alarm mechanism 108 Fault code mapping 109 Fault buffer mechanism 15 PROFIsafe 111 Contents of this chapter ...

Page 9: ...Diagnostic messages related to F Parameters 171 Typical communication errors 16 Verification and validation 173 Contents of this chapter 173 Verifying the achieved SIL PL level 173 Safety validation 173 Validation procedure 174 Acceptance test reports 174 Competence 174 Tools 174 Validation checklists for start up 174 Validation of the PROFIsafe connection 175 Validation of the STO function 175 Va...

Page 10: ...d UDP service ports 196 Safety functions 196 Safety data 196 General 197 Basic safety data 198 Relevant failure modes 198 Related standards and directives 198 Related standards 199 Other technical specifications 21 Appendix A PROFIdrive parameters and I M records of PROFINET IO 201 Contents of this chapter 201 PROFIdrive parameters 206 I M records 206 Call REQ PDU telegram for read write access to...

Page 11: ...Further information Table of contents 11 ...

Page 12: ...12 ...

Page 13: ...ge to the equipment They also tell you how to prevent the danger Notes draw attention to a particular condition or fact or give information on a subject The manual uses these warning symbols WARNING Electricity warning tells about hazards from electricity which can cause injury or death or damage to the equipment WARNING General warning tells about conditions other than those caused by electricity...

Page 14: ...nce work 2 Isolate and disconnect the unit from all possible power sources After you have disconnected the unit always wait for 5 minutes to let the intermediate circuit capacitors discharge before you continue 3 Disconnect all dangerous voltages connected to other connectors or parts in reach For example it is possible that 230 V AC is connected from outside to a relay output of the unit 4 Always...

Page 15: ...control program version 2 80 or later ACS580 drives ACS580 standard control program version 2 05 or later ACS380 drives ACS380 machinery control program version 2 05 or later Tools Drive composer pro version 1 7 or later For ABB PLCs Automation builder 1 0 or later includes PS501 Control Builder Plus version 2 3 0 safety license PS501 S For Siemens PLCs SIMATIC Step 7 V5 5 S7 Distributed Safety V5...

Page 16: ...n the safety application plan the installation as well as install and commission the safety application Read the manual before starting work on the safety application You must know the fundamentals of safety technology electricity wiring electrical components and electrical schematic symbols Purpose of the manual The manual explains how to install the FSPS 21 module and configure and commission th...

Page 17: ...mmunicate information and data via a network interface It is Customer s sole responsibility to provide and continuously ensure a secure connection between the product and Customer network or any other network as the case may be Customer shall establish and maintain any appropriate measures such as but not limited to the installation of firewalls application of authentication measures encryption of...

Page 18: ...IEC 61508 PFDavg Average frequency of dangerous failures per hour IEC 61508 PFH Performance level Levels a e correspond to SIL EN ISO 13849 1 PL Programmable logic controller PLC Adjustable speed electrical power drive system suitable for use in safety related ap plications Power drive systems Safety related PDS SR Adaptation of a communication protocol for a certain application field for example ...

Page 19: ...0018826 ACS580 01 drives 0 75 to 250 kW 1 0 to 350 hp hardware manual frames R0 R9 3AXD50000015497 ACS580 04 hardware manual 3AXD50000045815 ACS580 07 drives 75 to 250 kW hardware manual 3AXD50000032622 ACS580 07 250 to 500 kW hardware manual 3AXD50000029274 ACS380 hardware manual Drive firmware manuals 3AUA0000085967 ACS880 primary control program firmware manual 3AXD50000016097 ACS580 standard c...

Page 20: ... format on the Internet See www abb com drives documents For manuals not available in the Document library contact your local ABB representative For additional ABB safety information and solutions visit http www abb com safety 20 Introduction to the manual ...

Page 21: ...ribed in global ISO IEC machinery safety and or functional safety standards eg ISO 12100 13849 1 IEC 62061 These are also introduced in Functional safety Technical guide No 10 3AUA0000048753 English Before you take into use any system where FSPS 21 with its safety functions is used and also every time you modify any application parameters or the configuration related to safety you must check the s...

Page 22: ...mitations of Safe torque off STO function The Safe torque off function can be used for stopping the drive in the operational mode If a running drive is stopped by using the STO function the drive stops by coasting STO function can also be used for prevention of unexpected start up according to the limitations of IEC 60204 1 5 4 and ISO 14118 The Safe torque off function does not disconnect or isol...

Page 23: ...FIsafe over PROFINET It is also possible to use the module to control the PDS SR over PROFINET Through the FSPS 21 module you can start and stop the drive and reset drive faults give speed or torque reference to the drive read drive status word bits write to drive control word bits perform safety functions The protocol used to access these functionalities over the Ethernet is PROFINET IO Communica...

Page 24: ...he safety PLC The fault reaction function activates the fail safe mode as described in chapter FSPS 21 module modes and states page 117 Automatic acknowledgement FSPS 21 only has an automatic acknowledgement method for a safety function This means that when the safety function request is removed the FSPS 21 automatically enters the Operational state Automatic acknowledgement also takes place durin...

Page 25: ...er Other PN IO device ABB drive Other PN IO device Daisy chain topology using integrated Ethernet switch Switch or router Other PN IO device ABB drive ABB drive ABB drive Overview of the FSPS 21 module and the Ethernet network 25 ...

Page 26: ...26 ...

Page 27: ...TO function in the FSPS 21 module activates the drive STO function that is opens the STO circuit in the drive This prevents the drive from generating the torque required to rotate the motor If the motor is running when the STO function is activated it coasts to a stop For more information on the STO function in the drive see the drive hardware manual The operation of the STO function is described ...

Page 28: ...Zero speed limit is reached The SS1 function uses drive parameter 23 23 Emergency stop ramp to define the stop ramp see section Drive parameters related to safety functions page 43 for more information The FSPS 21 module monitors the stop ramp with a time limit If the motor speed does not reach the user defined zero speed limit within the specified time limit the module activates the drive STO fun...

Page 29: ... request is received from the safety PLC The module starts a counter for time A The SS1 t indication Off3 in the drive and safety PLC goes on 1 After time C has elapsed the drive starts to ramp down the motor speed Drive parameters define the deceleration ramp emergency stop ramp 2 The motor speed reaches the user defined zero speed limit B and the module activates the drive STO function 3 If the ...

Page 30: ...ne of the following modes Power down The power to the FSPS 21 is off The drive STO circuit is open Start up The FSPS 21 is starting up after power up Running The FSPS 21 is up and running It can be in different states see previous section depending on the status of safety functions and the safety fieldbus communication Failure detected The FSPS 21 has detected a failure drive STO is activated and ...

Page 31: ...e next module and so on 3 Connect the STO cable to the FSPS 21 module black connector 4 ACS880 Connect the yellow connector to drive s STO connector No Description 1 Lock 2 Mounting and grounding screw 3 RJ 45 connector X1 to Etherne 4 RJ 45 connector X2 for chainin 5 STO connector under connecto 6 Diagnostic LEDs 7 MAC ID 6 3 2 4 1 5 7 Lock 1 Mounting and grounding screw 2 RJ 45 connector X1 to E...

Page 32: ...st digit of the manufacturing year 4 5 for 2014 2015 WW Manufacturing week 01 02 for week 1 week 2 SSSS Integer starting every week from 0001 WS Manufacturing location 2 ABB MRP code of the FSPS 21 module 3 Combined ABB MRP code component revision serial number and manufacturing location 4 RoHS mark 5 32 Hardware description ...

Page 33: ...ts page 41 Installation site The subsystem elements must always be likely to operate within the range of temperature humidity corrosion dust vibration etc for which they are specified without the use of external environmental control see section Technical data The FSPS 21 module must only be used in an environment where no conductive dust or contaminants are present One way to ensure proper protec...

Page 34: ... Chapter Installation checklists page 41 provides additional advice for the planning All wiring must be well protected routed and clamped where practicable When installing cabling it must be assured that there is no pulling or pinching on the cables Ensuring the EMC compatibility The system must only be used in the EMC environment it is designed for or necessary mitigations must be applied 34 Plan...

Page 35: ... a Torx TX10 screwdriver to secure the FSPS 21 module to the drive See also the drive hardware manual Unpacking and examining the delivery 1 Open the option package 2 Make sure that the package contains fieldbus module type FSPS 21 STO cable with a connector suitable for ACS880 series drives quick guide 3 Make sure that there are no signs of damage 8 Mechanical installation 35 10 ...

Page 36: ...be used for fieldbus communication in the supply unit Note Do not install the FSPS 21 module on the FEA 03 F series extension adapter When the module is installed it makes the signal and power connection to the drive through a 20 pin connector To install or remove the module from the control unit 1 Pull out the lock verters on and start up guide dapter module instructions If you ignore them injury...

Page 37: ...le Diagnostic LEDs 4 Tighten the screw to torque 0 8 N m using a Torx TX10 screwdriver WARNING Do not use excessive force or leave the screw too loose Overtightening can damage the screw or module A loose screw decreases the EMC performance and can even cause an operation failure See the drive manual for further instructions on how to install the module to the drive Mechanical installation 37 10 ...

Page 38: ...38 ...

Page 39: ...hardware manual General cabling instructions Arrange the bus cables as far away from the motor cables as possible Avoid parallel runs Use bushings at cable entries Connecting the FSPS 21 to the Ethernet network and to the STO of the drive WARNING Obey the safety instructions If you ignore the safety instructions injury or death can occur If you are not a qualified electrician do not do electrical ...

Page 40: ...80 580 Remove the yellow connector from the cable and connect the wires to drive s STO connectors see figure below Electrical installation Layout of the module Connection procedure 1 Connect the network cable to connector X1 on the module 2 If you want to create a daisy chain network with the FSPS 21 modules connect connector X2 of the first module to connector X1 on the next module and so on 3 Co...

Page 41: ...on the safety system General checklist Check that The ambient operating conditions are within the allowed range Transportation stops and packing material have been removed from the installation area The module is fastened properly The drive and the module are properly grounded to the same potential The network cable is properly connected The STO cable is correctly installed Common cause failure CC...

Page 42: ...42 ...

Page 43: ...PS 21 module in ABB MyLearning portal Tools You need a control panel or the Drive composer PC tool to configure the FSPS 21 module For more information see Drive composer start up and maintenance PC tool user s manual 3AUA0000094606 English or a control panel user s manual Drive parameters related to safety functions This table lists the drive parameters related to the FSPS 21 module and the safet...

Page 44: ... through fieldbus Selects which indications are given when one or both Safe torque off STO signals are switched off or lost The indications also depend on whether the drive is running or stopped when this occurs STO indication run stop 31 22 The tables at each selection below show the indications gener ated with that particular setting Notes This parameter does not affect the operation of the STO ...

Page 45: ...nd PROFIsafe communication see FSPS 21 configuration parameters group A group 1 page 48 3 Set the drive parameters related to safety functions see Drive parameters related to safety functions page 43 4 Set up the PROFINET IO communication between the module and the safety PLC see Configuring the safety PLC page 126 5 Set up the PROFIsafe communication between the module and the safety PLC see Conf...

Page 46: ...46 ...

Page 47: ...ompatible with the FSPS 21 module unless otherwise stated PROFINET IO connection configuration After the adapter module has been mechanically and electrically installed you must prepare the drive for communication with the module The detailed procedure of activating the module for PROFINET IO communication with the drive depends on the drive type Normally you must set the PROFINET parameters to es...

Page 48: ...ec ted by the drive The value cannot be adjusted by the user If the value is 0 None the communication between the drive and the module has not been established FBA type 01 11 PNIO ABB Pro Selects the application protocol and communication profile for the network connection The selections available for PROFINET IO communic ation are listed below Protocol Profile 02 PROFINET IO protocol PROFIdrive p...

Page 49: ...ed to change the IP address configured via DCP it should be done with a DCP tool such as Siemens Step7 If some of the other methods are used to change the IP address the module must be restarted to enable any changes 0 Static IP IP address is set as Temporary through DCP by the controller Parameters 05 13 shows the set IP After reboot this setting goes back to static IP and address 0 0 0 0 is take...

Page 50: ...55 0 24 254 0 0 0 7 255 255 254 0 23 252 0 0 0 6 255 255 252 0 22 248 0 0 0 5 255 255 248 0 21 240 0 0 0 4 255 255 240 0 20 224 0 0 0 3 255 255 224 0 19 192 0 0 0 2 255 255 192 0 18 128 0 0 0 1 255 255 128 0 17 255 255 0 0 16 Subnet mask in CIDR notation 1 31 0 IP gateways connect individual physical IP subnets into a unified IP network When an IP node needs to communicate with an IP node on anoth...

Page 51: ...he PLC For more information on the supported PPO message types see section PPO types page 89 Telegram type 20 Cyclical communication between the master and the module has not been established yet 0 Unknown PPO3 selected 3 PPO3 PPO4 selected 4 PPO4 PPO6 selected 6 PPO6 PPO7 selected 7 PPO7 ST1 selected 8 ST1 ST2 selected 9 ST2 0 Enabled Disables the PROFIdrive alarm mechanism which generates alarms...

Page 52: ...me abbdrive 12 Note During every boot the FSPS 21 module checks the value of PN Name Index If the value is not Zero then the active PN Name In dex overrides the PROFINET station name If the new name is set by DCP Set command as permanent the new name is used and stored to flash The PN Name Index parameter value is not changed so after next boot the name is taken ac cording to the PN Name Index If ...

Page 53: ...d only Displays the status of the fieldbus adapter module communication Note The value names may vary by drive D2FBA A B comm status 31 Note Only active drive controlled channel will change comm status online PROFIsafe alone will not change the comm status Adapter is not configured 0 Idle Adapter is initializing 1 Exec init A timeout has occurred in the communication between the adapter and the dr...

Page 54: ...1 or 111 Selects the resolution of control word 16 bit or 32 bit received by the drive FBA data out 1 mas ter to drive 01 Control word 16 bits 1 CW 16bit Control word 32 bits 11 CW 32bit 0 or 2 Selects data word 1 received by the drive over the PROFINET network The content is defined by a decimal number in the range of 0 to 9999 as follows FBA data out 2 02 Not used 0 Virtual address area of drive...

Page 55: ... drive to master 01 Status word 16 bits 4 SW 16bit Status word 32 bits 14 SW 32bit 0 or 5 Selects data word 1 sent by the drive over the PROFINET network The content is defined by a decimal number in the range of 0 to 9999 as follows FBA data in 2 drive to master 02 Not used 0 Virtual address area of drive control 1 99 Parameter area of the drive 101 9999 Not used 0 None Status word 16 bits 4 SW 1...

Page 56: ...fieldbus communication break Note that this function monitors both communication between the fieldbus master and the adapter module and communication between the adapter module and the drive 4 With parameter 50 03 FBA A comm loss t out define the time between communication break detection and the selected action 5 Select application specific values for the rest of the parameters in group 50 starti...

Page 57: ...odule 1 Enable 50 01 FBA A enable Selects the fieldbus A reference 1 type and scaling 5 Frequency 50 04 FBA A ref1 type Selects the actual value type and scaling according to the currently active Ref1 mode defined in paramet er 50 04 5 Frequency 50 07 FBA A act1 type Displays the type of the fieldbus adapter module 133 PROFIsafe1 51 01 FBA A type Selects the PROFINET IO protocol and the PROFIdrive...

Page 58: ...l READY TO SWITCH ON Enter 47Fh 1151 decimal OPERATING Parameter setting examples ACS880 Speed control using PROFIdrive communication profile with PPO Type 4 This example shows how to configure a basic speed control application that uses the PROFIdrive profile In addition some application specific data is added to the communication The start stop commands and reference are according to the PROFIdr...

Page 59: ...Add 51 24 F Destination Ad dress Status word 4 SW 16bit 52 01 FBA DATA IN1 Actual value 1 5 Act1 16bit 52 02 FBA DATA IN2 Output power 01 14 52 03 FBA data in3 DC voltage 01 11 52 05 FBA data in5 Control word 1 CW 16bit 53 01 FBA DATA out1 Reference 1 speed 2 Ref1 16bit 53 02 FBA DATA out2 Constant speed 1 22 26 53 03 FBA data out3 Constant speed 2 22 27 53 05 FBA data out5 Validates the configura...

Page 60: ... the role of Media Redundancy Clients MRC Each node MRM or MRC has a pair of ports for connecting in the ring For FSPS 21 module the link speed of both ports is 100 Mbit s full duplex Note The number of nodes in the ring should not exceed 50 nodes Port 2 Port 1 PLC or switch MRM ABB drive ABB drive 1 3 2 1 4 Description No ABB drive equipped with FSPS 21 module 1 PLC or switch with MRM Media Redun...

Page 61: ...PN IO properties window is displayed 2 In the Properties PN IO window select Media Redundancy tab PROFINET IO Start up 61 ...

Page 62: ...3 From the Role drop down list select Manager Auto role for the PLC and then click OK 4 In the master station window click FSPS and then double click Interface 62 PROFINET IO Start up ...

Page 63: ...Properties Interface window is displayed 5 In the Properties Interface window select Media Redundancy tab PROFINET IO Start up 63 ...

Page 64: ...nt role for the FSPS module 7 In the Properties Interface window select IO Cycle and set watchdog time A recommended value for the watchdog time is 200 ms Make sure that the connection is maintained during the ring break 64 PROFINET IO Start up ...

Page 65: ... the master station window right click on PROFINET IO System and select PROFINET IO Domain Management The configured devices PN IO and FSPS are shown in the Domain management window PROFINET IO Start up 65 ...

Page 66: ...tion see section Configuring FSPS 21 with TIA14 page 136 To configure an MRP with TIA portal proceed as follows 1 In TIA portal Device overview expand PLC and select the desired PROFINET interface PROFINET interface view is displayed 2 In PROFINET interface view click General tab and select Media Redundancy and then select Manager auto role for the PLC 66 PROFINET IO Start up ...

Page 67: ...t Interface PROFINET interface view is displayed 4 In PROFINET interface view click General tab and select Media Redundancy and then select Client role for the FSPS 21 5 In the General tab select IO cycle and set watchdog time PROFINET IO Start up 67 ...

Page 68: ...an access one drive from two controllers through one FSPS 21 module For example one PLC to control the drive other Safety PLC for safety communication The PROFINET drive control and PROFIsafe can be used by separate PLCs Configuring Shared Device for ABB PLC with Automation builder Configuring drive control PLC 1 Select PPO telegram to use on slot 1 Leave slot 2 empty 2 Define PROFINET station nam...

Page 69: ...Configuring safety PLC 1 Select safety telegram to use on slot 2 Leave slot 1 empty PROFINET IO Start up 69 ...

Page 70: ...control PLC configuration 3 Under Option tab tick the Shared Device check box Configuring Shared Device for Siemens PLC with TIA portal Configuring drive control PLC 1 Select PPO telegram to use on slot 1 Leave slot 2 empty 70 PROFINET IO Start up ...

Page 71: ...tation name as in drive control PLC configuration 4 From the Shared Device tab select access rights to the PROFIsafe slot for the Safety PLC Using MRP and Shared Device in the same network It is possible to use Shared device together with MRP In this case MRP is configured into use from the switch and the Shared Device is configured into use from one of the PLCs PROFINET IO Start up 71 ...

Page 72: ...Switch or router ABB drive ABB drive ABB drive PLC Safety PLC 72 PROFINET IO Start up ...

Page 73: ...s word references and actual values between the master station and the drive With the FSPS 21 module the PROFINET network may employ either the PROFIdrive profile or the ABB Drives profile Both are converted to the native profile e g DCU or FBA by the adapter module In addition two Transparent modes for 16 bit and 32 bit words respectively are available With the Transparent modes no data conversio...

Page 74: ... PPO messaging is used If Standard Telegrams ST are used the communication profile is selected automatically The following sections describe the Control word the Status word references and actual values for the PROFIdrive and ABB Drives communication profiles Refer to the drive manuals for details on the native profiles PROFIdrive communication profile Control word and Status word The Control word...

Page 75: ...urther to SWITCH ON INHIBIT 0 Warning Ensure motor and driven machine can be stopped using this stop mode Proceed to ENABLE OPERATION 1 OPERATION_ENABLE 3 Inhibit operation Proceed to OPERATION INHIBIT 0 Normal operation Do not re ject traversing task Normal operation Proceed to RAMP FUNCTION GENER ATOR ENABLE OUTPUT 1 ENABLE_ RAMP_ GENER ATOR or 4 Reject traversing task Stop according to selected...

Page 76: ... defined by PROFIdrive parameter 934 12 As default mapped to Drive Main CW bit 12 Vendor specific bit as defined by PROFIdrive parameter 935 13 As default mapped to Drive Main CW bit 13 Vendor specific bit as defined by PROFIdrive parameter 936 14 As default mapped to Drive Main CW bit 14 Vendor specific bit as defined by PROFIdrive parameter 937 15 As default mapped to Drive Main CW bit 15 Status...

Page 77: ...als or is greater than supervision limit 1 10 Not at target position Actual frequency or speed value is within supervision limit 0 Homing procedure was ex ecuted and is valid Mapped to PROFIdrive SW bit 11 1 11 Vendor specific bit as defined by PROFIdrive parameter 939 No valid home position avail able 0 As default mapped to PROFIdrive SW bit 11 Traversing task acknowledge ment 0 1 Mapped to PROFI...

Page 78: ... Bit0 0 OFF1 ACTIVE SW Bit1 0 SW Bit0 1 CW Bit3 1 C D CW Bit5 0 OPERATION ENABLE SW Bit2 1 SW Bit5 0 from any state from any state Emergency stop OFF3 CW Bit2 0 n f 0 I 0 OFF3 ACTIVE Emergency stop OFF2 CW Bit1 0 SW Bit4 0 OFF2 ACTIVE RFG ENABLE OUTPUT RFG ENABLE ACCELERATION OPERATING B B C D CW Bit4 0 CW Bit4 1 CW Bit5 1 D CW Bit6 0 A C CW Bit6 1 SW Bit8 1 D from any state Fault SW Bit3 1 FAULT ...

Page 79: ...Bit5 0 CW Bit5 0 SW Bit10 13 0 Braking with ramp Intermediate stop CW Bit6 edge 0 1 F F F SW Bit10 13 0 CW Bit4 0 Braking with ramp E 1 In the Operating state of the general state machine SW bits 0 1 and 2 1 SW bit 6 0 F PROFIdrive_state_machine_posit pdf References ABB drives can receive control information from multiple sources including analog and digital inputs the drive control panel and a fi...

Page 80: ... hexadecimal 0 4000 0000h corresponds to 0 100 of the maximum reference as defined with a drive parameter for example speed scaling in ACS580 and ACS880 ABB Drives communication profile Control word and Status word The Control word is the principal means for controlling the drive from a fieldbus system It is sent by the fieldbus master station to the drive through the adapter module The drive swit...

Page 81: ...CELERATOR ENABLED Halt ramping Ramp Function Generator output held 0 Normal operation Proceed to OPERATION 1 RAMP_IN_ ZERO 6 Note This bit is effective only if the fieldbus interface is set as the source for this signal by drive parameters Force Ramp Function Generator input to zero 0 Fault reset if an active fault exists Proceed to SWITCH ON INHIB ITED 0 1 RESET 7 Note This bit is effective only ...

Page 82: ...INT 8 Actual value differs from reference is outside tolerance limits 0 Drive control location REMOTE EXT1 or EXT2 1 REMOTE 9 Drive control location LOCAL 0 Actual frequency or speed equals or exceeds supervision limit set by drive parameter Valid in both directions of rotation 1 ABOVE_ LIMIT 10 Actual frequency or speed within supervision limit 0 External Control Location EXT2 selected Note conce...

Page 83: ...t12 1 C D CW Bit5 0 SW Bit2 1 SW Bit5 0 from any state from any state Emergency stop OFF3 CW Bit2 0 n f 0 I 0 Emergency OFF OFF2 CW Bit1 0 SW Bit4 0 B B C D CW Bit4 0 CW xxxx x1xx xxx1 1111 CW xxxx x1xx xx11 1111 D CW Bit6 0 A C CW xxxx x1xx x111 1111 SW Bit8 1 D from any state Fault SW Bit3 1 CW Bit7 1 CW xxxx x1xx xxxx x111 CW xxxx x1xx xxxx 1111 and SW Bit12 1 state condition rising edge the bi...

Page 84: ... can receive control information from multiple sources ing analog and digital inputs the drive control panel and a us adapter module for example FENA To have the drive olled through the fieldbus you must select the module as the e for control information for example reference ng ences are scaled as shown below The values of REF1 MAX and REF2 MAX are set with drive meters See the drive manuals for ...

Page 85: ...he values of REF1 MAX and REF2 MAX are set with drive parameters See the drive manuals for further information 0 REFx MAX REFx MAX 0 ACT2 10000 ACT1 20000 ACT2 10000 ACT1 20000 Drive Fieldbus Scaling_actual_values pdf PROFINET IO Communication profiles 85 ...

Page 86: ...86 ...

Page 87: ... TCP IP channel is used for parameterization and configuration of devices and for acyclic operations The real time RT channel is used for cyclic data transfer and alarms The isochronous real time IRT channel is used for example in motion control applications not implemented in FSPS 21 PROFINET IO devices are structured in slots and sub slots which can contain modules and sub modules correspondingl...

Page 88: ...ng there is need to configure the IP in only one place hardware configuration and this avoids any IP conflicts among the devices PROFINET IO in FSPS 21 When PROFINET IO is selected as the communication protocol the FSPS 21 module can employ the ABB Drives Transparent 16 and Transparent 32 communication profiles or the PROFIdrive profile You can select the profile via FSPS 21 configuration paramete...

Page 89: ...fication PZD3 SW ACT PZD4 PZD5 PZD6 PZD7 PZD8 PZD9 PZD10 Fixed area Freely mappable area OUT area IN area ID VALUE Parameter channel DP V1 DP V1 DP V1 D Z P W K P VALUE IND PZD11 PZD11 PZD12 PZD12 Type 7 DP V1 OUT area Data sent from master to slave control data IN area Data sent from slave to master actual data Parameter identification ID Parameter identification IND Index for arrays VALUE Parame...

Page 90: ...rs or FSPS 21 parameters are accessed the corresponding slot sub slot and index are set and a PROFIdrive DP V1 message is placed on the data block of the record read or write frame Header and frame structures PROFINET IO uses the DCE RPC Distributed Computing Environment Remote Procedure Call protocol for acyclic read and write services I O controllers and supervisors take care of formulating most...

Page 91: ...de2 ErrorCode1 The table below lists the ErrorCode1 with PNIORW decoding PROFINET IO Communication protocol 73 ErrorCode1 The table below lists the ErrorCode1 with PNIORW decoding Error class Meaning Error code 0 9 Reserved 10 0x0A Application 0 Read error 1 Write error 2 Module failure 3 7 Reserved 8 Version conflict 9 Feature not supported 10 15 User specific 11 0x0B Access 0 Invalid index 1 Wri...

Page 92: ...n ErrorCode1 on page 73 Master DP V1 Slave Parameter processing Parameter request Parameter response PROFIdrive Write request DB47 Write response without data Read request DB47 without data Read response without data Read request DB47 without data Read response with data Parameter PROFIdrive Parameter response request DP V1 read_write_seq pdf The messaging employs DP V1 data units The PROFIdrive p...

Page 93: ...01 Subslot of the module access point MAP PAP Subslot 2 bytes Padding UI16 0x2F Index of the record data object Index 0xB02E 0xB02F UI32 0 0xFFFFFFFF Length of the data block Data length UI16 Field for transferring additional data Additional value 1 response only UI16 Field for transferring additional data Additional value 2 response only 24 bytes for request 20 bytes for response Padding Used onl...

Page 94: ... Format1 Byte 0 234 Number of the values following Number of Values1 See the Format field The values of the request In case of an odd number of bytes a zero byte is appended to ensure the word structure of the telegram Values1 1 Only if Request ID is 02h Change Parameter The Format Number of Values and Values fields are repeated for other parameters The table below shows the contents of the PROFId...

Page 95: ...ord 0x42 Double word 0x43 Error 0x44 Reserved 0x45 0xFF The table below shows the PROFIdrive parameter request error codes Used at Meaning Error Access to an unavailable parameter Impermissible parameter number 00h Change access to a parameter value that cannot be changed Parameter value cannot be changed 01h Change access with a value outside the limits Low or high limit exceeded 02h Access to an...

Page 96: ...upported Illegal format 17h Write request Number of values of the parameter data does not match the number of elements at the paramet er address Number of values inconsistent 18h Manufacturer specific error area 65h FF Vendor specific error Vendor specific error 65h Request not supported Request not supported 66h Request cannot be completed because of a communic ation error Communication error 67h...

Page 97: ...s also applicable for other blocks RDREC BOOL REQ VALID BOOL DWORD ID BUSY BOOL INT INDEX ERROR BOOL INT MLEN STATUS DWORD LEN INT ANY RECORD RECORD WRREC BOOL REQ DONE BOOL DWORD ID BUSY BOOL INT INDEX ERROR BOOL INT LEN STATUS DWORD ANY RECORD RECORD S7_read_write pdf Note The function block names for Siemens 12xx and 15xx series PLCs are RD_REC and WR_REC and this naming convention is also appl...

Page 98: ...84 PROFINET IO Communication protocol Positive Read response to DP V1 Read request Negative response to PROFIdrive Read request DP header 01 01 B0 2F 08 05 01 01 01 42 01 05 64 DP trailer DP V1 Response PROFIdrive V3 Parameter Channel DP header 01 01 B0 2F 08 85 01 01 01 44 01 00 00 DP trailer DP V1 Response PROFIdrive V3 Parameter Channel Slot number Subslot number Index Data length Response refe...

Page 99: ...e three parameters 12 04 20 08 and 30 19 are read using one telegram DP V1 Write request Read parameter value PROFINET IO Communication protocol 85 Example 1b Reading 3 drive parameters multi parameter In this example three parameters 12 04 20 08 and 30 19 are read using one telegram DP V1 Write request Read parameter value DP header 01 01 B0 2F 16 06 01 01 03 10 01 00 0C 00 04 DP V1 Command PROFI...

Page 100: ...ubslot number Index Data length Response reference mirrored Response ID Drive object ID Number of parameters Format 42h Word Number of values Parameter value The values 190h 400 1F4h 500 and 1Eh 30 are returned Example 2a Writing a drive parameter one array element Drive parameters are addressed so that the drive parameter group corresponds to the Parameter index PNU and the drive parameter number...

Page 101: ...t ID Number of parameters Attribute 10h Value Number of elements Parameter number Subindex Format 42h Word Number of values Value Write_param_1202_1 pdf 88 PROFINET IO Communication protocol DP header 01 01 B0 2F 04 07 02 01 01 DP trailer DP V1 Response PROFIdrive V3 Parameter Channel Slot number Slot number Index Data length Request reference mirrored Response ID Drive object ID mirrored Number o...

Page 102: ...ive V3 Parameter Channel 10 01 00 14 00 08 Par Channel cont d 42 01 01 2C Par Channel cont d 42 01 01 F4 DP trailer Par Channel cont d Slot number Subslot number Index Data length Request reference Request ID 02h Change Parameter Drive object ID Number of parameters Attribute 10h Value Number of elements Parameter number Subindex Value Number of values Format 42h Word Write_param_1202_2008_1 pdf 1...

Page 103: ...llowing examples show how parameter data is transferred using the DP V1 mechanisms READ and WRITE Note Only the data block part of the request is presented in the examples See section Read and write blocks on page 75 Example 1a Reading a drive parameter array element Drive parameters are addressed so that the drive parameter group corresponds to the Parameter index PNU and the drive parameter numb...

Page 104: ...red Response ID Drive object ID mirrored Number of parameters Format 42h Word Number of values Value of error values Slot number DP V1_Read_response_3 pdf The slave returns the product code of the drive 20Bh in this example Example 4 Configuring the process data written to the drive PROFIdrive parameter 915 393h can be used to define which data is written cyclically to a drive parameter as applica...

Page 105: ...drive V3 Parameter Channel 10 01 00 14 00 08 Par Channel continued 10 01 00 1E 00 13 DP trailer Par Channel continued Slot number Subslot number Index Data length Request reference Request ID 01h Request Parameter Drive object ID Number of parameters Attribute 10h Value Number of elements Parameter number Subindex DP V1_Write_request_2 pdf DP V1 Read response PROFINET IO Communication protocol 105...

Page 106: ...t 42h Word Number of values Parameter value Subsequently the contents of PZD3 in each Request frame are written to drive parameter 12 06 until a different selection is made Example 5 Determining the source of the process data read from the drive PROFIdrive parameter 916 394h can be used to define which data is read cyclically from the drive as application specific process data In the example below...

Page 107: ... by default and can be disabled with a configuration parameter 21 Alarm disable on page 13 DP header 01 01 B0 2F 08 0B 01 01 01 42 01 0C 05 DP trailer DP V1 Response PROFIdrive V3 Parameter Channel Subslot number Index Data length Request reference mirrored Response ID Drive object ID mirrored Number of parameters Format 42h Word Number of values Value of error values Slot number DP V1_Read_respon...

Page 108: ...306 6306 6320 6481 6487 630D 630F 64A1 64A2 64A3 64E1 6581 65A1 6682 6683 6684 6881 FF55 Microcontroller hardware or software 0x9000 3291 Mains supply 0x9001 3130 3220 Low voltage supply 0x9002 3210 DC link overvoltage 0x9003 2211 2281 2310 2312 2340 2381 3180 3181 3182 3183 3184 3185 3186 3187 3381 3385 5400 5482 5682 5692 FF56 Power electronics 0x9004 4110 4210 4212 4290 4310 4313 4981 7182 42F1...

Page 109: ...list that converts fault numbers to fault codes Read using the fault number as a subindex to get the corresponding fault code PNU947 Fault numbers according to the DRIVECOM profile The table below illustrates the structure of a fault buffer The fault buffer consists of two parameters fault number PNU 947 and fault code PNU 945 The rows of the fault buffer are represented by the parameter subindice...

Page 110: ...Subindex Fault code Fault number 8 0x900B 0x7510 Fault situation n 1 9 0 0 10 0 0 11 0 0 12 0 0 13 0 0 14 0 0 15 0 0 56 0 0 Fault situation n 7 57 0 0 58 0 0 59 0 0 60 0 0 61 0 0 62 0 0 63 0 0 110 PROFINET IO Communication protocol ...

Page 111: ...ety measures to minimize the effect of various transmission errors that can occur when messages are transferred in a complex network PROFIsafe is an application layer protocol that describes the safety communication between fail safe devices It is an additional layer on top of the standard PROFIBUS and PROFINET protocols There are two versions of the PROFIsafe protocol V1 can only be used with PRO...

Page 112: ... PROFIsafe communication bus The FSPS 21 module is installed on the ACS580 drive The safety PLC is connected to the FSPS 21 module The safety PLC activates safety functions via the PROFIsafe communication bus The PROFIsafe protocol secures the whole path from the location where a safety signal originates to the location where it is processed and vice versa The safety PLC sends PROFIsafe messages f...

Page 113: ...ion PROFIsafe message format The FSPS 21 module supports only the PROFIsafe short frame format The short frame supports a maximum of 12 octets of user data The frame also includes a CRC 3 octets and one Status Control Byte octet Therefore the maximum frame size of the message is 16 octets CRC2 Status Control Byte F Input F Output user data Data 3 1 Max 12 Size octets Control Byte and CRC2 bit orde...

Page 114: ... CRC2 Ni is the length of F Input user data Description Name Bit Octet Status Byte The value is always 0 Must be ignored by the F Host Reserved 7 Ni Vconsnr_d has been reset cons_nr_R 6 Toggle bit Toggle_d 5 Fail safe values FV activated FV_activated 4 Communication fault Watchdog timeout WD_timeout 3 Communication fault CRC error CE_CRC 2 Failure exists in the F Device Device_Fault 1 F Device has...

Page 115: ...om the FSPS 21 module to the safety PLC For all the bits in the F Input data one 1 means active and zero 0 non active PROFIsafe frame from F Device to F Host CRC 2 Status byte F Input data 3 octets 1 octet 2 octets as bits LSB Octet n MSB Octet 0 Octet 0 Octet 1 Octet 0 F Input data Description Name Bit Octet Type 1 Safe state 0 Operational state Device_sta te 0 0 Unsigned8 used as bits State Bit ...

Page 116: ...e F Output user data This table shows the bit order of the F Output data which is included in the PROFIsafe message sent to the FSPS 21 module from the safety PLC For all the bits in the F Output data one 1 means active and zero 0 non active PROFIsafe frame from F Host to F Device CRC 2 Control byte F Output data 3 octets 1 octet 2 octets as Int16 2 octets as bits LSB Octet n MSB Octet 0 Octet 0 L...

Page 117: ..._time 0 15 2 Signed16 3 For example value 21 2 1 s Negative values result in 0 0 s The safety PLC shall set reserved bits to value 0 This ensures the compatibility with future versions of the PROFIsafe profile where the reserved bits may be used FSPS 21 module modes and states Power down STO active Start up STO active Running Fail safe STO active Fault detected Description Transition Initial tests...

Page 118: ...mode Fail safe mode RUN mode The FSPS 21 module can be in the following states Operational Safe with the following sub states based on the PROFIsafe communication status Module passivation Module passivation reintegration Module passivation with a command The FSPS 21 module modes and states are described in the following figure and tables Note The FSPS 21 module stays in Safe state until it has re...

Page 119: ...are available to the programmer of an F Host program for example an AC500 S program in CoDeSys Description State PROFIsafe communication is up and running Safe stopping function eg SS1 is not requested or it is not yet performed to the end Operational PROFIsafe Control Byte bits in the F Host to the FSPS 21 module Active_FV 0 PROFIsafe control byte PROFIsafe Status Byte bits from the FSPS 21 modul...

Page 120: ...or or PROFIsafe watchdog timeout exceeded If the PROFIsafe communication is broken the safety application continuously attempts to establish a communication to the safety PLC A state transition to another state is possible only if the detected error has been solved PROFIsafe Status Byte bits in the F Host for the FSPS 21 module WD_timeout or CE_CRC 1 ABB_PS3 profile bits from the module to the F H...

Page 121: ...rt up mode by cycling power of the FSPS 21 module or by giving the reset command via the drive parameter 51 27 see the drive firmware manual Note Modes and states are not directly linked together The table above shows the states in RUN mode for simplicity For example in fail safe mode the PROFIsafe communication may also have an error and appropriate PROFIsafe status bytes are set Transitions betw...

Page 122: ...n one of the components during the signal transfer It is enough to consider a single fault only see PROFIsafe System Description Version November 2010 The worst case delay time WCDT and watchdog WD values for the FSPS 21 module is listed in the table below Device WD WCDT Device 10 ms 10 ms FSPS 21 The documentation of the safety PLC defines how you can calculate the processing time and transmissio...

Page 123: ...y time of the FSO module also depends on the safety functions that are used simultaneously and on the PROFIsafe cycle time The longest worst case delay time of the FSO module is 50 ms which is based on its internal watchdog Minimum watchdog time DAT HAT Bus Bus 1 3 4 Time 2 PROFIsafe_watchdog_time pdf 1 Device acknowledgement time DAT is the time it takes for the F Device such as the FSPS 21 modul...

Page 124: ...ule for the option slot in which the FSPS 21 module is installed into parameter 50 01 FBA A enable or 50 31 FBA B enable 2 Set the FSPS 21 parameters that correspond to the selected fieldbus channel Parameter groups 51 52 and 53 include the settings for FBA A and groups 54 55 and 56 for FBA B Groups 52 53 55 and 56 configure the contents of the normal PROFINET cyclic communication by mapping the w...

Page 125: ... Parameters for the PROFIsafe module properties F_Dest_Add 12 Allows defining the PROFINET station name PN Name Index 51 54 25 By default this value is 0 and the station name is set in PLC project When the value is set to other than 0 the PROFINET station name is overwritten in the format abbdrive xx where xx is the value of the parameter name index Example Setting this value to 12 results in the ...

Page 126: ...eps for starting the PROFINET and PROFIsafe communication with the FSPS 21 module For detailed information see the documentation of your safety PLC The examples apply to all drive types that are compatible with the FSPS 21 module Note Any safety PLC that supports PROFIsafe can be used with the FSPS 21 module Downloading the GSD file To configure the controller station you need a type definition GS...

Page 127: ...an empty password This is a project administrator who can for example access the safety controller station For detailed information on the passwords and access permissions in Automation Builder see the AC500 S Safety PLC user manual You can find the complete documentation of ABB PLCs and the Automation Builder application in www abb com PLC Before you start make sure that you have downloaded the F...

Page 128: ...ect In the project below these controller stations have been added controller station AC500 PM583 ETH safety controller station AC500 SM560 S and PROFINET controller CM579 PNIO Controller station Safety controller station PROFINET controller 128 PROFIsafe ...

Page 129: ...r additional information about PPO Type 4 see FSPS 21 PROFIsafe profiles page 115 8 Add the PROFIsafe module PROFIsafe ABB_PS3 to the second slot of the FSPS 21 module to define cyclic safety communication between the module and the PLC For additional information about PS3 telegrams see FSPS 21 PROFIsafe profiles page 115 I O module PROFIsafe module 9 Download the safety and non safety PLC program...

Page 130: ...ct to PLC Login and select the communication link used between Control Builder and the PLC Click Scan to find all PROFINET devices connected to the network In the Configure station name box select the station name defined for the module in step 10 in this example drive1 and click Assign IO Device name In the IP address and Network mask boxes type the IP address and subnet mask defined in step 11 a...

Page 131: ...rs can be modified for FSPS 21 F_Source_Add is the address of the safety controller station in this example AC500 SM560 S F_Dest_Add is the address of the FSPS 21 module This must match the control unit parameter 51 24 see section Drive parameters related to safety functions page 43 These two define the codename for the PROFIsafe relationship of this particular FSPS 21 module and the safety contro...

Page 132: ...ram that controls the drive Double click the AC500 This opens the PLC program in the CoDeSys programming tool 18 Create a safety program that controls the FSPS 21 via PROFIsafe Double click the AC500_S This opens the safety PLC program in the CoDeSys programming tool Note If you do not have a complete safety program you must at least implement watchdog toggling and operator acknowledgement accordi...

Page 133: ...Watchdog toggling can be implemented in the following way As an example automatic operator acknowledgement can be implemented in the following way PROFIsafe 133 ...

Page 134: ...oint select Communication parameters from the Online menu Note To make sure that the program is downloaded to the PLC even when no changes have been made select Clean all from the Project menu In the window that opens click Yes This downloads the program to the PLC In the Online menu select Create boot project This saves the program permanently to the PLC In the Online menu select Logout 20 Repeat...

Page 135: ... menu of the non safety program select Run This starts both programs Monitoring the PROFIsafe message It is possible to monitor the contents of the PROFIsafe message For example Check the variable values in the Current Value column on the PNIO Module IO Mapping tab PROFIsafe 135 ...

Page 136: ... Configuring FSPS 21 with TIA14 1 Open TIA and create a new project 2 Select your CPU from the list 136 PROFIsafe ...

Page 137: ... from the hardware catalog 5 Open the FSPS 21 device view and add by dragging and dropping the desired PPO and PS telegrams to slot 1 and 2 In this example we use PPO4 and PS3 For additional information about PPO and PS telegrams see or FSPS 21 PROFIsafe profiles page 115 PROFIsafe 137 ...

Page 138: ... to indicate that device is an f device with safety capability 7 Assign FSPS 21 to PROFINET controller Network configuration is updated IO addressing is assigned automatically to FSPS This can be seen in Device view highlighted red box 138 PROFIsafe ...

Page 139: ...In PLC properties enable F capability under the Fail safe submenu 9 In the F parameters submenu define the maximum allowed safety program execution interval If this value is exceeded PROFIsafe goes to safe state watchdog 10 In Ethernet addresses submenu set PLC IP address PROFIsafe 139 ...

Page 140: ... successful identification PLC will assign IP address to FSPS Note FB module parameters 51 04 onwards should be static 0 0 0 0 in drive 13 Configure FSPS PROFIsafe settings F_Source_Add PLC PROFIsafe address F_Dest_Add FSPS PROFIsafe address F_WD_Time Maximum allowed PROFIsafe message cycle time In this example we use 200ms Calculate your own value according to section Calculating the watchdog tim...

Page 141: ...dd OB86 Rack and station failure program block to prevent PLC from stopping due to an error eg in a drive fault situation when it sends an alarm to the PLC 15 Add new Function Block ABB Drive PROFIsafe 141 ...

Page 142: ...les to ABB_Drive FB 17 Add ABB_Drive FB to OB1 drag drop to network Assign new instance Data Block for ABB_Drive FB pop up when FB is added to OB When using multiple drives create one DB for each drive 142 PROFIsafe ...

Page 143: ...18 Select the corresponding FSPS PPO address for the drive HW input Value can be verified from the HW configuration in the FSPS PPO type properties under the Hardware Identifier tab PROFIsafe 143 ...

Page 144: ...19 In ABB_Drive FB add blocks DPRD_DAT and DPWR_DAT 20 Insert values to blocks 144 PROFIsafe ...

Page 145: ...limits If maximum limit is exceeded PLC will go to safe state 22 If you do not have a complete safety program you must at least implement acknowledgement for reintegration according to application requirements to be able to acknowledge the STO As an example automatic acknowledgement for reintegration can be implemented in the following way PROFIsafe 145 ...

Page 146: ...n section FSPS 21 PROFIsafe profiles page 115 See correct IO addresses from HW configuration 24 Save compile and download HW and SW to the PLC 25 Scan for accessible devices start search Note that firewall may block traffic Load configuration to target device 146 PROFIsafe ...

Page 147: ...26 In device configuration right click FSPS icon and select Assign device name PROFIsafe 147 ...

Page 148: ... device from list and click Assign name Note MAC ID can be found on the cover of the FB module 28 After PLC identifies the device on the network by its name the PLC will assign the IP address to it automatically Drive parameter group 51 values will update accordingly 148 PROFIsafe ...

Page 149: ...ming version V5 4 SP5 For detailed configuration instructions see the documentation of the safety PLC S7 Distributed Safety configuring and programming Programming and Operating Manual 07 2013 A5E00109537 05 Before you start make sure that you have downloaded the FSPS 21 GSD file from the ABB Document library See section 1 Start SIMATIC Manager and open create a SIMATIC project 2 Add the necessary...

Page 150: ...4 Select the controller station and rail from the catalog and drag them to the project This example project uses a CPU 317F 2 controller station V3 2 that is installed in a RACK 300 Rail 150 PROFIsafe ...

Page 151: ...rail select Industrial Ethernet as the subnet for the controller station 6 Install the FSPS 21 GSD file In the Options menu select Install GSD Files Browse for the GSD file that you downloaded from the ABB Document library Click Install PROFIsafe 151 ...

Page 152: ... Note In some versions of the SIMATIC environment you have to close the whole SIMATIC program and open it again to make the new GSD file visible in the object catalogue 152 PROFIsafe ...

Page 153: ... IO object for example PPO Type 7 to the first slot of the FSPS 21 module to define cyclic standard communication between the module and the PLC 9 Click and drag the PROFIsafe object PROFIsafe ABB_PS3 to the second slot of the FSPS 21 module to define cyclic safety communication between the module and the PLC PROFIsafe 153 ...

Page 154: ...IP address assigned here Use the same IP address for the FSPS 21 module also in other tools eg the Drive composer pro PC tool which you use to connect to the drive 12 Click OK 13 In the hardware configuration double click the IO object PPO Type 7 in Slot 1 to open the Properties window 14 Type a name for the IO object in this example PROFIsafe ABB_PS3 154 PROFIsafe ...

Page 155: ...Select Addresses tab to see the correct IO addresses PROFIsafe 155 ...

Page 156: ...15 On the Parameters tab configure the Stop mode and Control zero mode functions and define Fail safe values for the PLC output process data PZDs 156 PROFIsafe ...

Page 157: ...uration click FSPS In the PLC menu select Ethernet and select Assign Device Name Click the Update button Click the available device with the correct MAC address to which the device name will be assigned Click Assign name This assigns the name to the FSPS 21 module Click Close PROFIsafe 157 ...

Page 158: ...figuration double click the controller station for example CPU 317F 2 Select the F Parameters tab When prompted give the password for the Safety Program See the documentation of the SIMATIC system for details Make the necessary changes and click OK 158 PROFIsafe ...

Page 159: ...Parameters tab F_Dest_Add is the address of the FSPS 21 module This is a control unit parameter 51 24 see section Drive parameters related to safety functions page 43 These two define the codename for the PROFIsafe relationship of this particular FSPS 21 module and the safety controller station Calculating the watchdog time page 123 F_WD_Time is the PROFIsafe watchdog time See section Calculating ...

Page 160: ... give proper symbol names to the cyclic data Right click the IO object PPO Type 7 in Slot 1 and select Edit Symbols Add names for the symbols Repeat the same for the PROFIsafe object PROFIsafe ABB_PS3 in Slot 2 160 PROFIsafe ...

Page 161: ...n for example CPU 317F 2 Select Protection tab Select 1 Access protect for F CPU Check Can be bypassed with password Enter the password twice to the edit boxes Check CPU contains safety program 21 Save compile and download the hardware configuration to the PLC The PLC is now ready for communication with the FSPS 21 module 22 In SIMATIC Manager right click on the Blocks folder of the S7 Program of ...

Page 162: ...24 Double click on the FC1 block 25 Set DB1 as the I DB for the F program block and FB1 as the F program block 26 Click OK and close the dialog windows 162 PROFIsafe ...

Page 163: ...he FC blocks folder 29 Save the block and close the editor 30 In SIMATIC manager double click on FB1 31 If you do not have a complete safety program you must at least implement acknowledgement for reintegration according to application requirements to be able to acknowledge the STO PROFIsafe 163 ...

Page 164: ...Add acknowledgement for reintegration by assigning the value of ACK_REQ to ACK_REI in DB1092 In this example DB1092 Check the correct data block from your HW configuration 164 PROFIsafe ...

Page 165: ...lect Download If prompted accept the inclusion of standard blocks 36 Switch the controller station to run mode Monitoring the PROFIsafe message It is possible to monitor the contents of the PROFIsafe message For example In HW Configuration select Monitor Modify for the PROFIsafe telegram in Slot 2 of the FSPS 21 module PROFIsafe 165 ...

Page 166: ... make sure that drive parameter 51 21 is set to Enabled see the drive firmware manual ABB AC500 S In the ABB AC500 S system you can read PROFINET diagnostics messages from Automation Builder or with a separate PNIO_DEV_DIAG function block in the non safety PLC program To read the alarm data of the last active alarm from Automation Builder 1 Select FSPS_21 2 On the Diagnostics for Profinet slave ta...

Page 167: ...Siemens TIA14 To view diagnostics messages in TIA right click on the device you wish to diagnose and choose Online diagnostics PROFIsafe 167 ...

Page 168: ...PLC menu select Diagnostic Setting 2 Select Hardware diagnostics 3 In the window that opens select the FSPS 21 module of your system 4 Click the Module Information button 5 To read the diagnostic messages select the IO Device Diagnostics tab 168 PROFIsafe ...

Page 169: ...6 To check the Device number of the FSPS 21 module select the General tab PROFIsafe 169 ...

Page 170: ... 11 PROFIsafe F_Dest_Add Mismatch of safety destination address F_Dest_Add 64 0x0040 F_Dest_Add of 0 or FFFFh is not allowed Safety destination address is not valid F_Dest_Add 65 0x0041 A valid F_Dest_Add is within range 1 65534 F_Source_Add of 0 or FFFFh is not allowed Safety source address is not valid F_Source_Add 66 0x0042 A valid F_Source_Add is within range 1 65534 Watchdog time 0 ms is not ...

Page 171: ...evice did not receive new data within the configured watchdog period A pos sible solution is to increase watchdog time if safety calculation allows or decrease PROFINET cycle time Transmission error timeout F_WD_Time or F_WD_Time_2 elapsed 78 0x004E Typical communication errors This table lists some typical error situations in the PROFINET and PROFIsafe communication What to do Cause Fault Check t...

Page 172: ...of the whole system before the changes take ef fect All errors solved but you still cannot start the PROFIsafe communication If this does not help reboot also the FSPS 21 module and the drive To reboot the FSPS 21 module switch the power off and on or use drive parameter FBA A B PAR REFRESH parameter 51 27 54 27 see the drive firm ware manual To reboot the drive switch the power off and on or use ...

Page 173: ... the implemented safety system meets the requirements specified for the system in the safety requirements specification phase The most convenient way to verify the required SIL PL level reached with the implemented system is to use a specific safety calculator software Safety validation Validation procedure It is always the responsibility of the machine builder to ensure that the functionality of ...

Page 174: ...pplication a list of all safety related parameters and their values the drive STO has no safety related parameters but listing the non safety related parameter 31 22 STO indication run stop and its setting is recommended documentation of start up activities references to failure reports and resolution of failures the test results for each safety function checksums date of the tests and confirmatio...

Page 175: ... make sure that the LEDs do not indicate any unexpected conditions See chapter Fault tracing for details 10 Make sure that the diagnostic messages at the safety controller station do not contain any unexpected entries Validation of the STO function Follow these steps to validate the STO function 1 Make sure that the STO function is configured correctly 2 Make sure that you can run and stop the mot...

Page 176: ...on is configured correctly 2 Make sure that you can run and stop the motor freely 3 Start the drive and set it to a motor speed typical for the application 4 Activate the SS1 t function from the safety PLC 5 Make sure that the motor speed ramps down properly and the time monitoring delay is set correctly 6 Make sure that the drive STO is activated when the drive reaches zero speed 7 Make sure that...

Page 177: ...NG Until all the safety functionality is validated the system must not be considered safe See chapter Verification and validation page 173 WARNING FSPS 21 module has automatic acknowledgement method Make sure that the system is designed so that this does not cause unacceptable risk Checks Before starting the system for the first time make sure that the installation has been checked according to in...

Page 178: ... starting the system does not cause any danger 178 Start up ...

Page 179: ...ngs and faults Only faults will cause the drive to stop All event types are shown in the Event logger Fault messages What to do AUX code s Description Fault Code Gather the AUX codes from this fault and con tact ABB The fault is not recog nized by the drive FW FSx undefined fault 0x7A9A No possibility to fix Contact ABB FSX internal faults like CPU or memory or peripherals FSx internal fault 0x7A9...

Page 180: ...UX codes from this fault and contact ABB STO feedback does not match the hi and ctrl state Check that the temper ature of installation is according to the ambi ent conditions require ments 0000 0003 Overtemperature sensor 1 FSX temperature fault eg overtemperature FSx temperature fault 0x7A9D Gather the AUX codes from this fault and con tact ABB Check that the temper ature of installation is accor...

Page 181: ...seen in Drive composer event log Warning messages What to do AUX code s Description Warning Code Gather the AUX codes from this warning and contact ABB The fault is not recog nized by the drive FW FSx undefined warn ing 0xA7DC Fault tracing 181 ...

Page 182: ...ng persists gather the AUX codes from this fault and con tact ABB Check PLC program status 0000 0005 PLC gave illegal wd time value If warning persists gather the AUX codes from this fault and con tact ABB Check PLC program status 0000 0006 PLC requested sil is higher than we are capable If warning persists gather the AUX codes from this fault and con tact ABB Check PLC program status 0000 0007 PL...

Page 183: ...us 0000 0012 Crc failure in cyclic communication If warning persists gather the AUX codes from this fault and con tact ABB Calculate a new watch dog time See section PROFIsafe response time 0000 0013 Watchdog timeout in cyclic communica tion If the warning reoccurs gather the AUX codes from this fault and con tact ABB 0000 0014 PLC set bit4 activ ate_fv in cyclic communication Event messages Descr...

Page 184: ...green Device needs commissioning due to configuration missing incom plete or incorrect The device may be in the Standby state This may be caused by the adapter waiting for a response from a DHCP server This may also be caused by the adapter waiting for Duplicate Address Detection to complete If Duplicate Address Detection has detected an IP conflict the IP is configured to 0 0 0 0 and can be recon...

Page 185: ... MODULE status LED Device is receiving transmitting on the Ethernet Flashing green Used for identification The flashing is started by the PROFINET master and also the module LED is flashing orange Reporting problems and failures If you detect any failure in the safety module or safety functions always contact your local ABB representative Fault tracing 185 ...

Page 186: ...186 ...

Page 187: ...ge 13 and chapter Safety instructions in the drive hardware manual If you ignore them injury or death or damage to the equipment can occur Planning All maintenance and the repair actions on a safety critical system are safety critical You must plan and perform them accordingly Before making any changes make sure to back up drive parameters Tools You need the Drive composer PC tool or a control pan...

Page 188: ... set backup will automatically include this config uration PROFIdrive CW and SW user bit mapping See PROFIdrive parameters page 201 PROFIdrive parameters 934 943 Note Backup will include this configuration only when it is stored with PROFIdrive parameter 971 Writable SNMP MIB 2 string System location When set backup will automatically include this config uration System name System contact The sett...

Page 189: ...her drive 1 Stop the driven machinery and prevent an unexpected start up 2 Make a backup file of the drive parameters before drive replacement You can make a backup of the drive configuration using the control panel or the Drive composer PC tool See applicable drive FW manual Control panel manual or Drive composer manual 3 Disconnect the supply with the supply disconnecting device WARNING Read and...

Page 190: ...alidation Note The STO function is the basic safety function and it has to be validated first 8 Update hardware and firmware versions of the new drive to the logbook of the driven machine Note You can restore default fieldbus configuration to the drive and module with parameter 96 06 Parameter restore using the selection Reset all fieldbus settings This clears also other parameters from the drive ...

Page 191: ...nstructions in the drive hardware manual If you ignore them injury or death or damage to the equipment can occur When you decommission the FSPS 21 module make sure that the safety of the machine is maintained until the decommissioning is complete Mark clearly on the module that it is decommissioned Maintenance 191 ...

Page 192: ...192 ...

Page 193: ...We reserve all rights in this document and in the information contained therein Reproduction use or disclosure to third parties without express authority is strictly forbidden ABB Oy PROPRIETARY AND SECRET INFORMATION CONFIDENTIAL ESTO_MAIN_ASSY ASSEM 21 A Initial Approval 13 Sep 17 T Huoso General data Into an option slot on the drive control unit Installation IP20 Degree of protection Cardboard ...

Page 194: ...ed 1000 2000 m 3300 6600 ft above sea level air outside the module derated to 15 49 C 5 120 F 2000 4000 m 6600 13200 ft above sea level air outside the module de rated to 15 40 C 5 104 F Altitude installa tion site 40 70 C 40 158 F 40 70 C 40 158 F 15 70 C 5 158 F Air temperature same same 5 95 Relative humidity No condensation allowed If corrosive gases are present the maximum allowed humidity is...

Page 195: ...ng Topology Max 50 nodes allowed for FSPS 21 module in a ring topology In a chain maximum recommended amount of nodes is 50 More can be used but PROFINET cycle time should be adjusted because of the delays in the network Each FSPS 21 has an integrated switch which adds 19 μs forwarding delay for the minimum Ethernet frame Length of PROFINET cyclic frame FSPS 21 uses is minimum Ethernet frame so 50...

Page 196: ...guration tool and Drive composer pro tools Discovers ABB specific Ethernet devices in a local network segment by listening to and responding to UDP broadcasts ABB Netconfig 24576 UDP Simple Network Management Protocol SNMP SNMP 161 UDP Note Used only when PROFINET IO protocol is selected Safety functions Stopping functions Safe torque off STO Safe stop 1 time controlled SS1 t Safety data General T...

Page 197: ...ards EN ISO 13849 1 EN IEC 62061 IEC 61508 IEC 61511 or ABB Drives Technical guide No 10 Functional safety 3AUA0000048753 English Basic safety data The FSPS 21 module is a type B safety component as defined in IEC 61508 2 The FSPS 21 data related to safety standards IEC 61508 EN IEC 61800 5 2 EN ISO 13849 1 IEC 61511 and EN IEC 62061 is listed below for the subsystem of the FSPS 21 module Maximum ...

Page 198: ...es Related standards Name Standard Safety of machinery General principles for design Risk assessment and risk reduction EN ISO 12100 2010 Safety of machinery Safety related parts of control systems Part 1 General principles for design EN ISO 13849 1 2015 Safety of machinery Safety related parts of control systems Part 2 Validation EN ISO 13849 2 2012 Safety of machinery Electrical equipment of mac...

Page 199: ...djustable speed electrical power drive systems Part 5 2 Safety requirements Functional IEC 61800 5 2 2016 EN 61800 5 2 2007 Safety of machinery Functional safety of safety related electrical electronic and pro grammable electronic control systems IEC 62061 2015 Ed 1 2 EN 62061 2005 AC 2010 A1 2013 A2 2015 European Machinery Directive 2006 42 EC Other technical specifications Version Specification ...

Page 200: ...200 ...

Page 201: ... I M Identification Maintenance records of the PROFINET IO communication protocol PROFIdrive parameters Description Data type R W1 Par no Assignment PZD1 to PZD12 in PPO write Array 12 Unsigned16 R W 915 Assignment PZD1 to PZD12 in PPO read Array 12 Unsigned16 R W 916 Device system number Octet String4 R 919 Telegram selection Unsigned16 R 922 21 Appendix A PROFIdrive parameters and I M records of...

Page 202: ...ition set point A XSOLL_A Signed32 28 Position actual value A XIST_A Unsigned16 32 Traversing block selection SATZANW not supported Unsigned16 33 Actual traversing block AKTSATZ not supported Signed32 34 Target position TARPOS_A not supported Unsigned32 35 Velocity VELOCITY_A 101 9999 Drive specific Operator control rights parameter identification PKW Unsigned16 R W 927 Mode Value Parameters canno...

Page 203: ...election switch for Control word bit 12 See parameter 933 for coding Unsigned16 R W 934 Selection switch for Control word bit 13 See parameter 933 for coding Unsigned16 R W 935 Selection switch for Control word bit 14 See parameter 933 for coding Unsigned16 R W 936 Selection switch for Control word bit 15 See parameter 933 for coding Unsigned16 R W 937 Selection switch for Status word bit 11 Unsig...

Page 204: ...Error Types Array n Unsigned16 R 946 If you use a DRIVECOM fault code as an index when reading PNU946 the corresponding Channel Error Type is returned Fault number coded according to the DRIVECOM profile Array 64 Unsigned16 R 947 Contents Subindex See parameter 945 Last alarm3 Unsigned16 R 953 Second last alarm3 Unsigned16 R 954 Third last alarm3 Unsigned16 R 955 Fourth last alarm3 Unsigned16 R 95...

Page 205: ...0 4 see parameter 964 Array n Unsigned16 R 975 Meaning Sub index Value 2 Axis 5 Number list of defined parameters If the subindex is 0 the end of the list has been reached If the subindex is the num ber of the next list parameter the list is continued there Array n Unsigned16 R 980 981 Map 16 bit selection3 Used to request the data type for mapped parameters if mapping is done with parameter 915 o...

Page 206: ...FF3 I M3 0xAFF4 I M4 Response structure for I M0 Read only Coding Size Contents 10 Octets Header 0x1A ABB Automation 2 Octets MANUFACTURER_ID I M block 6438177508335 EAN code for FSPS 21 kit 20 Octets ORDER_ID Serial number of FSPS 21 module 16 Octets SERIAL_NUMBER Hardware version of FSPS 21 module 2 Octets HARDWARE_REVISION Format V255 255 255 E g V1 0 0 software version 100 4 Octets SOFTWARE_RE...

Page 207: ...ets RESERVED Note I M1 I M2 and I M3 are blank 0x20 by default Response structure for I M3 Read Write Coding Size Contents 10 Octets Header Description of the device set by the user 54 Octets DESCRIPTOR I M block Response structure for I M4 Read Write I M4 is read only and shows the PROFIsafe configuration CRC Coding Size Contents 10 Octets Header Security code for identifying sessions and changes...

Page 208: ...208 ...

Page 209: ...rewrite the IP configuration of the adapter modules Installation The ABB IP configuration tool is part of the ABB Automation Builder software No separate installation is needed Finding adapter modules in the network 1 Open the ABB IP configuration tool 2 Click the Scan button The FSPS 21 adapter modules present in the network appear on the results list 22 Appendix B ABB IP configuration tool 209 ...

Page 210: ...rk page 209 2 On the results list click to select the adapter module whose IP configuration you want to modify 3 Below New configuration define the IP configuration settings according to your network configuration 4 If you want the adapter module to use a static IP address instead of DHCP clear the DHCP check box 210 Appendix B ABB IP configuration tool ...

Page 211: ...5 To apply the new settings click the Send Configuration button The new current IP address and configured IP address appear on the results list Appendix B ABB IP configuration tool 211 ...

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Page 213: ... by navigating to www abb com searchchannels Product training For information on ABB product training navigate to new abb com service training Providing feedback on ABB manuals Your comments on our manuals are welcome Navigate to new abb com drives manuals feedback form Document library on the Internet You can find manuals and other product documents in PDF format on the Internet at www abb com dr...

Page 214: ...www abb com drives 3AXD50000158638A 2019 ABB Oy All Rights Reserved Specifications subject to change without notice 3AXD50000158638 Rev A EN EFFECTIVE 2019 02 01 ...

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