PROFIsafe the easy way to integrate safety

H. BorgmannPhoenix Contact Electronics GmbH

Hendrik BorgmannPhoenix Contact Electronics GmbHBad Pyrmont, Germanyhborgmann@phoenixcontact.com+49 5281 946 21 32

• Safety supporter since 2004• Functional Safety Engineer (TÜV) since 2008• Manager of safety industry solutions & customer support since 2014

Required measures for machine safety

Machinery Directive

Product Safety Law

Harmonised Standards

EN ISO 13849EN 62061

2006/42/EG

Safety Lifecycle for Machines

Structured procedureFor the implementation of all required measures for achieving machine safety, Phoenix Contact works according to the phases of the safety lifecycle*

* The phases of the safety lifecycle in accordance with EN ISO 13849-1 and EN 62061

Our work is:SystematicBindingTraceableReproducibleConsistentSustainableReliable

• Support for all required measures for achieving machine safety

ConsultationModeration incl. documentation templatesEngineeringTraining

• Development and support of industrial solutions• Safety support

Technology and product hotline during office hoursProduct hotline 24 hours a day, 365 days a yearOn-site service

Services for safety lifecycle

What is PROFIsafe?PROFIsafe…

• is the first communication standard according to IEC 61508 to support standard and failsafe communication on one and the same cable

• has been standardized through cooperation between numerous manufacturers and end users in the PROFIBUS User Organization (PNO)

• is listed as an international standard in IEC 61784-3-3• enables failsafe communication for PROFIBUS and

PROFINET based on standard network components

PROFIsafe topology

Safety-integrity up toSIL3 / Kat. 4 / PL e

PROFIsafe-application

Standardized interfaces

PROFINET24V DC400V ACCompressed air

Valve-station

&

Black channel principle

Source: PROFIsafe Profile V2.6 (2013)

PROFIsafe-protocol

PROFINET-IO-data

safestandardsafe standard standard standardstandard

PROFIsafe-telegram

Safe IO-data

max. 12 bytes ormax. 123 bytes

Status-/Controlbyte

1 byte1 byte

Checksum

3 bytes or4 bytes

PROFIsafe-failure detectionConsecutive

numberTimeOut ID sender/

receiverCRC-

checksumCorruption of data - - - XPermanent repetition - X - -Incorrect sequence X - - -Loss X X - -Delay > WD-Time - X - -Insertion X - X -Masquerade - - - XAddressing X - X -Out-of-sequence X - - -

PROFIsafe Devices• ABB PLC+IO-Controller• Euchner MGB Muntifunctional gate box• FANUC Robot controller• FESTO Valve station• KUKA Robot controller• LENZE Failsafe frequency inverter• LEUZE Light curtain• Phoenix Contact IO-system IB IL 24 PSD…• Phoenix Contact PLC+IO-Controller, PROFIsafe-Gateway• SEW Failsafe frequency inverter• SICK Laserscanner, Licht curtain• Siemens PLC+IO-Controller, IOs, etc.• TR-Electronic Encoder• TWK Encoder

Evolution from safety-relays to PROFIsafe

Safety-relayS33 S34

S22 S11 S12 A2

-1SN1

-1SN2

-1SN3

-K4

Estop-Button

Safety-relay

Quit

-1SN1 -1SN2 -1SN3

SafetyProg

1SN1 1SN2 1SN3

Quit

Function-block

SF_EmergencyStop_V1_00

EstopOK

Estop-Button

Estop-Button

Reference high current test laboratory

• Test laboratory for overvoltage protectionproducs and components of Phoenix Contact

• High voltages, high current, magnetic fields• Galvanic insulation of operator panel and

actuators and by optical cables• IO-station is supplied by a transformator and on

high voltage potential for a short moment• IO-controller with PROFIsafe to protect the

operator and the equipment(Short circuit power 240MW)

Application elektrostatic paintshop

• Paint particles find their target by electrostaticload with low loss

• IO-controller is located on ground potential 0V • Some IO-stations are located on high voltage

potential ~ 80.000-90.000Volt• Failsafe connunication by PROFIsafe-protocol• Galvanic insulation by optical cables• Supply-voltages insulated by transformators

Reference Volkswagen Amarok

• Volkswagen factory in Hannover, Germany• Bodyshop-application• IO-controller: Siemens CPU 3xx-F• IO-system: Phoenix Contact INLINE-System

Reference Audi A3 / A4

• Automotive bodyshop application in the Audi factories Ingolstadt, Germany and Györ, Hungary

• PROFIsafe control technology ofPhoenix Contact

• PROFIsafe-applications with safe-IO-devicesof more then 10 different manufacturers

• Up to 100 PROFIsafe-devices at one controller• Application conform to the VASS-Standard

(VW, Audi, Seat, Skoda)

Reference metro Barcelona

• Controlling firebreak doors in metro tunnels• Trains are allowed to pass the tunnels, when

doors are opened and locked by bolts• Network redundancy by an optical ethernet ring• Very robust to electromagnetical fields by optical

cables• The PROFIsafe-application saves a lot of

copper/money because parallel wireing is not required any more

Main cabinet

Distance 2.500m from door cabinet to door cabinet.

Failsafe data-transmission by PROFINET and opticalcables.

Good network-availebility by redundant rings.

Door cabinet

Optical cable

Crane clutch at a nuclear power plant in Germany

• Removeable crane clutch for containers with nuclear contents

• Supply voltage by accumulators • No cables between crane and clutch • PROFIsafe data transmission by Bluetooth• Crane-function and clutch-function are locked

to each other by the PROFIsafe plc system

Crane system of the nuclear power plant in Germany

S7-CPU-F

S7-IOs

PN BK

PSDI

PSDO

FL BT EPA FL BT EPA

PROFINET PROFINETBluetooth

PROFIsafe-communication

Crane-Box Clutch-BoxBluetooth

Thank You very much!!!