ABB AC500-S User manual

MANUAL
AC500-S
Safety user manual V1.2.0
Original instructions

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Table of contents
1 Introduction..................................................................................................................................................... 5
1.1 Purpose..................................................................................................................................................... 5
1.2 Document history...................................................................................................................................... 5
1.3 Validity....................................................................................................................................................... 7
1.4 Important user information........................................................................................................................ 7
1.5 Definitions, expressions, abbreviations..................................................................................................... 8
1.6 Functional safety certification.................................................................................................................. 10
1.7 References / related documents.............................................................................................................. 11
1.8 Applicable standards............................................................................................................................... 11
2 Overview of AC500-S safety PLC................................................................................................................. 13
2.1 Overview................................................................................................................................................. 13
2.1.1 System..................................................................................................................................... 13
2.1.2 Safety components.................................................................................................................. 14
2.2 Intended use............................................................................................................................................ 16
2.3 Safety loop.............................................................................................................................................. 17
2.4 Safety values........................................................................................................................................... 17
2.5 Qualified personnel................................................................................................................................. 18
2.6 Lifecycle.................................................................................................................................................. 18
2.7 Installation of safety modules.................................................................................................................. 18
2.8 Exchange of modules.............................................................................................................................. 19
2.9 AC500-S restart behavior........................................................................................................................ 19
2.10 Replacing AC500-S safety PLC components........................................................................................ 19
2.11 Environmentally friendly disposal.......................................................................................................... 19
2.12 Safe communication.............................................................................................................................. 19
2.13 Safety function and fault reaction.......................................................................................................... 21
2.13.1 Safety CPU (SM560-S / SM560-S-FD-1 / SM560-S-FD-4).................................................... 22
2.13.2 Safety module with safety input channels (DI581-S, DX581-S and AI581-S)........................ 22
2.13.3 Safety module with safety output channels (DX581-S).......................................................... 23
2.14 Safety function test................................................................................................................................ 23
2.15 Troubleshooting..................................................................................................................................... 23
2.16 FAQ - AC500-S safety PLC................................................................................................................... 28
3 AC500-S safety modules.............................................................................................................................. 32
3.1 Safety CPU - SM560-S / SM560-S-FD-1 / SM560-S-FD-4..................................................................... 32
3.1.1 Purpose.................................................................................................................................... 32
3.1.2 Functionality............................................................................................................................. 32
3.1.3 Mounting, dimensions and electrical connection..................................................................... 39
3.1.4 Diagnosis and LED status display............................................................................................ 41
3.1.5 Safety CPU module states....................................................................................................... 43
3.1.6 Safety and non-safety CPU interaction.................................................................................... 47
3.1.7 Technical data.......................................................................................................................... 47
3.1.8 Ordering data........................................................................................................................... 50
3.2 Generic safety I/O module behavior........................................................................................................ 50
3.2.1 Overview.................................................................................................................................. 50
3.2.2 Safety I/O module states.......................................................................................................... 50
3.2.3 Undervoltage / overvoltage...................................................................................................... 59
3.2.4 Diagnosis................................................................................................................................. 60
3.3 DI581-S safety digital input module......................................................................................................... 61
3.3.1 Purpose.................................................................................................................................... 61
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3.3.2 Functionality............................................................................................................................. 62
3.3.3 Mounting, dimensions and electrical connection..................................................................... 65
3.3.4 Internal data exchange............................................................................................................. 69
3.3.5 I/O configuration....................................................................................................................... 69
3.3.6 Parameterization...................................................................................................................... 69
3.3.7 Circuit examples....................................................................................................................... 69
3.3.8 LED status display................................................................................................................... 81
3.3.9 Technical data.......................................................................................................................... 82
3.3.10 Ordering data......................................................................................................................... 85
3.4 DX581-S safety digital input/output module............................................................................................ 86
3.4.1 Purpose.................................................................................................................................... 86
3.4.2 Functionality............................................................................................................................. 87
3.4.3 Mounting, dimensions and electrical connection..................................................................... 91
3.4.4 Internal data exchange............................................................................................................. 95
3.4.5 I/O configuration....................................................................................................................... 95
3.4.6 Parameterization...................................................................................................................... 95
3.4.7 Circuit examples....................................................................................................................... 96
3.4.8 LED status display................................................................................................................. 101
3.4.9 Technical data........................................................................................................................ 102
3.4.10 Ordering data....................................................................................................................... 106
3.5 AI581-S safety analog input module..................................................................................................... 107
3.5.1 Purpose.................................................................................................................................. 107
3.5.2 Functionality........................................................................................................................... 108
3.5.3 Mounting, dimensions and electrical connection.................................................................... 110
3.5.4 Internal data exchange........................................................................................................... 113
3.5.5 I/O configuration..................................................................................................................... 113
3.5.6 Parameterization.................................................................................................................... 113
3.5.7 Circuit examples..................................................................................................................... 114
3.5.8 LED status display.................................................................................................................. 118
3.5.9 Technical data........................................................................................................................ 119
3.5.10 Ordering data....................................................................................................................... 122
3.6 TU582-S safety I/O terminal unit........................................................................................................... 123
3.6.1 Functionality........................................................................................................................... 123
3.6.2 Mounting, dimensions and electrical connection................................................................... 124
3.6.3 Technical data........................................................................................................................ 126
3.6.4 Ordering data......................................................................................................................... 127
4 Configuration and programming............................................................................................................... 128
4.1 Overview............................................................................................................................................... 128
4.2 Workflow................................................................................................................................................ 129
4.3 System configuration and programming................................................................................................ 130
4.3.1 Installation.............................................................................................................................. 130
4.3.2 License activation................................................................................................................... 130
4.3.3 Creation of new project and user management..................................................................... 130
4.3.4 Working with PROFINET/PROFIsafe F-Devices................................................................... 131
4.3.5 Instantiation and configuration of safety modules / definition of variable names................... 133
4.3.6 Programming of AC500-S safety CPU................................................................................... 141
4.3.7 Checking of program and system configuration..................................................................... 159
4.4 CODESYS Safety programming guidelines.......................................................................................... 172
4.4.1 Overview................................................................................................................................ 172
4.4.2 Framework............................................................................................................................. 172
4.4.3 Language-specific programming guidelines.......................................................................... 174
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4.4.4 General programming guidelines........................................................................................... 180
4.4.5 Safety and non-safety parts of the application....................................................................... 181
4.5 Safety code analysis tool....................................................................................................................... 181
4.6 AC500-S libraries.................................................................................................................................. 182
4.6.1 Overview................................................................................................................................ 182
4.6.2 Safety_Standard.lib................................................................................................................ 183
4.6.3 SafetyBase_PROFIsafe_LV200_AC500_V22.lib................................................................... 187
4.6.4 SafetyBlocks_PLCopen_AC500_v22.lib................................................................................ 191
4.6.5 SafetyDeviceExt_LV100_PROFIsafe_AC500_V27.lib........................................................... 294
4.6.6 SafetyExt2_LV100_AC500_V27.lib........................................................................................ 298
4.6.7 SafetyExt_AC500_V22.lib...................................................................................................... 300
5 Safety times................................................................................................................................................. 317
5.1 Overview............................................................................................................................................... 317
5.2 Fault reaction time................................................................................................................................. 317
5.3 Safety function response time............................................................................................................... 317
6 Checklists for AC500-S commissioning................................................................................................... 326
6.1 Overview............................................................................................................................................... 326
6.2 Checklist for creation of safety application program.............................................................................. 326
6.3 Checklist for configuration and wiring.................................................................................................... 328
6.4 Checklist for operation, maintenance and repair................................................................................... 330
6.5 Verification procedure for safe iParameter setting in AC500-S safety I/Os........................................... 332
6.5.1 Verification procedure workflow............................................................................................. 333
6.5.2 Verification tables for iParameter settings in AC500-S safety I/Os........................................ 334
7 Safety application examples...................................................................................................................... 342
7.1 Overview............................................................................................................................................... 342
7.2 Example 1: diagnostics concept............................................................................................................ 343
7.2.1 Functional description of safety functions.............................................................................. 343
7.2.2 Graphical overview of safety application interface................................................................. 344
7.2.3 Declaration of used variables................................................................................................. 344
7.2.4 Program example................................................................................................................... 345
7.2.5 Additional notes...................................................................................................................... 345
7.3 Example 2: muting................................................................................................................................. 346
7.3.1 Functional description of safety functions.............................................................................. 347
7.3.2 Graphical overview of the safety application interface........................................................... 348
7.3.3 Declaration of used variables................................................................................................. 348
7.3.4 Program example................................................................................................................... 350
7.3.5 Additional notes ..................................................................................................................... 351
7.4 Example 3: two-hand control................................................................................................................. 352
7.4.1 Functional description of safety functions.............................................................................. 352
7.4.2 Graphical overview of the safety application interface........................................................... 353
7.4.3 Declaration of used variables................................................................................................. 353
7.4.4 Program example................................................................................................................... 354
7.4.5 Additional notes...................................................................................................................... 354
8 Index............................................................................................................................................................. 356
Appendix...................................................................................................................................................... 359
A System data for AC500-S-XC................................................................................................... 360
B Usage of safety CPU with V2 non-safety CPU PM5xx............................................................. 366
C Usage of safety CPU with V3 non-safety CPU PM56xx........................................................... 384
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1 Introduction
1.1 Purpose
This safety user manual describes AC500-S safety PLC system. It provides detailed information
on how to install, run, program and maintain the system correctly in functional safety applica-
tions up to SIL 3 according to IEC 61508:2010, SILCL 3 according to IEC 62061:2015 and per-
formance level e (cat. 4) according to ISO 13849-1:2015.
ABB’s AC500 series is a PLC-based modular automation solution that makes it easy to mix and
match safety and non-safety I/O modules to meet automation market requirements.
1.2 Document history
Rev. Description of version / changes Who Date
1.2.0 Various typos were corrected and various improvements in the texts and
illustrations were made. Layout was changed to current ABB branding.
Major changes:
● Chapter 4.3.7.1: New safety verification tool SVT was added.
● Safety modules are supported by AC500 V3 non-safety CPUs. Spe-
cific information on handling safety modules with non-safety CPUs
transferred to appendices B + C.
Appendix B contains all specific information about safety modules
with V2 non-safety CPUs PM5xx.
Appendix C contains all specific information about safety modules
with V3 non-safety CPUs PM56xx.
● Chapter 3.1.2.6: "Firmware, boot code and boot project update" was
updated.
● Assembly instructions of safety I/O modules were updated.
ABB 19.06.2020
1.1.0 Various typos were corrected. Various improvements in the text.
Major changes:
● Information about SM560-S-FD-1(-XC) and SM560-S-FD-4(-XC)
safety CPUs was added.
● Ch. 4.6.7: New PROFIsafe F-Device library SafetyDevi-
ceExt_LV100_PROFIsafe_AC500_V27.lib was added.
● Ch. 4.6.8: New Safety library SafetyExt2_LV100_AC500_V27.lib was
added.
● Detailed information about relevant standards was added.
● Checklists for AC500-S commissioning in Chapter 6 were updated.
ABB 16.03.2018
1.0.5 Various typos were corrected. Minor improvements in the text and
removal of screen shots for older versions of Automation Builder.
Major changes:
● New PROFIsafe F-Host library SAFETY-
BASE_PROFIsafe_LV200_AC500_V22.lib is used in the document.
● FAQ (Frequently Asked Questions) list was added.
● Ch. 2.4: Detailed safety values for AC500-S modules were provided.
● Ch. 4.3.6: "DANGER!" note was added to explain PROFIsafe
Device_Fault bit usage.
● Ch. 6.3: New checklist item 9 was added.
ABB 23.10.2017
Introduction
Document history
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Rev. Description of version / changes Who Date
1.0.4 Various typos were corrected. Minor improvements in the text.
Major changes:
Licensing information was updated:
● Ch. 4.1: Notice Block with reference to PS501-S license installation
removed.
● Ch. 4.2: Figure 63 updated (Programming workflow, step 2) was
enhanced for the license handling of Automation Builder version
V2.0.2 (or higher).
● Ch. 4.3.2: "Licence activation" was extended with additional licensing
information for usage of Automation Builder version V2.0.2 (or
higher).
Additional information according to the new F-Host library "SAFETY-
BASE_PROFIsafe_AC500_V22_Ext.lib" was added:
● Ch 4.6.1: Table for library "SAFETY-
BASE_PROFIsafe_AC500_V22_Ext.lib" was updated.
● Ch. 4.6.3: The chapter was updated and renamed acc. to the new
library name "SAFETYBASE_PROFIsafe_AC500_V22_Ext.lib".
● Ch. 6.2: Checklist item 20 was updated according to the new library
name "SAFETYBASE_PROFIsafe_AC500_V22_Ext.lib".
ABB 27.03.2017
1.0.3 Various typos were corrected. Additional abbreviations were included in
the abbreviation list.
The entire document was re-styled:
● The yellow background on notices and recommendations was
replaced by a light-grey background because of document standardi-
zation.
● "DANGER" and "NOTICE" symbols were replaced by standard sym-
bols from German Standard DIN 4844-2 in text boxes.
The text was changed in the document:
● More standard terms are now used in the document.
● Values for storage and transport temperatures were extended.
● Vertical mounting option (with derating) is added for SM560-S Safety
CPU and corrected for DI581-S and AI581-S Safety I/O modules.
● LREAL is not supported by SM560-S Safety CPUs and was removed
from the document.
● POU SF_MAX_POWER_DIP_GET description was modified.
● "DANGER" text box was added for POU
SF_DPRAM_PM5XX_S_SEND to explain limitations for POU usage.
● F_WD_Time2 and Device_WD2 term definitions in Chapter 5.3 were
corrected.
● "F_Host_WD" was replaced with "the value set using
SF_WDOG_TIME_SET" inside of "NOTICE" box in Chapter 5.3
ABB 28.05.2015
1.0.2 Words "Original Instructions" have been added to document title ABB 17.04.2015
Introduction
Document history
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Rev. Description of version / changes Who Date
1.0.1 Minor typos were corrected. TÜV SÜD certificate was added.
The text was changed in the document:
● Safety I/O inputs and outputs are not electrically isolated from the
other electronic circuitry of the module.
● The safety values for safety outputs of DX581-S (-XC) module are
only valid if the parameter "Detection" is set to "On".
● DC (diagnostic coverage) for DX581-S (-XC) module shall be
≥ 94 %.
● The clarification was added that the boot project update on SM560-S
is possible only if no boot project is loaded on SM560-S.
● Not more than one communication error (CE_CRC or Host_CE_CRC
output signals become equal to TRUE) per 100 hours is allowed to
be acknowledged by the operator using OA_C input signal without
consulting the responsible safety personnel.
● SM560-S cycle time shall be included three times instead of two
times in Safety Function Response Time calculation.
● The values for input delay accuracy in Safety Function Response
Time calculation were updated.
● Update of Appendix A with system data for AC500-S-XC.
ABB 08.03.2013
1.0.0 First release ABB 19.12.2012
1.3 Validity
The data and illustrations found in this documentation are not binding. ABB reserves the right to
modify its products in line with its policy of continuous product development.
1.4 Important user information
This documentation is intended for qualified personnel familiar with functional safety. You must
read and understand the safety concepts and requirements presented in this safety user
manual prior to operating AC500-S safety PLC system.
The following special notices may appear throughout this documentation to warn of potential
hazards or to call attention to specific information.
DANGER!
The notices referring to your personal safety are highlighted in the manual by
this safety alert symbol, which indicates that death or severe personal injury
may result if proper precautions are not taken.
NOTICE!
This symbol of importance identifies information that is critical for successful
application and understanding of the product. It indicates that an unintended
result can occur if the corresponding information is not taken into account.
Introduction
Important user information
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1.5 Definitions, expressions, abbreviations
1oo2 One-out-of-Two safety architecture, which means that it includes two channels
connected in parallel, such that either channel can process the safety function.
AC500 ABB non-safety PLC
AC500-XC ABB non-safety PLC suitable for extreme environmental conditions
AC500-S ABB safety PLC for applications up to SIL 3 (IEC 61508), SILCL 3 (IEC 62061)
and PL e (ISO 13849-1)
AC500-S-XC ABB safety PLC for applications up to SIL 3 (IEC 61508), SILCL 3 (IEC 62061)
and PL e (ISO 13849-1) suitable for extreme environmental conditions
ADC Analog to digital converter
AOPD Active opotoelectronic protective device
Automation
Builder
Integrated engineering suite for ABB PLCs, including IEC 61131-3 editor
CODESYS
CCF Common cause failure
Control
Builder Plus
PS501
Integrated engineering suite for ABB PLCs, including IEC 61131-3 editor
CODESYS, predecessor of Automation Builder
CPU Central processing unit
CRC Cyclic redundancy check. A number derived from and stored or transmitted
with a block of data in order to detect data corruption.
DC Diagnostic coverage
DPRAM Dual-ported random access memory
IEC International electro-technical commission standard
EDM External device monitoring signal, which reflects the state transition of an
actuator
EMC Electromagnetic compatibility
EN European norm (european standard)
EPROM Erasable programmable read-only memory
ESD Electro static discharge
ESPE Electro-sensitive protective equipment (for example a light curtain)
F-Host Data processing unit that is able to perform a special protocol and to service
the "black channel" Ä [3]
F-Device Passive communication peer that is able to perform the special protocol, usu-
ally triggered by the F-Host for data exchange Ä [3]
F-Parameter Fail-safe parameter as defined in
Ä [3]
FAQ Frequently asked questions
FB Function block
FBD Function block diagram (IEC 61131 programming language)
Flash
memory
Non-volatile computer storage chip that can be electrically erased and reprog-
rammed
FV Fail-safe value
GSDML Generic station description markup language
ID Identification
IO controller Controller that controls the automation task in PROFINET context
Introduction
Definitions, expressions, abbreviations
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IO device Field device, monitored and controlled by an IO controller in PROFINET con-
text
iParameter Individual safety device parameter
LAD Ladder logic diagram (IEC 61131 programming language)
Loop-back The programmable routing feature of a bus device re-routes unintentionally an
F-Host message back to the F-Host, which expects a message of the same
length (refer to www.profisafe.net for further details).
LSB Least significant bit
MSB Most significant bit
MTBF Mean time between failures
MTTF Mean time to failure
Muting Muting is the intended suppression of the safety function. This is required, e.g.
when transporting the material into the danger zone.
NC Break contact. Normally-closed contacts disconnect the circuit when the relay
is activated; the circuit is connected when the relay is inactive.
NO Make contact. Normally-open contacts connect the circuit when the relay is
activated; the circuit is disconnected when the relay is inactive.
OEM Original equipment manufacturer
OSSD Output signal switching device
Passivation The passivation is the special state of safety I/O modules which leads to the
delivery of safe substitute values, which are ‘0’ values in AC500-S, to the
safety CPU.
PC Personal computer
PELV Protective extra low voltage
PES Programmable electronic system (refer to IEC 61508)
PFD Probability of failure on demand
PFH Probability of failure per hour
PL Performance level according to ISO 13849-1
PLC Programmable logic controller
POU Program organization unit
PROFIsafe Safety-related bus profile of PROFIBUS DP/PA and PROFINET IO for commu-
nication between the safety program and the safety I/O in the safety system
PROFINET Industrial technical standard for data communication over Industrial Ethernet
Proof Test
Interval
The proof test is a periodic test performed to detect failures in a safety-related
system so that, if necessary, the system can be restored as close as possible
to its previous new state. The time period between these tests is the proof test
interval.
PS Programming system
PTC Positive temperature coefficient
RAM Random access memory
Reintegration It is the process of switching from substitute values "0" to the process data.
Safety vari-
able
It is a variable used to implement a safety function in a safety-related system
SCA Safety code analysis - ABB software tool to automatically check CODESYS
Safety programming rules
SD card Secure digital memory card
Introduction
Definitions, expressions, abbreviations
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SELV Safety extra low voltage
SFRT Safety function response time
SIL Safety integrity level (IEC 61508)
SILCL SIL claim limit (IEC 62061)
ST Structured text (IEC 61131 programming language)
SVT Safety Verification Tool - ABB software tool to verify the AC500-S safety config-
uration in Automation Builder
TÜV Technischer Überwachungs-Verein (technical inspection association)
TWCDT Total worst case delay time
ULP Unit in the last place, which is the spacing between floating-point numbers, i.e.,
the value the least significant bit represents if it is 1 (refer to
http://en.wikipedia.org/wiki/Unit_in_the_last_place for more details).
WLAN Wireless local area network
1.6 Functional safety certification
The AC500-S safety modules are safety-related up to SIL 3 according to IEC 61508:2010,
SILCL 3 according to IEC 62061:2015 and performance level e according to ISO 13849-1:2015,
as certified by TÜV SÜD Rail GmbH (Germany).
The AC500-S is a safety PLC which operation reliability is significantly improved compared to a
non-safety PLC using 1oo2 redundancy in the hardware and additional diagnostic functions in
its hardware and software. The embedded safety integrity diagnostic functions are based on the
safety standards current at the time of certification Ä TÜV SÜD Rail Certification Report for
AC500-S [2]. These safety integrity tests include test routines, which are run during the whole
operating phase, making the AC500-S safety PLC suitable for the safety machinery and
process applications up to SIL 3 according to IEC 61508:2010, SILCL 3 according to
IEC 62061:2015 and performance level e according to ISO 13849-1:2015.
NOTICE!
Please refer to TÜV SÜD Rail Certification Report for AC500-S Ä [2] for a com-
plete list of standards and further details, like versions of standards, etc.
The proof test interval for the AC500-S safety PLC is set to 20 years.
PFH, PFD, MTTFd, category and DC values from IEC 61508:2010, IEC 62061:2015 and
ISO 13849-1:2015 for AC500-S safety modules satisfy SIL 3, SILCL 3 and PL e requirements
Ä Chapter 2.4 “Safety values” on page 17.
Introduction
Functional safety certification
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