Transcript Step 7

Simatic S7 PLC
Instrument Control Systems 2014
Lothar Kern
CS&E / CE
Instrument Control Systems Seminar 2014, 20th-24th October
Agenda Day 4
Introduction to SIMATIC / Step 7
 PROFINET / PROFIBUS
 Coffee break
 HMI WinCCFlexible
 Safety Applications
 ESO Vacuum&Cryogen.Control Library
 Lunch break
 Hands-On TwinCAT & S7

Instrument Control System Seminar, 20th-24th October 2014
Agenda

Introduction to SIMATIC / Step 7
 PLC Hardware and Architecture
Fieldbuses
 Hardware Signal Standards
 Future S7 PLC Hardware at ESO
 HMI – Local Operator Panels
 Instrument Control Software Interface
 PLC Software Engineering

Instrument Control System Seminar, 20th-24th October 2014
Simatic PLC Series (1)

SIMATIC S7 PLC were introduced 1995 as successor of SIMATIC S5

three series: S7 200 / 300 / 400
S7 200: low performance range
It was a “foreign object” as it had complete different instructions and
engineering tools


S7 300: low to medium performance
Instrument Control System Seminar, 20th-24th October 2014
Simatic PLC Series (2)

S7 400: high performance applications
 also as high availability version (redundant CPU / periphery modules)
 multi processor capabilities (up to 4 CPUs in one rack)
 SIMATIC Manager as engineering tool for both, S7 300 and S7 400
(current version: Step 7 V 5.5 / Professional 2010)
Instrument Control System Seminar, 20th-24th October 2014
Simatic PLC Series (3)

in the course of time all models were continuously enhanced
today, a big variety of controllers is available, including Soft-PLC (PCand
embedded controller-based, WIN AC and S7-mEC, also available with
Realtime
Kernel WinAC RTX and WinAC RTX F)

Instrument Control System Seminar, 20th-24th October 2014
Modular Design

all S7 series, relevant for ESO (300, 400, 1500), have a modular design:

Mounting Rail:
 pure mechanical aluminum profile for 300 and 1500
 rack with passive backplane for 400
 35mm DIN-rail for ET200S

Power Supply Module:
 always necessary for 400
 can be omitted for 300, 1500 and ET200S if suitable 24VDC available


CPU

Digital / Analog I/O Modules

Communication Modules (Ethernet, Profibus, Serial)

Interface Modules (for connecting I/O Extension Racks)

“Function Modules” (Motor Controllers, Counter, Encoder Interface…)
all of them designed for mounting plate, not for19” rack mounting!
Instrument Control System Seminar, 20th-24th October 2014
S7-300 Modules
S7 300 Rack
Mounting Rail
Power Supply
(can be omitted
when suitable
24VDC available)
CPU
I/O Modules
Instrument Control System Seminar, 20th-24th October 2014
Bus Connector
S7-300 max Number of Modules

S7 300: max. 8 I/O Modules + 1 Interface Module
Instrument Control System Seminar, 20th-24th October 2014
S7-300 Centralized Extension

Centralized extension with Interface Modules

distance rack to rack up to 1.5 / 3 / 10m
Instrument Control System Seminar, 20th-24th October 2014
S7-400 Modules

S7 400: Different Racks, 9 / 18 Slots

depending on size of PS and CPU, a maximum of 7 / 16 I/O modules
Instrument Control System Seminar, 20th-24th October 2014
S7-400 Extension Racks

Centralized and / or remote extension with various Interface Modules

distance rack to rack up to 1.5 / 3 / 102 / 600 m
Connecting Cable
Instrument Control System Seminar, 20th-24th October 2014
Terminator Plug
Agenda

Introduction to SIMATIC / Step 7
 PLC Hardware and Architecture

Fieldbuses
 Hardware Signal Standards
 Future S7 PLC Hardware at ESO
 HMI – Local Operator Panels
 Instrument Control Software Interface
 PLC Software Engineering

Instrument Control System Seminar, 20th-24th October 2014
Supported Fieldbuses

S7 supports three fieldbus types:

PROFIBUS (Process Field Bus)

PROFINET (Process Field Network)

AS-I (Actuator-Sensor-Interface)
not (yet..) used at ESO
Instrument Control System Seminar, 20th-24th October 2014
all providing realtime capability
all three are appropriate
for Fail-Safe functionality
Supported Fieldbuses

CAN Bus? ….”yes, we CAN”, but….

Communication processors available from 3rd party only

Gateways PROFINET / PROFIBUS  CAN from 3rd party

not (yet) in use at ESO

only if there is real need for
Instrument Control System Seminar, 20th-24th October 2014
Future of PROFIBUS
 PROFIBUS: industrial fieldbus with the most installed nodes (> 50Mio)
worldwide,
established in the early 1990s
PROFINET: introduced 2003 , rapidly increasing market share, better
performance and
higher flexibility compared to PROFIBUS

Instrument Control System Seminar, 20th-24th October 2014
Remote IO with Fieldbus

PROFINET is favored fieldbus at ESO for S7 PLC

Fieldbuses allow easy deployment of remote I/O

mainly two series in use at ESO:

ET200S
bit-modular design

ET200M
uses S7-300 series I/O modules

both available with interface modules for PROFINET or PROFIBUS
Instrument Control System Seminar, 20th-24th October 2014
CPU Fieldbus Support

Connection with CPU through built-in interface(s)

e.g. : CPU315-2 DP
 CPU has a PROFIBUS DP interface
CPU317-2 PN/DP  CPU has PROFIBUS DP and PROFINET interfaces
CPU314
 CPU has no PROFIBUS / PROFINET interface
CPU1513-1 PN  CPU has a PROFINET interface
for CPUs without internal PN / PB interface, or for segmenting
fieldbuses,
corresponding Communication Processor Modules can be added

Fieldbus

technology also allows connecting third party equipment
PROFIBUS and PROFINET are standardized busses
PROFIBUS & PROFINET InternationaI (PI) Organisation offers test and
certification
services


no problems to be expected when using certified equipment
Instrument Control System Seminar, 20th-24th October 2014
Fieldbus Example: MUSE
Instrument Control System Seminar, 20th-24th October 2014
Fieldbus Example: MUSE
Cabinet 1
Power
Supply
230AC 24DC
CPU
Cabinet 2
Signal Modules
Ethernet
Switch
- Sensors
- Control Switches
- Actuators
Power Profinet
Supply Interface
Signal Modules
230AC 24DC
Ethernet / Profinet
Profibus
JUMO Imago500 (TeePee)
Touchpanel
Instrument Control System Seminar, 20th-24th October 2014
JUMO Imago500 (TeePee)
Agenda

Introduction to SIMATIC / Step 7
 PLC Hardware and Architecture 
Fieldbuses 
 Hardware Signal Standards
 Future S7 PLC Hardware at ESO
 HMI – Local Operator Panels
 Instrument Control Software Interface
 PLC Software Engineering

Instrument Control System Seminar, 20th-24th October 2014
PLC Hardware Signal Standards

Hardware signal standards:

digital signals
 24VDC with common ground for digital in-/outputs
 inputs draw ~ 7mA
 outputs can drive up to 0.5 or 2A (depending on the output module)
 no TTL signals!
 relay modules with dry contacts available

analog signals
 0 – 10V
±10V
 0 – 20mA
 4 – 20mA
 ±20mA
 RTD (PT100 preferred) in 2/3/4-wire configuration
lower range limit: - 200 °C / 73K (- 240 °C / 30K when using
undershoot range)
 TC (no relevance for vacuum / cryogenic applications)
Instrument Control System Seminar, 20th-24th October 2014
Agenda

Introduction to SIMATIC / Step 7
 PLC Hardware and Architecture 
Fieldbuses 
 Hardware Signal Standards 
 Future S7 PLC Hardware at ESO
 HMI – Local Operator Panels
 Instrument Control Software Interface
 PLC Software Engineering

Instrument Control System Seminar, 20th-24th October 2014
PLC Future Roadmap
ESO currently uses only S7 300 and 400 series and for few exceptions
the
ET200S CPU (IM151-8)


2009: Introduction S7 1200 series (successor of S7 200)
together with the engineering software Step 7 Basic V 10
not used at ESO

end of 2012: Introduction S7 1500 controller family, which will replace
S7 300 and S7 400 in the long run
S7 1500 requires TIA Portal 12 (or higher) for programming

in 2012: Introduction ET200SP (distributed I/O)
Q1/2014 release of TIA Portal 13; according to several user forums, the
first
stable and practical version of TIA Portal, though still slow and
resource-hungry
compared to Step 7 V 5.5 (which Siemens calls now Step 7 Classic)


since Q2/2014 fail-safe version of S7 1500 is available
Future ESO projects will use S7 1500 / TIA Portal
Instrument Control System Seminar, 20th-24th October 2014
S7-1500 and TIA Portal
S7-1500
Instrument Control System Seminar, 20th-24th October 2014
ET200SP
Agenda

Introduction to SIMATIC / Step 7
 PLC Hardware and Architecture 
Fieldbuses 
 Hardware Signal Standards 
 Future S7 PLC Hardware at ESO 
 HMI – Local Operator Panels
 Instrument Control Software Interface
 PLC Software Engineering

Instrument Control System Seminar, 20th-24th October 2014
HMI – Operator Panels
HMI (Human-Machine-Interface) functionality implemented with
Touchpanels


TP277 6” (not recommended, too low screen resolution)

MP277 8”

MP377 15”

Panels have no rotating parts inside
(no fan / harddisk)

Operating system: Windows CE

connected to CPU via Ethernet

Engineering software: WinCCFlexible 2008 (Standard or Advanced)
Instrument Control System Seminar, 20th-24th October 2014
2nd Generation Touchpanels

Problem:
above listed panels obsolete as of October 1st 2014
(still available as spare-part until Oct 2022)
Successor is the Comfort Panel series (TP700 … TP2200, “2nd
Generation”)
BUT this requires WinCC Comfort (TIA) as engineering software

Background information: WinCCFlexible “Integration”

historically Step 7 and WinCCFlexible were separate products
“Integration” of WinCCFlexible into Step 7 allows direct access and linkage
to
PLC data, a nice feature which helps a lot in saving time and avoiding errors

when migrating ONLY the WinCCFlexible project to WinCC TIA, this is
not
available any more


“Device Proxy” in TIA Portal is in practice not a real substitute
Instrument Control System Seminar, 20th-24th October 2014
Agenda

Introduction to SIMATIC / Step 7
 PLC Hardware and Architecture 
Fieldbuses 
 Hardware Signal Standards 
 Future S7 PLC Hardware at ESO 
 HMI – Local Operator Panels 
 Instrument Control Software Interface
 PLC Software Engineering

Instrument Control System Seminar, 20th-24th October 2014
Instrument Control Software Interface

Interface to Instrument Control Software (Workstation) via Ethernet TCP
Siemens PLC uses a proprietary communication protocol: ISO_ON_TCP
(RFC1006)


three options :
 Siemens Softnet for Linux Library (API)
 “Libnodave”; an equivalent communication library
GNU / LGPLv2
 Softing echocollect e UA
this is a gateway device, “speaking” RFC1006 on one side and acting as
an OPC UA Server on the other side
Advantage: homogeneous communication protocol for all PLC (Beckhoff
and Siemens) at INS-SW
Drawback: device needs configuration for connection parameters and
tag definition (tools for semi-automatic mass generation of the tag
definition in preparation)
Instrument Control System Seminar, 20th-24th October 2014
Network Separation
dedicated Communication Processor separates local Ethernet from INS
CTRL

Distributed I/O
CPU
CP
Ethernet / Profinet
INS CTRL Network
INS-WS
Instrument Control System Seminar, 20th-24th October 2014
OPC UA Gateway

echocollect can act as “Network Gateway” and separates networks
CPU
Distributed I/O
Ethernet / Profinet
INS CTRL Network
INS-WS
Instrument Control System Seminar, 20th-24th October 2014
echocollect e UA
Agenda

Introduction to SIMATIC / Step 7
 PLC Hardware and Architecture 
Fieldbuses 
 Hardware Signal Standards 
 Future S7 PLC Hardware at ESO 
 HMI – Local Operator Panels 
 Instrument Control Software Interface 
 PLC Software Engineering

Instrument Control System Seminar, 20th-24th October 2014
PLC Software Engineering
SIMATIC Manager / Step 7 Professional 2010
Instrument Control System Seminar, 20th-24th October 2014
Hardware Configuration
HW Config serves the purpose of adding and configuring all stations and modules
to the project. Properties like I/O addresses, analog signal range and much more
are set here.
Instrument Control System Seminar, 20th-24th October 2014
Absolute / Symbolic Addressing
Controller internally always works with absolute addressing. But the editor
supports symbols/comments. With the symbol editor symbol name and comments
are assigned to the absolute addresses.
Instrument Control System Seminar, 20th-24th October 2014
Block Types

Program is organized in “blocks”

Individual blocks can be down-/uploaded, deleted, copied, renamed
independent from each other

different block types:
OB (organisation block)
cyclically, timer
they are called by the operating system,

interrupt, hardware events
FC (function)
internal

to be called in the user program; only temporary
data (no “memory”)
FB (function block)
needs

to be called in the user program; with “memory”;
always a dedicated “Instance Data-Block”



DB (data block)
data blocks contain only data, no logical code
UDT (user defined
data types)
for defining data structures to be used repeatedly
SFC / SFB (system
functions/-blocks)
functions/function blocks embedded in the firmware
providing various system functions (e.g.
communication,
copying data, reading system clock…)
Instrument Control System Seminar, 20th-24th October 2014
LAD/STL/FBD Editor
Most of the coding work is done within the LAD/STL/FDB editor.
Instrument Control System Seminar, 20th-24th October 2014
Comparison FBD / STL / LAD
There are three “languages” available:
FBD
STL
LAD
(Function Block Diagram)
well suitable for binary logic
looks like logic gate diagram
not all instructions available
available
creates some overhead code
easy diagnosis/monitoring
comments per network
(Statement List)
(Ladder Diagram)
“the” native language
assembler-like
all instructions available
comparable to FBD
looks a bit like a circuit diagram
not all instructions
most compact/efficient code
monitoring can be cumbersome
comments per code line
creates some overhead code
easy diagnosis/monitoring
comments per network
Every language is finally translated into STL by the editor (partially hidden for the user)
The processor only “understands” STL
To a certain extent, switching over between those 3 languages is possible:
FBD or LAD  STL: always possible
conditionally
Instrument
Control System Seminar, 20th-24th October
FBD  LAD and
2014
STL  FBD or LAD: only
Programming Language: SCL
SCL (Structured Code Language) as additional language (included in Step 7 Professional)
syntax close to Pascal
editor with syntax highlighting
well suited for algorithms and maths
no conversion to/from FBD/STL/LAD
needs to be compiled (generating STL)
code usually not as compact/efficient as
STL
Instrument Control System Seminar, 20th-24th October 2014
Programming Language: S7-GRAPH
S7-GRAPH is an additional language for graphical editing of sequences
(included in Step 7 Professional)
allows graphical editing of sequences and flowcharts
with alternative / simultaneous branches, jumps etc.
offers monitoring functionality and automatic generation
of diagnostics
But: data structure not documented, Siemens internal
Not in use for Instruments in order to avoid vendor lock-in and to minimize dependencies with proprietary
software tools
Instrument Control System Seminar, 20th-24th October 2014
NetPro Editor: Communication
Communication links to external systems are edited (partially) with NetPro
Exceptions hereof are:
Serial (RS232/422/485, TTY) communication via CP
 CP PtP Param editor
“Open Communication via Ethernet” (integr.Ethernet IF)
Comm.Library
Instrument Control System Seminar, 20th-24th October 2014
 FB/UDT/DB
Communication Links + Protocols
For Serial Communication the following protocol drivers are available:

ASCII

3964R

RK512

Modbus Master / Slave
Ethernet Communication:

TCP

ISO-on-TCP

UDP
With additional communication processors:

http, ftp, email, webserver
Furthermore proprietary protocols for PLC-PLC communication:

Fetch/Write

Put/Get

Send/Receive
Instrument Control System Seminar, 20th-24th October 2014
Agenda

Introduction to SIMATIC / Step 7 
 PLC Hardware and Architecture 
Fieldbuses 
 Hardware Signal Standards 
 Future S7 PLC Hardware at ESO 
 HMI – Local Operator Panels 
 Instrument Control Software Interface 
 PLC Software Engineering 

Instrument Control System Seminar, 20th-24th October 2014
Agenda Day 4
Introduction to SIMATIC / Step 7 
 PROFINET / PROFIBUS
 Coffee break
 HMI WinCCFlexible
 Safety Applications
 ESO Vacuum&Cryogen.Control Library
 Lunch break
 Hands-On TwinCAT & S7

Instrument Control System Seminar, 20th-24th October 2014
PROFIBUS DP (1)
Profibus DP (decentralized periphery) is a
Master – Slave type Fieldbus
 Master polls slave data
 most common physical media is RS485 with
copper cable / half-duplex

also fiber optic couplers or PCF (plastic fiber)
available (EMC exposed areas)

each node needs a unique address, 1…126

max. 126 nodes on one logical bus

RS485 requires segmenting when number of
nodes exceeds 32 and / or cable length
exceeds a baud-rate dependent length
 put repeater in between

baud rates from 9.6kBd … 12 MBd
some devices do not support all baud rates
most common baud is 1.5 MBd

max. copper cable length @1.5MBd: 200m

electrically first and last device need terminating
resistors (appropriate connectors available)
Instrument Control System Seminar, 20th-24th October 2014
PROFIBUS DP (2)
 a failing or disconnected slave does not necessarily shutdown datatraffic

protocol supports multi-master, but usually single-master architecture

max. address volume per slave: 224 byte input / 224 byte output

basic principle of PROFIBUS DP is a cyclic refresh of all slaves data
most (low speed) applications run PROFIBUS in a non-synchronized
independent loop
bus update time increases with number of slaves and data amount to be
transferred

for time critical applications and hard deterministic a mode with equidistant bus
cycles is
configurable; PLC code execution can be synchronized to the bus update cycle
(drives applications / multiple axes electronic gear function etc.)

some time reserved for non-IO slaves data traffic, e.g. for connecting
programming
device or HMI devices (lower priority)

built-in diagnostics on both ends, master monitors accessibility of the
configured slaves,
slaves monitor cyclic communication with their master and go to a safe state in
case of
timeout

th-24th October 2014
Instrument
Control
System Seminar,

master
provides
data20about
slaves status
for the user program  specific
PROFIBUS DP Topology
 Basic topology with Profibus DP is a line

star topology and optical ring require OLMs (optical link module)

pseudo-star topology can be achieved with multiple RS485 repeaters
Instrument Control System Seminar, 20th-24th October 2014
PROFIBUS Copper Cabling
”Fast-Connect-Cable”
Connector (D-Sub 9) with built in terminator
Various connector types, partially with
service socket at the rear; short stub for
connecting temporary equipment (service
computer) is tolerated
Designed for quick and easy field assembly
There’s also rugged equipment for direct field mounting with protective grade >=
IP54, they
use M12 connectors
Instrument Control System Seminar, 20th-24th October 2014
PROFIBUS M12 Connectors
There’s also rugged equipment for direct field mounting with protective grade >=
IP54, they
use 5-pin M12 connectors
Instrument Control System Seminar, 20th-24th October 2014
PROFIBUS DP Configuration
 PROFIBUS DP nodes are configured within SIMATIC Manager / HW Config

Siemens devices contained in hardware catalog

3rd party equipment can be integrated, devices come with a “GSD” file
(Generic Station Description)
this standardized file format contains all relevant characteristics of the device
GSD files can be imported into the Step 7 hardware catalog
 device is seamlessly integrated
Instrument Control System Seminar, 20th-24th October 2014
PROFIBUS FMS / PA
Besides PROFIBUS DP there are some other flavors of PROFIBUS
PROFIBUS FMS:
Prozess Field Bus-Fieldbus Message Specification
Not any more relevant, was in use as communication link between PLC and
higher
level supervision and monitoring systems; nowadays practically completely
replaced
with Ethernet

PROFIBUS PA:
Prozess Field Bus-Process Automation
Widespread in chemical industries
Two wire cable not only carries data but also power supply for low-power
devices
e.g. intelligent sensors for temperature, flow, pH….. and also actuators like
control
valves
this minimizes the cabling effort
much more limitations to be taken into account: current consumption of
devices,
supports only low baud rates of 31.25kBd and is therefore too slow for many
applications

Instrument Control System Seminar, 20th-24th October 2014
PROFINET IO (1)
PROFINET (process field network) is an
Ethernet based Fieldbus

no polling, send clock assigned during
startup, afterwards each device sends
data autonomous with the defined rate
 three different device types:
IO Controller (e.g. PLC CPU)
IO Device (e.g. remote IO station)
IO Supervisor (e.g. maintenance computer
running analysis/diagnosis SW for
PROFINET data traffic)

physical transfer media:
Ethernet technologies 100Base-TX
or 100Base-FX full duplex
most common:
4-wire copper cable / 2 twisted pairs , shielded, >= Cat5
Multimode Fiber 50/62.5um
but also wireless technologies are supported – IWLAN (industrial W-LAN)

device identification by MAC / IP address and device name
Instrument Control System Seminar, 20th-24th October 2014
PROFINET IO (2)
 uses TCP/IP communication with prioritizing mechanisms for realtime
capabilities
PROFINET IO RT: (RT = Real Time) reaction time typically below 10ms
PROFINET IO IRT: (IRT = Isochronous Real Time) reaction time typically below
1ms
 PROFINET IO IRT uses internally PTP (precision time protocol) based on IEC
61588 but
only for relative syncing the devices
 no possibility for absolute time synchronisation with S7 PLC
IRT requires network components (switches) supporting PTP
more restrictive with respect to the topology (number of cascaded switches…)
IO Devices have a built-in 2-port switch
 failure or power outage of a single device interrupts the data traffic to/from
the
following devices
If this is not acceptable, implement a star topology by using multiport switches


all PROFINET IO equipment supports autonegotiate / auto-crossover

a hardware device can act as IO Controller and IO Device at the same time
number of device in principle only limited by Ethernet structure (subnet address
volume)


various protocols can co-exist on PROFINET network: TCP/IP, UDP…
Instrument Control System Seminar, 20th-24th October 2014
PROFINET IO Topology
 PROFINET IO supports all usual topologies: line, star, tree, optical ring and
mixtures
out of them
Instrument Control System Seminar, 20th-24th October 2014
PROFINET Cabling
”Fast-Connect” technology enables quick
and easy field assembly
Of course also standard patch cables
can be used
Max. cable length between 2 devices: 90m
M12 connectors are also in use
Most IO devices are not available with built in
optical Interfaces
 Fibers only to be used for long distances,
in noisy environment, moving cables
 media converter necessary
Instrument Control System Seminar, 20th-24th October 2014
PROFINET IO Configuration
 same as PROFIBUS

nodes / topology are configured within SIMATIC Manager / HW Config / NetPro

Siemens devices contained in hardware catalog

3rd party equipment: Integration via GSD file
Instrument Control System Seminar, 20th-24th October 2014
Agenda Day 4
Introduction to SIMATIC / Step 7 
 PROFINET / PROFIBUS 
 Coffee break
 HMI WinCCFlexible
 Safety Applications
 ESO Vacuum&Cryogen.Control Library
 Lunch break
 Hands-On TwinCAT & S7

Instrument Control System Seminar, 20th-24th October 2014
WinCCFlexible: Live Demo
Instrument Control System Seminar, 20th-24th October 2014
Agenda Day 4
Introduction to SIMATIC / Step 7 
 PROFINET / PROFIBUS 
 Coffee break
 HMI WinCCFlexible 
 Safety Applications
 ESO Vacuum&Cryogen.Control Library
 Lunch break
 Hands-On TwinCAT & S7

Instrument Control System Seminar, 20th-24th October 2014
Fail-Safe CPU and IO
ET200S
300 Series
400 Series
‘Hard-PLC‘
Controller
Fieldbus
Centralized
and/or
Remote I/O
ET200S
Instrument Control System Seminar, 20th-24th October 2014
ET200pro
ET200M
Fail-Safe IO Communication with Fieldbus
Almost the same flexibility as with Standard IO
Instrument Control System Seminar, 20th-24th October 2014
PROFIsafe Protocol
For fail-safe communication the PROFISAFE layer is added on top of the
standard bus protocol (PROFINET IO RT / PROFIBUS DP).
PROFISAFE supports fail-safe and standard communication on the same
medium.
Instrument Control System Seminar, 20th-24th October 2014
Quick Excursion: SIL
SIL (Safety Integrity Level) is a benchmark for the quality - or better the probability of a
failure of a SRCF (Safety Related Control Function).
In IEC62061 a safety integrity requirement is expressed as a target failure value for
the probability of dangerous failure per hour of a SRCF
The desired SIL is defined in the final step of a comprehensive risk assessment
procedure.
Furthermore it directly influences the required Hardware Fault Tolerance
Instrument Control System Seminar, 20th-24th October 2014
Components of SRCFs
A safety function (usually) consists of three parts,
which must be considered collectively.
Each part needs to be „qualified“ to fulfill the
determined SIL, but also the sum of all PFHd*)
values must stay within the limits of the requested
SIL.
Special requirements not only on the evaluation unit (e.g. PLC, safety relay)
but also on the sensors and actuators!
Certified Safety Equipment
*)
„Proven in use“ Equipment and
calculation of PFHd values; MultiChannel, Diversity….
PFHd = Probability of dangerous failure per hour
Instrument Control System Seminar, 20th-24th October 2014
Sensor Evaluation
Generally SIL3 can be achieved with S7 Safety PLC, but this depends on the circuitry
SIL3:
Two-channel evaluation &
pulsed supply voltage
SIL2:
Two-channel evaluation
2 separate sensors
2-channel sensor
equivalent
2-channel sensor
non-equivalent
Instrument Control System Seminar, 20th-24th October 2014
Controlling Actuators
Instrument Control System Seminar, 20th-24th October 2014
Principle of Safety Program Execution
The safety program is executed twice inside the CPU.
Time redundancy and diversity replace complete (= hardware) redundancy.
Operators
A, B
Operation
C
Output
AND
Coding
Divers
Operators
Comparison
/A, /B
OR
Divers
Operation
Time redundancy
Instrument Control System Seminar, 20th-24th October 2014
D = /C
Stop
by D ≠ /C
Divers
Output
Time
Major Differences to Standard Programs

very limited instruction set

many restrictions for read/write access with certain operands

programming languages only F-FBD and F-LAD

resource-hungry (auto-generated drivers for safety IO, dual execution +
comparison)

compiling after each modification necessary

download only with CPU stop
Instrument Control System Seminar, 20th-24th October 2014
VLT 4 LGSF Safety-Interlock-System
Safety- and Interlock System (SIS) Architecture
Instrument Control System Seminar, 20th-24th October 2014
VLT 4 LGSF Safety-Interlock-System
Based on S7-300 with
CPU319F
With 14 Remote I/O
Nodes, distributed over
8 cabinets and 160
Safety Digital I/O it is
currently the largest
fail-safe PLC at ESO
Instrument Control System Seminar, 20th-24th October 2014
UT2 Safety-Interlock-System
Upgraded from relay to S7-300 with ET200S remote IO
Instrument Control System Seminar, 20th-24th October 2014
Distributed Safety: Live Demo
Instrument Control System Seminar, 20th-24th October 2014
Agenda Day 4
Introduction to SIMATIC / Step 7 
 PROFINET / PROFIBUS 
 Coffee break
 HMI WinCCFlexible 
 Safety Applications 
 ESO Vacuum&Cryogen.Control Library
 Lunch break
 Hands-On TwinCAT & S7

Instrument Control System Seminar, 20th-24th October 2014
Vacuum/Cryo Library: Live Demo
Instrument Control System Seminar, 20th-24th October 2014
Agenda Day 4
Introduction to SIMATIC / Step 7 
 PROFINET / PROFIBUS 
 Coffee break
 HMI WinCCFlexible 
 Safety Applications 
 ESO Vacuum&Cryogen.Control Library
 Lunch break
 Hands-On TwinCAT & S7

Instrument Control System Seminar, 20th-24th October 2014
End
Thank you very much
for your attention!
Instrument Control System Seminar, 20th-24th October 2014