Application example  09/2016

Laser Scanner with

Monitoring Case Switching
Safety Integrated

https://support.industry.siemens.com/cs/ww/en/view/58804919
 Warranty and liability

Warranty and liability

Note The Application Examples are not binding and do not claim to be complete
regarding the circuits shown, equipping and any eventuality. The Application
Examples do not represent customer-specific solutions. They are only intended
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We do not accept any liability for the information contained in this document.
Any claims against us – based on whatever legal reason – resulting from the use of
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described in this Application Example shall be excluded. Such an exclusion shall
not apply in the case of mandatory liability, e.g. under the German Product Liability
Act (“Produkthaftungsgesetz”), in case of intent, gross negligence, or injury of life,
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 Table of contents

Table of contents
Warranty and liability ................................................................................................... 2
1 Introduction ........................................................................................................ 4
1.1 Overview............................................................................................... 4
1.2 Mode of Operation ................................................................................ 5
1.3 Components used ................................................................................ 8
2 Engineering ...................................................................................................... 10
2.1 Hardware setup .................................................................................. 10
2.2 Configuration ...................................................................................... 11
2.2.1 Configuration in the TIA Portal ........................................................... 11
Implementing the laser scanner ......................................................... 11
Assigning the PROFIsafe address ..................................................... 14
Configuring F-DI ................................................................................. 15
2.2.2 Configuration in the Configuration & Diagnose Software (CDS) ....... 16
Connection establishment .................................................................. 16
PROFIsafe address ............................................................................ 16
Control inputs ..................................................................................... 17
Field sets ............................................................................................ 17
Monitoring cases ................................................................................ 18
2.2.3 Loading the configuration into the laser scanner ............................... 19
2.3 Operation ............................................................................................ 21
2.4 Error handling ..................................................................................... 24
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2.4.1 LEDs of F-CPU ................................................................................... 24

2.4.2 Indications on the laser scanner ........................................................ 24
3 Useful information ........................................................................................... 25
3.1 SICK S3000 PROFINET IO basics .................................................... 25
3.2 Mode of operation details ................................................................... 30
3.2.1 User program structure ...................................................................... 30
3.2.2 Program block LaserScanner ............................................................. 32
Re-initialization of laser scanner ........................................................ 33
Re-integration of laser scanner .......................................................... 33
3.2.3 Program block: MonitoringCaseSwitching ......................................... 34
3.3 Evaluation of the Safety Function ...................................................... 36
3.3.1 Standards ........................................................................................... 36
3.3.2 Safety function .................................................................................... 36
3.3.3 Evaluation according to IEC 62061 .................................................... 37
3.3.4 Evaluation according to ISO 13849-1 ................................................ 39
4 Appendix .......................................................................................................... 41
4.1 Service and support ........................................................................... 41
4.2 Links and references .......................................................................... 41
4.3 Change documentation ...................................................................... 42

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 1 Introduction
1.1 Overview

1 Introduction
1.1 Overview
An assembly cell with a robot has two workstations that can alternately be freely
accessed by an operator:
 Case 1: While the robot works at station 1, 
the operator can load or unload at
station 2.
 Case 2: While the robot works at station 2, 
the operator can load or unload at
station 1.

During operation, the situation changes due to the movement of the robot:
The hazardous area becomes the working area and vice versa.
The following figure schematically shows the two cases in the assembly cell.

Figure 1-1
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To monitor this assembly cell, a SICK safety laser scanner S3000 is to be used in
conjunction with a fail-safe SIMATIC S7-1500 (F-CPU).

Figure 1-2

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 1 Introduction
1.2 Mode of Operation

The laser scanner monitors a danger area, depending on the robot’s position, and
shuts down its safe OSSD output (Output Signal Switching Device) upon entering
the protective field, which causes the F-CPU to shut down the robot.
The laser scanner S3000 is able to select between up to four monitoring cases,
each with their own protective and warning field.

1.2 Mode of Operation

Setup
Figure 1-3 Structure
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F-CPU and laser scanner communicate via PROFINET with the fail-safe
“PROFIsafe” profile.
The robot’s position is detected via two sensors (e.g. SIRIUS position switch).

Note This application example does not describe how to control the robot. For this, an
error-secure output is set to which an indicator light is connected.

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 1 Introduction
1.2 Mode of Operation

Monitoring cases
Two monitoring cases are implemented in the application example. Depending on
the signals from the position switches, the F-CPU switches between the two
monitoring cases. For this, the F-CPU monitors a normally-closed contact of each
position switch.
 Monitoring case 1: Sensor 1 is “0“, Sensor 2 is “1“  robot is in place 1
 Monitoring case 2: Sensor 1 is “1“, Sensor 2 is “0“  robot is in place 2

Note In the TIA Portal project, the monitoring of up to four monitoring cases is
prepared. By this, the application example can easily be expanded.

Monitoring the case switching

Switching from monitoring case 1 to monitoring case 2 means:
 Sensor 1 changes from “0” to “1”
 Within the switching time, sensor 2 changes from “1” to “0”

The maximum permissible time for switching between two monitoring cases is
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monitored by the F-CPU. The permissible switching time depends on the specific
application and can be configured in the project.
Figure 1-4 shows the correlations for four sensors and switching from monitoring
case 1 to monitoring case 2.

Figure 1-4 Chronological sequence of monitoring case switching

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1.2 Mode of Operation

Control of laser scanner

Via four bits, the F-CPU transmits the current monitoring case to the laser scanner.
Depending on the sensor signals, two of the four bits are always set.
In case of an invalid combination of these control signals, the laser scanner shuts
down the OSSD output safely.
The assignment of the control signals to the monitoring cases can be found in
Table 3-5.
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 1 Introduction
1.3 Components used

1.3 Components used

The application example has been created with the following components:

Hardware components
Table 1-1
Component Numbe Article number Note
r
DIN rail 1 6ES7590-1AE80-0AA0
Power Supply 1 6EP1333-4BA00 70 W
Fail-safe S7-CPU 1 6ES7516-3FN01-0AB0
SIMATIC memory card 1 6ES7954-8LF02-0AA0 24 MB
Digital input module (DI) 1 6ES7521-1BL00-0AB0
Digital output (DQ) 1 6ES7522-1BH00-0AB0
Fail-safe digital input (F- 1 6ES7526-1BH00-0AB0
DI)
Fail-safe digital output (F- 1 6ES7526-2BF00-0AB0
DQ)
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Front connector 4 6ES7592-1BM00-0XB0 Push-in, 40-pin

Position switch 2 3SE5 / 3SF1
Button 3 3SU1 2X break contact, 1x
make contact
Indicator light 3 3SU1 Robot, error lamp,
acknowledgment lamp
SICK S3000 PROFINET 1 1045652
IO
safety laser scanner
Plug connector with 1 2049575
cable
for S3000 PROFINET IO
Configuration cable 1 6034574 Optional to load the
configuration via USB
instead of TCP/IP

Software components
Table 1-2
Component Article number Note
STEP 7 Professional V13 SP1 6ES7822-1AA03-0YA5 Update 9
STEP 7 Safety Advanced V13 SP1 6ES7833-1FA13-0YA5 Update 5
Configuration & Diagnostic V3.7.1
Software (CDS) Supplied with laser
scanner
GSDML file SICK S3000 Supplied with laser
scanner

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 1 Introduction
1.3 Components used

Downloads
Table 1-3
File Content
58793869_Laserscanner_DOC_V20_de.pdf This document
58793869_Laserscanner_PROJ_V20.zip TIA Portal project, configuration file
for CDS
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 2 Engineering
2.1 Hardware setup

2 Engineering
2.1 Hardware setup

Figure 2-1 Circuit diagram F-CPU

L+
M

L+ M L+ M L+ M L+ M L+ M

CPU
DI DQ F-DI F-DQ
1516F

PN 1 2 3 1 2 1 2 21 22 1 2
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Start Error Robot

Stop

Ack AckReq

Pos. switch 1

Pos. switch 2

Table 2-1 Hardware assembly procedure

No. Action
1. Wire the F-CPU according to Figure 2-1.
2. Connect the supply connector of the laser scanner to 24 V DC.
3. Connect the supply connector to the laser scanner.
4. Connect the laser scanner with your network.
5. Connect the configuration cable with your PC/PG and the laser scanner.

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2.2 Configuration

2.2 Configuration
2.2.1 Configuration in the TIA Portal

The enclosed project does not require any further configuration. If you want to
replicate the application example with other components, then the most important
settings are shown in this chapter.

Implementing the laser scanner

To integrate the SICK safety laser scanner into the STEP 7 hardware catalog, a
device master file (GSDML file) is required. This file comes with the laser scanner
or can be downloaded from the product website at \4\.

Note When opening the project, the GSDML file is automatically installed.

To implement the laser scanner into a new project, proceed as follows.

Table 2-2
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Action
1. In the TIA Portal in the menu list, click on “Options > Manage general station
description files (GSD)”.

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2.2 Configuration

Action
2. Click on the “...” button and select the file path to the GSDML file.

3. Select the GSDML file to be installed and click “Install”.

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4. Open “Devices & networks” from the project navigation.

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2.2 Configuration

Action
5. Per Drag&Drop, drag the “S3000” laser scanner from the hardware catalogue
into the work area. You can find it under “Other field devices”.
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6. Click on “Not assigned” and assign the laser scanner to the F-CPU.

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2.2 Configuration

Assigning the PROFIsafe address

Table 2-3
Action
1. Open “Devices & networks” from the project navigation in the TIA Portal.
2. Double-click on the laser scanner.
3. In the device overview, select the line “S3000 In/Out_1“.

4. Open the properties in the inspector window and select “PROFIsafe“ in the area
navigation.
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5. In “F_Dest_Add“, enter a clear PROFIsafe or destination address. The same

address also needs to be configured in the CDS.

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2.2 Configuration

Configuring F-DI
Both position switches are connected to an F-DI. Since the function block
„MonitoringCaseSwitching“ checks the plausibility of the signals, the sensor
evaluation in the F-DI is set to „1oo1 evaluation“. Proceed as follows.

Table 2-4
Action
6. Open “Devices & networks” from the project navigation in the TIA Portal.
7. Double-click on the F-CPU.
8. Double-click on the F-DI to open the properties.
9. Select “Inputs 0 -15 > Inputs > Channel parameters” in the area navigation.
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10. Under “Sensor evaluation“, select “1oo1 evaluation“.

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2.2 Configuration

2.2.2 Configuration in the Configuration & Diagnose Software (CDS)

This chapter describes the most important settings that were made in the
application example for the SICK safety laser scanner:

Note It is not necessary to make the settings in the application example, since they
are already included in the supplied configuration file. The present chapter is
only for your information.

Prerequisites
For the configuration, the laser scanner must be connected to the PG/PC. The
software “Configuration & Diagnose Software (CDS)” from the SICK company must
be installed on the PG/PC.
The CDS can be used to configure all available parameters of the S3000 and
define the field geometries of the protective fields and warning fields.
The result of the configuration is stored in a configuration file (.skp). The
configuration file is downloaded to the laser scanner.

Connection establishment
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For the application example, the configuration was performed via the local serial
interface of the laser scanner.

PROFIsafe address
To ensure that the laser scanner can be operated as a PROFIsafe node, it must
have its own PROFIsafe address. The PROFIsafe address of the laser scanner
was taken from the TIA Portal project (see chapter 2.2.1) and entered in the CDS.

Figure 2-2

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2.2 Configuration

Control inputs
Two monitoring cases are implemented in the application example, four monitoring
cases are prepared. Therefore, the “Input A-B” case is configured.

Figure 2-3

Field sets
Two field sets are configured:
 Field set 1 (protective field 1, warning field 1)
 Field set 2 (protective field 2, warning field 2)
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Figure 2-4

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2.2 Configuration

Monitoring cases
Two monitoring cases are configured:
 Monitoring case 1 with field set 1
 Monitoring case 2 with field set 2

Figure 2-5

Restart
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The “without restart interlock” case is configured. A restart interlock is already

implemented in the STEP 7 program.

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2.2 Configuration

2.2.3 Loading the configuration into the laser scanner

This chapter shows you how to load the configuration into the laster scanner via
TCP/IP.

NOTE You must assign an IP address to the laser scanner before you can load the
configuration into it. This happens automatically when you download the TIA
Portal project to the F-CPU.

NOTE Alternatively you can load the configuration with a USB configuration cable by
dragging the laser scanner to the COM port in CDS.

To load the configuration via TCP/IP, proceed as follows.

Table 2-5
Action
1. Connect the laser scanner with your computer via a network.
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2. Open the CDS.

3. Open the configuration file
“58804919_Laserscanner_S71500_CONFIG_V20.skp” from the supplied
archive.
4. With the right mouse button click “S3000 (192.168.0.2)” and select “Connect”.

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2.2 Configuration

Action
5. With the right mouse button, click on the device “S3000 PROFINET IO“ and
select “Configuration draft > Transfer”.

6. Log in as “Authorized client” with the factory set password “SICKSAFE“.

Note: Change this password for security reasons before commissioning
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your machine.
7. Confirm the dialog with “Continue”.
8. Check the protocol and release the configuration by clicking on the “Release”
button.

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2.3 Operation

2.3 Operation
Test of monitoring case 1:
Table 2-6
No. Action Explanation Indicator light Laser scanner
1)
Robot Error Display
1 Press the Acknowledgment off off No error
acknowledgment necessary
pushbutton after power on
2 Press the start --- on off No error
pushbutton
3 Press the stop --- off off No error
pushbutton
4 Press the start --- on off No error
pushbutton
5 Set object in warning Non-active on off No error
field 2 monitoring case
6 Set object in protective Non-active on off No error
field 2 monitoring case
7 Set object in warning Active on off Warning field violated
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field 1 monitoring case

8 Set object in protective Active off on Protective field
field 1 monitoring case violated
9 Press the start --- off on Protective field
pushbutton violated
10 Remove object from field Restart lock, off on No error
set 1 acknowledgment lamp
flashes
11 Press the start Restart interlock off on No error
pushbutton
12 Press the --- off off No error
acknowledgement
pushbutton
13 Press the start --- on off No error
pushbutton
1)
See chapter 2.4.2.

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2.3 Operation

Setting monitoring case 2

Table 2-7
No. Action Explanation Indicator light Laser scanner
1)
Robot Error Display
1 Switch ... Switching must be on off No error
performed within the
...from monitoring case 1: time
“maxSwitchingTime“,
Sensor 1 = “0” which is
Sensor 2 = “1” parameterized in the
“Laserscanner”
...to monitoring case 2: block.
Sensor 1 = “1”
Sensor 2 = “0”
1)
See chapter 2.4.2.

Test of monitoring case 2:

Table 2-8
No. Action Explanation Indicator light Laser scanner
1)
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Robot Error Display

2 Set object in warning Non-active 
monitoring on off No error
field 1 case
3 Set object in protective Non-active 
monitoring on off No error
field 1 case
4 Set object in warning Active on off Warning field violated
field 2 monitoring case
5 Set object in protective Active off on Protective field
field 2 monitoring case violated
6 Press the start off on Protective field
pushbutton violated
7 Remove object from field Restart lock, off on No error
set 2 acknowledgment lamp
flashes
8 Press the start Restart interlock off on No error
pushbutton
9 Press the off off No error
acknowledgement
pushbutton
10 Press the start on off No error
pushbutton
1)
See chapter 2.4.2.

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2.3 Operation

Simulation of an error during monitoring case switching

Table 2-9
No. Action Explanation Indicator light Laser scanner
1)
Robot Error Display
1 Sensor 1: Non-permissible switching off on Incorrect operation of
unchanged “1“ state of the sensors the control inputs
Sensor 2:
from “0“ to “1“
2 Press the start off on Incorrect operation of
pushbutton the control inputs
3 Press the off on Incorrect operation of
acknowledgment the control inputs
pushbutton
4 Press the start off on Incorrect operation of
pushbutton the control inputs
5 Sensor 1: After the error removal, off on Initialization
unchanged “1“ the laser scanner is
Sensor 2: automatically reinitialized
from “1“ to “0“ and reintegrated.
8 Press the Acknowledgment lamp off off No error
acknowledgment flashes as soon as laser
pushbutton scanner is ready
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1)
See chapter 2.4.2.

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2.4 Error handling

2.4 Error handling

2.4.1 LEDs of F-CPU

Table 2-10 LEDs of F-CPU

LED Explanation
Robot Error Acknowledgment

off off off No start command

on off off Robot is active
off on off Error detected
off on flashes Error fixed, user acknowledgment
required

2.4.2 Indications on the laser scanner

The display of the laser scanner shows the laser scanner states. The following
table shows the most important states for this application example.
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Table 2-11 Information on the laser scanner

State Laser scanner display Explanation
LED Segment
No error Green: on ---

Warning field Green: on Object in the warning field

violated Yellow: on
Protective field Green: on Object in the protective field
violated Yellow: on
Incorrect Green: on Incorrect operation of the control
operation of the inputs for switching the monitoring
control inputs cases during operation
Incorrect Green: on Incorrect operation of the control
operation of the inputs for switching the monitoring
control inputs cases during initialization

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 3 Useful information
3.1 SICK S3000 PROFINET IO basics

3 Useful information
3.1 SICK S3000 PROFINET IO basics
The application example focuses on the use of a safety laser scanner for SIMATIC
Safety Integrated for Factory Automation.
A safety laser scanner from SICK is used as an example.
This chapter describes the basics of the SICK S3000 PROFINET IO safety laser
scanner.

Field of Application
The S3000 PROFINET IO safety laser scanner is used for personnel and plant
protection. The laser scanner allows monitoring of hazardous areas on machines
or vehicles.
Examples of applications:
 Protection of machines with changing hazardous areas
 Hazardous area protection in robot cells and production systems
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Mode of Operation
The S3000 is an optical sensor that scans its surroundings in two dimensions using
infrared laser beams. The S3000 works on the principle of time of flight
measurement. The figure below shows the principle of operation.

Figure 3-1

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 3 Useful information
3.1 SICK S3000 PROFINET IO basics

The S3000 sends out very short light pulses (S). When the light is incident on an
object, it is reflected and received by the safety laser scanner (E). From the time
between sending and receiving (Δt), the S3000 calculates the distance to the
object.
In the S3000, there is also a mirror rotating at a constant speed that deflects the
light pulses so that they cover an arc of 190° (Figure 3-2). By determining the angle
of rotation of the mirror, the S3000 determines the direction of the object.
From the measured distance and the direction of the object, the safety laser
scanner determines the exact position of the object.

Figure 3-2
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Protective field and warning field

The protective field (Figure 3-3 (1)) secures the hazardous area on a machine or
vehicle. As soon as the safety laser scanner detects an object in the protective
1)
field, the S3000 switches the OSSD signal output to the off status (“0” signal) and
thus initiates the shutdown of the machine or stop of the vehicle.
The warning field (Figure 3-3 (2)) can be defined so that the safety laser scanner
detects an object before the actual hazardous area and, for example, triggers a
warning signal.

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3.1 SICK S3000 PROFINET IO basics

Figure 3-3

1)
OSSD (output signal switching device): Signal output of the protective device that
is used to stop the dangerous movement.

Field set
Protective field and warning field form a pair, the so-called field set. With the aid of
the Configuration & Diagnostic Software, these field sets are configured and
transferred to the S3000. Up to eight field sets can be defined and saved in the
S3000 PROFINET IO.
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Monitoring case
With the S3000 safety laser scanner, you can define different monitoring cases to
match the protective fields and warning fields to the situation on the machine. This
allows situation-specific monitoring of changing hazardous areas, for example
during the different production phases of a machine.
When configuring using the Configuration & Diagnostic Software, a monitoring
case x is assigned a field set y (protective field y, warning field y).

Example
Figure 3-4 shows an example of hazardous area protection with two areas to be
monitored. Two monitoring cases are defined in the robot cell shown in this figure:
 Monitoring case 1: Warning field 1 (WF1) and protective field 1 (SF1)
 Monitoring case 2: Warning field 2 (WF2) and protective field 2 (SF2)

Depending on where the robot is located in the robot cell, the respective monitoring
case is active:
 The robot is located on the left: Monitoring case 2 is active
 The robot is located on the right: Monitoring case 1 is active

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Figure 3-4

In the figure, the robot is located on the right of the robot cell, i.e. monitoring case 1
is active. This means:
 When the operator enters protective field 1, the robot will stop.
 The operator may enter protective field 2 and warning field 2.
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Communication via PROFINET

The S3000 PROFINET IO is operated as an IO device on PROFINET. All input
signals and output signals of the laser scanner are exchanged with the IO
controller via the PROFINET interface.

Secure Communication
Safety-related components and standard components can be operated together on
PROFINET. This is enabled by PROFIsafe, an extension of PROFINET.
PROFIsafe defines how safety-related IO devices (e.g., a SICK safety laser
scanner) securely communicate with safety-related IO controllers (e.g., a SIMATIC
F-CPU) via a network.

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3.1 SICK S3000 PROFINET IO basics

Process image of the SIMATIC F-CPU

F-CPU and safety laser scanner cyclically exchange signals via the process image.

Figure 3-5

Input signals
laser scanner

F-CPU (IO controller) Safety

laser scanner
User Process image
(IO device)
program outputs

6 bytes
PROFINET
Process image with
inputs PROFIsafe
6 bytes
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Output signals
laser scanner

Examples of input signals of the laser scanner (F-CPU outputs):

 Number of the monitoring case
 Reset protective field
 Initialize

Examples of output signals of the laser scanner (F-CPU inputs):

 Protective field unoccupied
 Warning field unoccupied
 Contamination

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3.2 Mode of operation details

3.2 Mode of operation details

3.2.1 User program structure

Overview
Figure 3-6

Main StartStop

Blink

Monitoring
Main Laser
Case
Safety Scanner
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Switching

ACK_GL

Program blocks of the standard user program

Table 3-1
Program block Function
StartStop Represents the standard user program for controlling the
robot
Blink Generates a blinking signal for the acknowledgment lamp

Program blocks of the safety program

Table 3-2
Program block Function
MainSafety  Calls the block “LaserScanner”
 Switches the actuator
 Re-integrates passivated F-I/O
LaserScanner  Calls the block “MonitoringCaseSwitching“
 Evaluates and controls the laser scanner
MonitoringCaseSwitching Monitoring case switching
ACK_GL Re-integrates passivated F-I/O

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3.2 Mode of operation details

Data exchange between standard user program and safety program

In order to exchange data between the standard user program and the safety
program, two global data blocks are used:
 DataToSafety
 DataFromSafety

The DataToSafety data block is written by the standard user program and read by
the safety program. The DataFromSafety data block is written by the safety
program and read by the standard user program.

Figure 3-7 Data exchange

DataTo
Safety

Standard user
Safety program
program

DataFrom
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Safety

The standard user program transmits the control signal “condition” to safety
program.
The safety program transmits the following signals to the standard user program:
 Release signal “release”
 “ackReq“: Acknowledgment required by the user

Note More information on the exchange of data between the standard user program
and the safety program can be found under \3\.

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3.2 Mode of operation details

3.2.2 Program block LaserScanner

Function
The program block has the following functions:
 Evaluating the OSSD signals
 Calling up MonitoringCaseSwitching to switch the monitoring case
 Evaluating errors and restart lock
 Automatically re-initializing the laser scanner after an invalid control signal to
switch the monitoring case
 Automatically re-integrating the laser scanner
 Outputting the release signal

Parameters of the function block

Figure 3-8 Function block “LaserScanner“
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Table 3-3 Parameter “LaserScanner“

Parameter Declaration Type Description
OSSD IN Bool OSSD signal of laser scanner
1)
pos1 IN Bool Sensor for monitoring case 1
1)
pos2 IN Bool Sensor for monitoring case 2
1)
pos3 IN Bool Sensor for monitoring case 3
1)
pos4 IN Bool Sensor for monitoring case 4
maxSwitchingTime IN Time Maximum permissible switching time
ackReqLS IN Bool Bit “ACK_REQ“ of the F-I/O data block of the laser
scanner
ack IN Bool Acknowledgment by the user

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3.2 Mode of operation details

Parameter Declaration Type Description

release OUT Bool Release signal of the safety function
error OUT Bool An error has occurred
ackReq OUT Bool Acknowledgment required by the user
2)
caseA1 OUT Bool Control signals for switching the monitoring cases
caseA2 OUT Bool
caseB1 OUT Bool
caseB2 OUT Bool
initLS OUT Bool Signal for re-initializing the laser scanner after an invalid
control signal
ackReiLS OUT BOOL Bit “ACK_REI“ of the F-I/O data block of the laser
scanner
1)
Non-existent sensors must be interconnected with a “1” signal.
2)
Table 3-5 shows the assignment of the control signals

Re-initialization of laser scanner

When receiving invalid control signals (e.g. no sensor is “0”), the laser scanner
switches to an error state that can only be exited via a restart or re-initialization.
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A re-initialization is triggered automatically by the “Laserscanner” block as soon as

the position switches output valid signals again. The re-initialization of the laser
scanner takes a few seconds. The re-integration is carried out automatically. After
that, the error, which has been caused by the invalid signals of the position
switches, must be acknowledged by the user.

Figure 3-9

Re-integration of laser scanner

During a passivation of the laser scanner (e.g. communication error or re-
initialization due to invalid control signals), this is recognized as an error in the
“Laserscanner” function block and requires an acknowledgment by the user.
To prevent the user from having to press the acknowledgment button twice in a row
(re-integration of laser scanner and acknowledgment of error), the laser scanner is
always re-integrated automatically.

Figure 3-10

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3.2 Mode of operation details

3.2.3 Program block: MonitoringCaseSwitching

Function
Monitoring case switching
This block implements monitoring case switching of max. four monitoring cases.
For this purpose, the F-CPU reads in the status of max. 4 sensors, derives the
monitoring case number from this information and writes the respective control
signals (A1, A2, B1, B2) to the laser scanner. The laser scanner activates the field
set that is allocated to the monitoring case number.
One sensor (break contact) is allocated to each monitoring case:
 Monitoring case 1: Sensor 1
 Monitoring case 2: Sensor 2
 Monitoring case 3: Sensor 3
 Monitoring case 4: Sensor 4

Monitoring case x is selected when the following conditions apply:

 The sensor for monitoring case x is active (“0” signal)
 All other sensors are not active (“1” signal)
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Switching time monitoring

The time that is required to switch between two monitoring cases (switching time)
is monitored. The switching time can be parameterized on the block.
The following conditions are monitored:
 After switching a sensor from “0” to “1”, another sensor must switch from “1” to
“0” within the monitoring time.
 After switching, exactly one of the following cases must be present:
– Sensor 1 has “0” signal and all other sensors have “1” signal
– Sensor 2 has “0” signal and all other sensors have “1” signal
– Sensor 3 has “0” signal and all other sensors have “1” signal
– Sensor 4 has “0” signal and all other sensors have “1” signal
If the above conditions are not met, an error has occurred.

Response in the event of an error

The control signals (from the F-CPU to the laser scanner) for switching the
monitoring cases (A1, A2, B1, B2) are deleted (“0”).
In the laser scanner, the deletion of the control signals (“0”) causes the following
actions:
 Reset of the OSSD output, which causes the F-CPU to shut down the robot.
 Error display on the laser scanner: “Incorrect operation of the control inputs”.

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3.2 Mode of operation details

Implementation in the application example

Two monitoring cases are implemented in the application example. The code is
prepared for max. 4 monitoring cases. To use additional monitoring cases, perform
the following steps:
 Configure the additional field sets and allocate the monitoring cases using the
CDS
 Interconnect the additional sensors for the monitoring cases at the call
interface of the program block

Parameters of the function block

Figure 3-11 Function block “MonitoringCaseSwitching“

Table 3-4 Parameter “MonitoringCaseSwitching“

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Parameter Declaration Type Description

1)
pos1 IN Bool Sensor for monitoring case 1
1)
pos2 IN Bool Sensor for monitoring case 2
1)
pos3 IN Bool Sensor for monitoring case 3
1)
pos4 IN Bool Sensor for monitoring case 4
maxSwitchingTime IN Time Maximum permissible switching time
2)
caseA1 OUT Bool Control signals for switching the monitoring cases
caseA2 OUT Bool
caseB1 OUT Bool
caseB2 OUT Bool
error OUT Bool Error when monitoring the switching time
1)
Non-existent sensors must be interconnected with a “1” signal.
2)
The following table shows the assignment.

Table 3-5 Control signals to control the current monitoring case

Sensor for monitoring case Control signals from F-CPU to laser Monitorin
scanner g case
Sensor 1 Sensor 2 Sensor 3 Sensor 4 Bit B2 Bit B1 Bit A2 Bit A1
0 1 1 1 0 1 0 1 1
1 0 1 1 0 1 1 0 2
1 1 0 1 1 0 0 1 3
1 1 1 0 1 0 1 0 4

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3.3 Evaluation of the Safety Function

3.3 Evaluation of the Safety Function

3.3.1 Standards

For an evaluation of the safety function, the following versions of the standards
were used:

Table 3-6
Version Mentioned below
EN ISO 13849-1:2015 ISO 13849-1
EN 62061:2005 + A2:2015 IEC 62061

3.3.2 Safety function

The following safety function is important for the further considerations:

“If the laser scanner’s safety field is harmed during the current monitoring
case, the robot needs to be shut down.”
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Note This application example ignores the “React” subsystem. Therefore, the
evaluation of the safety function is incomplete.

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3.3 Evaluation of the Safety Function

3.3.3 Evaluation
according to IEC 62061

Detection
The subsystem “Capture” consists of the following safety-related parts:
 Safety laser scanner
 Position switch

The failure probabilities of the safety-related parts are summed up.

Both position switches are considered as a non-equivalent, two-channel system.
The following table lists possible errors of the position switches and their
recognition by the safety program.

Table 3-7
Error Recognition
Wire break If at the time of the wire break, the robot activates the
concerned position switch (”0” signal), the error is
recognized at the latest when the robot changes its
position (both sensors report “0”). Otherwise, the error is
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immediately recognized.
At any point, the relevant protection field is active.
Actuator break or position If at the time of the break, the robot activates the
switch break-off unconcerned position switch (”0” signal), the error is
recognized at the latest when the robot changes its
position (both sensors report “1”).
Otherwise, the error is immediately recognized.
At any point, the relevant protection field is active.
Jamming of actuator or If at the time of the error, the robot activates the
welding of a contact concerned position switch (”0” signal), the error is
recognized at the latest when the robot changes its
position (both sensors report “0”). Otherwise, the error is
immediately recognized.
At any point, the relevant protection field is active.

Due to the evaluation of the signals in the “MonitoringCaseSwitching“ function

block, a diagnostic coverage of 99 % can be assumed.

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3.3 Evaluation of the Safety Function

The following table shows the parameters of the evaluation of the position
switches.

Table 3-8
Parameter Value Explanation Definition
B10 10,000,000 Manufacturer information SIEMENS AG
Switching cycles
Percentage 0.2 (20%) Manufacturer information
of dangerous failures
T1 20 years Manufacturer information
Lifetime
Subsystem architecture D 2 channels, 2 components: User
Single fault tolerance with
diagnostic function
Operations/ 6/hour Assumption
Test interval
 (CCF factor) 0.1 (10%) For installations according to
Susceptibility to common IEC 62061, a CCF factor of 0.1
cause failures (10%) is achieved.
DC ≥ 0,99 Plausibility check by the safety
Diagnostic coverage (99%) program
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Table 3-9
Component PFHD SILCL Definition
-8
S3000 safety laser scanner 8,00 ∙ 10 SILCL 2 SICK AG
-9
Position switch 1,20 ∙ 10 SILCL 3 Calculation
-8
Total 8,12 ∙ 10 SILCL 2 Calculation

Evaluation
Table 3-10
Component PFHD SILCL Definition
-9
CPU 1516F-3PN/DP 2,00 ∙ 10 SILCL 3 SIEMENS AG
incl. PROFIsafe
-9
ET 200MP F-DI 1,00 ∙ 10 SILCL 3
-9
ET 200MP F-DQ 2,00 ∙ 10 SILCL 3
-9
Total 5,00 ∙ 10 SILCL 3

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3.3 Evaluation of the Safety Function

Result
Table 3-11
Subsystem PFHD SIL achieved
-8
Detection 8,12 ∙ 10 SILCL 2
-9
Evaluation 5,00 ∙ 10 SILCL 3
Reaction --- ---
-8
Total 8,62 ∙ 10 SILCL 2
SIL 2

Note The “React” subsystem must comply with a SILCL 2 in order for the safety
function to reach SIL 2.

3.3.4 Evaluation according to ISO 13849-1

Detection
The same explanations as in chapter 3.3.3 apply.
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The following table shows the parameters of the evaluation of the position
switches.

Table 3-12
Parameter Value Explanation Definition
B10 10,000,000 Manufacturer information SIEMENS AG
Switching cycles
Percentage 0.2 (20%) Manufacturer information
of dangerous failures
T1 175,200 h Manufacturer information
Lifetime (20 years)
Architecture Category 4 2 channels, 2 component User

Operations/ 6/hour Assumption

Test interval
CCF measures ≥ 65 Sufficient measures against
(points) CCF according to ISO 13849-1
Susceptibility to table F.1 have to be provided
common cause failures
DC ≥ 0,99 Plausibility check by the safety
Diagnostic coverage (99%) program

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3.3 Evaluation of the Safety Function

Table 3-13
Component PFHD PL Definition
-8
S3000 safety laser scanner 8,00 ∙ 10 PL d SICK AG
-8
Position switch 2,47 ∙ 10 PL e Calculation
-7
Total 1,04 ∙ 10 PL d Calculation

Evaluation
Table 3-14
Component PFHD PL Definition
-9
CPU 1516F-3PN/DP 2,00 ∙ 10 PL e SIEMENS AG
incl. PROFIsafe
-9
ET 200MP F-DI 1,00 ∙ 10 PL e
-9
ET 200MP F-DQ 2,00 ∙ 10 PL e
-9
Total 5,00 ∙ 10 PL e

Result
Table 3-15
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Subsystem PFHD PL achieved

-7
Detection 1,04 ∙ 10 PL d
-9
Evaluation 5,00 ∙ 10 PL e
Reaction --- ---
-7
Total 1,09 ∙ 10 PL d
PL d

Note The “React” subsystem must comply with a PL d in order for the safety function
to reach PL d.

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 4 Appendix
4.1 Service and support

4 Appendix
4.1 Service and support
Industry Online Support
Do you have any questions or need assistance?
Siemens Industry Online Support offers round the clock access to our entire
service and support know-how and portfolio.
The Industry Online Support is the central address for information about our
products, solutions and services.
Product information, manuals, downloads, FAQs, application examples and videos
– all information is accessible with just a few mouse clicks at:
https://support.industry.siemens.com/

Technical Support
The Technical Support of Siemens Industry provides you fast and competent
support regarding all technical queries with numerous tailor-made offers
– ranging from basic support to individual support contracts. You send queries to
Technical Support via Web form:
www.siemens.com/industry/supportrequest
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Service offer
Our range of services includes, inter alia, the following:
 Product trainings
 Plant data services
 Spare parts services
 Repair services
 On-site and maintenance services
 Retrofitting and modernization services
 Service programs and contracts
You can find detailed information on our range of services in the service catalog:
https://support.industry.siemens.com/cs/sc

Industry Online Support app

You will receive optimum support wherever you are with the "Siemens Industry
Online Support" app. The app is available for Apple iOS, Android and Windows
Phone:
https://support.industry.siemens.com/cs/ww/en/sc/2067

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 4 Appendix
4.2 Links and references

4.2 Links and references

Table 4-1 Links and references
No. Topic
\1\ Siemens Industry Online Support
https://support.industry.siemens.com
\2\ Entry page of this application example
https://support.industry.siemens.com/cs/ww/en/view/58804919
\3\ SIMATIC Safety – Configuring and Programming
https://support.industry.siemens.com/cs/ww/en/view/54110126
\4\ Product website SICK S3000 PROFINET IO
https://www.sick.com/us/en/opto-electronic-protective-devices/safety-laser-
scanners/s3000-profinet-io-advanced/s30a-6111cp/p/p120141

4.3 Change documentation

Table 4-2 Change documentation
Version Date Modifications
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V1.0 03/2012 First version

V2.0 09/2016 Exchange of S7-300 for a S7-1500
Migration to TIA Portal V13 SP1

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