Siemens SIMATIC KP8 User manual

KP8, KP8F
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SIMATIC HMI
HMI device
KP8, KP8F
Operating Instructions
10/2010
A5E03284305-01
Preface
Overview
1
Safety instructions and
approvals
2
Planning the use
3
Mount and connect KP8 and
KP8F
4
Operator controls and
displays
5
Setting the KP8 and KP8F
6
Operating KP8F in a fail-safe
manner
7
Maintain and service KP8
and KP8F
8
Technical specifications
9
Appendix
A
Abbreviations
B

Legal information
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
NOTICE
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation for the specific task, in particular its warning notices and
safety instructions. Qualified personnel are those who, based on their training and experience, are capable of
identifying risks and avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be adhered to. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this
publication may be trademarks whose use by third parties for their own purposes could violate the rights of the
owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.
Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E03284305-01
Ⓟ 10/2010
Copyright © Siemens AG 2010.
Technical data subject to change

KP8, KP8F
Operating Instructions, 10/2010, A5E03284305-01 3
Preface
Purpose of the operating instructions
This operating manual provides information for manuals derived from the requirements for
mechanical engineering documentation according to DIN EN 62079. This information relates
to the place of use, transport, storage, mounting, use and maintenance.
These operating instructions are intended for:
● Project planning engineers
● Users
● Commissioning engineers
● Maintenance personnel
Pay particular attention to the chapter "Safety Instructions (Page 19)".
Required knowledge
General knowledge of automation technology and process communication is needed to
understand the operating instructions.
It is also assumed that those using the manual have experience in using personal computers
and an understanding of Microsoft operating systems.
You must have knowledge about the STEP 7 software and about safety-related technology.
Scope
The operating instructions applies to the following HMI devices:
● KP8, order number 6AV3688-3AY36-0AX0
● KP8F, order number 6AV3688-3AF37-0AX0
Note
The manual is part of the HMI device and will be required for repeat commissioning.
Retain all enclosed and additional documents for the entire service life of the HMI device.
You must pass on all these documents to future owners of the HMI device.
Registered trademarks
The following designations marked with the protective note ® are registered trademarks of
the Siemens AG:
● HMI®
● SIMATIC®
● WinCC®

Preface
KP8, KP8F
4 Operating Instructions, 10/2010, A5E03284305-01
Notes on fail-safe operation
The following sections of these operating instructions contain important information about the
fail-safe operation of the KP8F:
● Safety instructions and approvals (Page 19)
● Requirements for fail-safe operation (Page 36)
● Connecting the HMI device (Page 42)
● Setting KP8F - STEP 7 (Page 64)
● Operating KP8F in a fail-safe manner (Page 73)
● Sensor evaluation of the fail-safe channels (Page 93)
Documentation for fail-safe systems
● System description "Safety technology in SIMATIC S7"
– Provides general information on the use, structure, and mode of operation of the fail-
safe automation systems S7 Distributed Safety and S7 F/FH Systems
– Contains detailed technical information which can be represented for the fail-safe
technology both in S7-300 and S7-400.
– Contains information about the calculation of monitoring and reaction times of the fail-
safe systems "S7 Distributed Safety" and of "S7 F/FH Systems".
● "S7 Distributed Safety, Configuring and Programming" Manual and Online Help
Describes the configuration of the F-CPU and of the fail-safe I/O and the programming of
the F-CPU in F-FBD or F-LAD
● "Automation System S7-1200, CPU Data" Reference Manual
Describes the standard functions of the CPU 1211C, CPU 1212C and CPU 1214C.
● "Automation System S7-400, CPU Data" Reference Manual
Describes the standard functions of CPU 416F-3 PN/DP, CPU 414-3 PN/DP and
CPU 416-3 PN/DP
● "Automation System S7-300, CPU Data" Reference Manual
Describes the standard functions of CPU 315F-2 PN/DP, CPU 317F-2 PN/DP, CPU 315-
2 PN/DP and CPU 317-2 PN/DP.

Preface
KP8, KP8F
Operating Instructions, 10/2010, A5E03284305-01 5
Style conventions
This manual uses the following style conventions:
Style Convention Scope
"Add screen" Terminology in the user interface, for example dialog names,
tabs, buttons, menu commands
Required input, for example, limits, tag values.
Path information
"File > Edit" Operational sequences, for example, shortcut menu commands
<F1>, <Alt+P> Keyboard operation
Please observe notes labeled as follows:
Note
A
note contains important information about the product described in the manual and its use,
or a specific section of the manual to which you should pay particular attention.
Naming conventions
This manual uses the following naming conventions:
Naming convention Applies to
Plant System
Machining center
One or more machines
Actuate By means of the touch screen on the HMI device
By means of the button on the HMI device
By operating a mouse on the HMI device
Switching cabinet Mounting cabinet
Switching cabinet
Switchboard
Console
Figures
This manual contains illustrations of the described devices. The illustrations can deviate from
the details of the delivered device.

Preface
KP8, KP8F
6 Operating Instructions, 10/2010, A5E03284305-01
Technical Support
Technical support for the products covered in the manual is available in the Internet at:
● Technical Support (http://support.automation.siemens.com/WW/view/en/4000024)
● Support Request (http://support.automation.siemens.com/WW/view/en/16605654)
● Service (http://support.automation.siemens.com/WW/view/en/16604318)
● Contacts and office locations (http://www.automation.siemens.com/mcms/aspa-
db/en/Pages/default.aspx)
● Training center (http://sitrain.automation.siemens.com/sitrain/default.aspx?AppLang=en)
Additional information on SIMATIC products is available in the Internet at:
● Industry Portal (http://www.automation.siemens.com/_en/portal/index.htm)
● Overall SIMATIC documentation
(http://www.automation.siemens.com/simatic/portal/html_76/techdoku.htm)
Recycling and disposal
The products described in this manual are recyclable because of the low level of
contaminants in their components. Contact a certified disposal service company for
environmentally sound recycling and disposal of your old devices.
Used batteries and rechargeable batteries
Used batteries and lithium ion batteries are hazardous waste. Always dispose of used
batteries and lithium ion batteries properly in accordance with the regulations in effect.
Identify the container provided for this purpose with the label, "Used batteries and
rechargeables".
Note
Batteries and rechargeables do not belong in the garbage. The user is legally obliged to
return used batteries and rechargeable batteries. You can deposit used batteries and
rechargeables at any public collection site and anywhere batteries or rechargeables of
similar type are sold.
You can also send batteries and rechargeables to the following address:
Siemens AG
Industry Sector
Returns Center
Siemensstr. 2
90766 Fürth
Germany

KP8, KP8F
Operating Instructions, 10/2010, A5E03284305-01 7
Table of contents
1 Overview.................................................................................................................................................. 11
1.1 Product Overview.........................................................................................................................11
1.2 Scope of delivery .........................................................................................................................11
1.3 Design of KP8 and KP8F.............................................................................................................12
1.4 Accessory kit................................................................................................................................14
1.5 Service packages.........................................................................................................................15
1.6 Performance features ..................................................................................................................15
1.7 Communication and enabled PLCs .............................................................................................16
1.8 Operating KP8F in a fail-safe manner .........................................................................................16
2 Safety instructions and approvals ............................................................................................................ 19
2.1 Safety Instructions .......................................................................................................................19
2.2 Approvals .....................................................................................................................................21
2.3 TÜV certificate..............................................................................................................................23
2.4 Notes about Usage ......................................................................................................................23
2.5 Electromagnetic compatibility ......................................................................................................26
3 Planning the use...................................................................................................................................... 29
3.1 "Plan use" check list.....................................................................................................................29
3.2 Ambient conditions for storage and transport..............................................................................29
3.3 Ambient conditions for operation .................................................................................................30
3.4 Mounting Positions and Type of Fixation.....................................................................................32
3.5 Preparing for Mounting ................................................................................................................34
3.6 Insulation resistance, protection class and degree of protection.................................................36
3.7 Requirements for fail-safe operation............................................................................................36
3.7.1 Sensor for 1oo1 mode .................................................................................................................36
3.7.2 Sensor for 1oo2 mode .................................................................................................................38
3.7.3 Cables..........................................................................................................................................40

Table of contents
KP8, KP8F
8 Operating Instructions, 10/2010, A5E03284305-01
4 Mount and connect KP8 and KP8F.......................................................................................................... 41
4.1 "Mounting and connection of HMI device" checklist ................................................................... 41
4.2 Check the scope of delivery........................................................................................................ 41
4.3 Mounting the HMI device ............................................................................................................ 41
4.4 Connecting the HMI device......................................................................................................... 42
4.4.1 Connection sequences and lines ................................................................................................ 42
4.4.2 Ports............................................................................................................................................ 43
4.4.3 Connecting the power supply...................................................................................................... 44
4.4.4 Connect standard inputs/outputs ................................................................................................ 45
4.4.5 Connect KP8F - fail-safe inputs .................................................................................................. 46
4.4.6 Connecting the PLC .................................................................................................................... 48
4.5 Switching on and testing the HMI device....................................................................................50
4.6 Securing the cables..................................................................................................................... 51
5 Operator controls and displays ................................................................................................................ 53
5.1 Front-sided control elements and displays ................................................................................. 53
5.2 Rear operator controls and displays ........................................................................................... 54
5.3 Labeling keys .............................................................................................................................. 55
6 Setting the KP8 and KP8F....................................................................................................................... 57
6.1 "Setting the KP8 and KP8F" checklist......................................................................................... 57
6.2 Integrating GSD in STEP 7 ......................................................................................................... 57
6.3 Setting controller - communication HMI device........................................................................... 58
6.4 Configuring Media Redundancy Protocol ................................................................................... 61
6.5 Setting KP8F - STEP 7 ............................................................................................................... 64
6.6 Setting PROFIsafe address for KP8F .........................................................................................67
6.7 KP8F – Configure Shared Device ............................................................................................... 68
6.8 KP8F – Configure Shared Device for non fail-safe controller ..................................................... 71
7 Operating KP8F in a fail-safe manner...................................................................................................... 73
7.1 Overview ..................................................................................................................................... 73
7.2 Passivate HMI device.................................................................................................................. 74
7.3 Error diagnostics ......................................................................................................................... 75
7.4 Repair error and reintegrate........................................................................................................ 76
7.5 Response times of the PROFIsafe devices ................................................................................ 78
8 Maintain and service KP8 and KP8F ....................................................................................................... 81
8.1 Maintenance and care................................................................................................................. 81
8.2 Spare parts and repairs............................................................................................................... 82

Table of contents
KP8, KP8F
Operating Instructions, 10/2010, A5E03284305-01 9
9 Technical specifications........................................................................................................................... 83
9.1 Dimensional diagram ...................................................................................................................83
9.2 Technical specifications ...............................................................................................................84
9.3 Fail-safe mode .............................................................................................................................86
9.4 Interface description.....................................................................................................................89
9.4.1 Inputs and outputs KP8................................................................................................................89
9.4.2 Inputs and outputs KP8F .............................................................................................................90
9.4.3 PROFINET...................................................................................................................................91
9.5 Bit assignment in the process image ...........................................................................................91
9.6 Sensor evaluation of the fail-safe channels .................................................................................93
A Appendix.................................................................................................................................................. 95
A.1 ESD guideline ..............................................................................................................................95
B Abbreviations........................................................................................................................................... 97
Glossary .................................................................................................................................................. 99
Index...................................................................................................................................................... 103

Table of contents
KP8, KP8F
10 Operating Instructions, 10/2010, A5E03284305-01

KP8, KP8F
Operating Instructions, 10/2010, A5E03284305-01 11
Overview 1
1.1 Product Overview
Application scenarios of the HMI device
The HMI device shows you operating states of a plant. You can actively control a running
production process based on this information.
The HMI device is designed for mounting in control panels, and replaces keys and LEDs that
are individually mounted. The HMI device is mounted in a mounting cut-out and connects to
a SIMATIC controller via PROFINET. The HMI device can be set for immediate use. In
comparison to conventional wiring, substantially less time is needed for commissioning and
the device provides increase security against failure during runtime.
Fail-safe mode with KP8F
Thanks to the integrated PROFIsafe communication, the HMI device can be used in fail-safe
mode for simple sensor applications. In regards to the safety-relevant signals, safety
categories SIL3, Performance Level e and category 4 are reached.
The KP8 and the KP8F are intended for installation in the following extension units:
● Extension Unit 15", Order number 6AV7674-0KG00-0AA0
● Extension Unit 19" left, order number 6AV7674-0KH00-0AA0
● Extension Unit 19" right, order number 6AV7674-0KJ00-0AA0
1.2 Scope of delivery
The scope of delivery includes:
● 1 KP8 or KP8F
● 1 accessory kit
● 1 data carrier with ATEX handbook

Overview
1.3 Design of KP8 and KP8F
KP8, KP8F
12 Operating Instructions, 10/2010, A5E03284305-01
1.3 Design of KP8 and KP8F
Front view and side view




① Labeling strips
② Oblong holes for a mounting clamp
③ Keyboard
Plan view

Overview
1.3 Design of KP8 and KP8F
KP8, KP8F
Operating Instructions, 10/2010, A5E03284305-01 13
Rear view KP8




① Power supply connection and digital inputs and outputs
② Bar for strain relief
③ Seal
④ PROFINET interfaces

Overview
1.4 Accessory kit
KP8, KP8F
14 Operating Instructions, 10/2010, A5E03284305-01
Rear view KP8F





① Power supply connection and digital inputs and outputs
② Bar for strain relief
③ DIP switch
④ Seal
⑤ PROFINET interfaces
1.4 Accessory kit
The accessory kit for the KP8 contains:
● A 12-pin plug connector
● Four mounting clamps for mounting the HMI device
The accessory kit for the KP8F contains the following:
● A 16-pin plug connector
● Four mounting clamps for mounting the HMI device
The accessory kit can include documents.

Overview
1.5 Service packages
KP8, KP8F
Operating Instructions, 10/2010, A5E03284305-01 15
1.5 Service packages
KP8
This service pack contains:
1 set connector, 12-pin, order number 6AV6671-3XY39-4AX0
KP8F
This service pack contains:
1 set connector, 16-pin, order number 6AV6671-3XY49-4AX0
KP8, KP8F
This service pack contains:
1 set plastic mounting clamps, order number 6AV6671-8XK00-0AX2
1.6 Performance features
Performance features KP8
The HMI device offers a wide range of features that can be used without the need for
programming:
● 8 short-stroke keys with integrated LEDs
The LEDs allow for the display of different colors. The colors red, yellow, blue, green and
white are displayable.
● 8 clamps, rear
The clamps are used as digital inputs or outputs to the connection of external sensors.
● Integrated light and button tests - after turning on the HMI device
● Communication via PROFINET
● SIMATIC design
Through this, the HMI devices can be arranged closely next to each other.
Expansion with external input/output devices
The functionality of the HMI device can be extended using input and output devices, for
example lamps or key switches.

Overview
1.7 Communication and enabled PLCs
KP8, KP8F
16 Operating Instructions, 10/2010, A5E03284305-01
Performance features KP8F
The KP8F has the following additional performance features compared to the KP8:
● Fail-safe digital inputs for:
– An EMERGENCY STOP button or alternatively
– Two single-channel evaluations
1.7 Communication and enabled PLCs
Enabled PLCs
The HMI device has been enabled for use with the following type of PLC:
● SIMATIC S7-1200
● SIMATIC S7-400, SIMATIC S7-400F
● SIMATIC S7-300, SIMATIC S7-300F
● WinAC and Embedded Controllers
NOTICE
Safety-related communication
A non fail-safe control does not provide any safety-directed communication.
A SIMATIC S7F PLC is required for fail-safe communication.
Released protocols
The HMI device uses the following protocols for communication with the controller:
● PROFINET IO for standard communication
● PROFIsafe Mode V2.0 for the fail-safe communication of the KP8F
1.8 Operating KP8F in a fail-safe manner
Configuring software
For fail-safe operation of the HMI device, the following software is required:
● STEP 7 V5.5
● SIMATIC S7 Distributed Safety, as of V5.4

Overview
1.8 Operating KP8F in a fail-safe manner
KP8, KP8F
Operating Instructions, 10/2010, A5E03284305-01 17
Fail-safe automation system
Fail-safe automation system (F systems) are used in plants requiring higher levels of safety.
F systems control production processes in such a way that residual error probability is taken
into consideration to achieve a safe operating state when a shutdown occurs. An immediate
shutdown therefore does not pose a danger to people or the environment.
Operating KP8F in a fail-safe manner
The KP8F device is a PROFINET IO device on Industrial Ethernet.
In fail-safe mode the HMI device registers the signal states of compatible emergency stop
buttons and transmits corresponding safety frames to the controller. The controller and the
HMI device communicate with each other using the fail-safe protocol, PROFIsafe.
The HMI device can operate in fail-safe mode corresponding to SIL3, Performance Level e
and category 4 if the safety functions are appropriately configured in STEP 7 with the "S7
Distributed Safety" add-on package.
Fail-safe mode of the HMI devices differs from standard mode essentially in that during
communication, the signals are checked for being error-free (error-safe). In the event of a
fault, the HMI device is placed in a safe state.
The fail-safe connection fulfills the following requirements:
● Single-channel mode with 1oo1 parameterization
– Safety category SIL2 corresponding to IEC 61508:2010
– Safety category Performance Level d corresponding to IEC 13849:2006
– Safety category category 3 corresponding to EN 954:1996
● Two-channel mode with 1oo2 parameterization
– Safety category SIL3 corresponding to IEC 61508:2010
– Safety category Performance Level e corresponding to IEC 13849:2006
– Safety category category 4 corresponding to EN 954:1996
The HMI device can be operated simultaneously in standard mode and fail-safe mode.
Diagnostics function of KP8F
The fail-safe KP8F includes non-configurable diagnostic functions. The diagnostics functions
are always active. The diagnostics result is automatically made available by the HMI device
in STEP 7 and passed on to the fail-safe controller in the event of a fault.

Overview
1.8 Operating KP8F in a fail-safe manner
KP8, KP8F
18 Operating Instructions, 10/2010, A5E03284305-01
Example configuration of a F-system with KP8F
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The example shows the simultaneous operation of fail-safe and non fail-safe devices.
In the example, each PROFINET IO device communicates with just one PROFINET IO-
controller. The PROFIsafe device communicates here exclusively with the F-PROFINET IO
controller.

KP8, KP8F
Operating Instructions, 10/2010, A5E03284305-01 19
Safety instructions and approvals 2
2.1 Safety Instructions
WARNING
Injury or material damage
If you do not follow precisely the safety guidelines and manuals in this handbook, this may
result in sources of danger and make safety functions ineffective. This can result in
personal injuries or material damage.
Follow the safety guidelines and instructions precisely.
Observe the safety and accident prevention instructions applicable to your application in
addition to the safety instructions given in this manual.
Project security
WARNING
Injury or material damage
The configuration engineer for a system PLC must take precautions so that an interrupted
program can be restarted normally after voltage dips or power failures.
A dangerous operating state must not occur during the entire process of the control
program, also during troubleshooting - also not in the short-run.

Safety instructions and approvals
2.1 Safety Instructions
KP8, KP8F
20 Operating Instructions, 10/2010, A5E03284305-01
Safety during commissioning and operation
WARNING
Installation according to the instructions
Commissioning of the HMI device is forbidden until it has been absolutely ensured that the
machine which is to be operated with the HMI device complies with Directive 2006/42/EC.
Before commissioning, check to see if the regulations of the directive 2006/42/EC are
fulfilled.
Open-type resource
The HMI device is an open-type resource. This means that the HMI device may only be
installed in cabinets that allow the device to be operated from the front side.
Access to the control cabinet in which the HMI device is installed should only be possible
by means of a key or tool and only for trained and authorized personnel.
Danger, high voltage
Opening the cabinet will expose high voltage parts. Contact with these parts could be fatal.
Switch off the power supply to the cabinet before opening it.
When operating the HMI device in hazardous areas the following warning applies.
WARNING
Explosion Hazard
Do not disconnect while circuit is live unless area is known to be non-hazardous.
Substitution of components may impair suitability for Class I, Division 2 or Zone 2.
Safety during operation
Note
High frequency radiation, from mobile phones for example, can cause unintentional
operating situations.
Recall
Note
If a safety case occurs for the KP8F, the customer of the KP8F will be immediately informed
by the Siemens sales department they ordered from and told about suitable measures.