ABB AC500-S User Manual

Safety User Manual
V1.0.4
Original Instructions
AC500-S

ABB AC500-S Specifications

General

Programming Software	Automation Builder
Protection Class	IP20
Communication Protocols	Ethernet/IP, Modbus, PROFINET, PROFIBUS, CANopen
Programming Languages	IEC 61131-3 (LD, FBD, IL, ST, SFC)
Safety Standard	IEC 61508
Power Supply	24 V DC
Certifications	CE, UL, cUL, ATEX

Summary

1 Introduction

1.1 Purpose

Describes the manual's objective and scope, covering installation, operation, and maintenance.

1.2 Document history

Lists revisions and changes made to the document across different versions.

1.3 Validity

States that data and illustrations are non-binding and subject to product development changes.

1.4 Important user information

Highlights crucial notices and warnings for safe operation and potential hazards.

1.5 Definitions, expressions, abbreviations

Provides a glossary of technical terms, expressions, and abbreviations used in the manual.

1.6 Functional safety certification

Details the safety certifications and standards met by the AC500-S modules.

1.7 References/Related documents

Lists other relevant documents, standards, and resources for further information.

2 Overview of AC500-S Safety PLC

2.1 Overview

General introduction to the AC500-S Safety PLC system and its capabilities.

2.1.1 System

Describes the AC500-S as an integrated part of the AC500 platform.

2.1.2 Safety components

Lists the key safety-related hardware components of the AC500-S system.

2.2 Intended use

Specifies the proper applications and user responsibilities for AC500-S components.

2.3 Safety loop

Explains the components that constitute a typical safety loop.

2.4 Safety values

Presents safety-related values like SIL, PL, DC, PFHd, MTTFd, and T1.

2.5 Qualified personnel

Defines the necessary qualifications for personnel using the AC500-S system.

2.7 Installation of safety modules

Provides essential rules and considerations for installing safety modules.

2.12 Safe communication

Details the requirements for secure data transfer in safety applications.

2.13 Safety function and fault reaction

Describes how safety functions operate and react to system faults.

2.13.1 Safety CPU (SM560-S)

Explains the safety function and fault reaction of the SM560-S Safety CPU.

2.13.2 Safety module with safety input channels (DI581-S, DX581-S and AI581-S)

Details safety functions and fault reactions for input modules.

2.13.3 Safety module with safety output channels (DX581-S)

Details safety functions and fault reactions for output modules.

2.14 Safety function test

Outlines the necessary steps for testing safety functions and system acceptance.

2.15 Troubleshooting

Provides solutions for common problems and error messages encountered.

3 AC500-S Safety Modules

3.1 SM560-S Safety CPU

Details about the SM560-S Safety CPU hardware, including elements and indicators.

3.1.1 Purpose

Explains the intended use and function of the SM560-S Safety CPU in safety applications.

3.1.2 Functionality

Describes the operational capabilities and features of the SM560-S Safety CPU.

3.1.2.2 Floating-point operations

Details the handling and limitations of floating-point arithmetic in the Safety CPU.

3.1.3 Mounting, dimensions and electrical connection

Provides instructions for physical installation and electrical connections.

3.1.4 Diagnosis and LED status display

Explains LED indicators for status and error diagnostics on the Safety CPU.

3.1.5 SM560-S module states

Describes the different operational states of the SM560-S module.

3.1.6 SM560-S and PM5xx interaction

Describes communication and interaction between Safety CPU and Non-Safety CPU.

3.1.7 Technical data

Lists key technical specifications and operating parameters for the SM560-S CPU.

3.2 Generic Safety I/O module behaviour

General information on the behavior and states of safety I/O modules.

3.2.1 Overview

Introduction to safety I/O modules and their compatibility within the AC500 system.

3.2.2 Safety I/O module states

Describes the operational states of safety I/O modules and their transitions.

3.2.2.1 Description of Safety I/O module states

Details the specific states (INIT, RUN, SAFE STOP, DEBUG) and their meanings.

3.2.3 Undervoltage/Overvoltage

Describes module behavior and passivation during voltage fluctuations.

3.2.4 Diagnosis

Explains how to diagnose issues using LEDs and error messages.

3.3 DI581-S digital safety input module

Details about the DI581-S digital safety input module.

3.3.1 Purpose

Explains the intended use of the DI581-S module as an expansion module.

3.3.2 Functionality

Describes the features and capabilities of the DI581-S module, including test pulses.

3.3.3 Mounting, dimensions and electrical connection

Instructions for physical installation and electrical wiring of the module.

3.3.5 I/O configuration

Explains that configuration data is stored on SM560-S and PM5xx CPUs.

3.3.6 Parameterization

Details the process of setting module parameters using configuration software.

3.3.7 Circuit examples

Provides examples of electrical connections for safety digital inputs.

3.3.8 LED status display

Explains the meaning of status LEDs on the DI581-S module.

3.3.9 Technical data

Lists technical specifications, including signal voltage and cable length.

3.3.10 Ordering data

Provides part numbers and order codes for the DI581-S module.

3.4 DX581-S digital safety input/output module

Details about the DX581-S digital safety input/output module.

3.4.1 Purpose

Explains the intended use of the DX581-S module as an expansion module.

3.4.2 Functionality

Describes the features and operations of the DX581-S module, including test pulses.

3.4.3 Mounting, dimensions and electrical connection

Instructions for physical installation and electrical wiring of the module.

3.4.5 I/O configuration

Explains that configuration data is stored on SM560-S and PM5xx CPUs.

3.4.6 Parameterization

Details the process of setting module parameters using configuration software.

3.4.7 Circuit examples

Provides electrical connection examples for DX581-S input/output.

3.4.8 LED status display

Explains the meaning of status LEDs on the DX581-S module.

3.4.9 Technical data

Lists technical specifications for the DX581-S module.

3.4.10 Ordering data

Provides part numbers and order codes for the DX581-S module.

3.5 AI581-S analog safety input module

Details about the AI581-S analog safety input module.

3.5.1 Purpose

Explains the intended use of the AI581-S module for analog inputs.

3.5.2 Functionality

Describes the features and operations of the AI581-S module, including input ranges.

3.5.3 Mounting, dimensions and electrical connection

Instructions for physical installation and electrical wiring of the analog module.

3.5.5 I/O configuration

Explains that configuration data is stored on SM560-S and PM5xx CPUs.

3.5.6 Parameterization

Details parameter settings for the AI581-S module.

3.5.7 Circuit examples

Provides electrical connection examples for analog inputs.

3.5.8 LED status display

Explains the meaning of status LEDs on the AI581-S module.

3.5.9 Technical data

Lists technical specifications for the AI581-S analog input module.

3.5.10 Ordering data

Provides part numbers and order codes for the AI581-S module.

3.6 TU582-S Safety I/O Terminal Unit

Details about the TU582-S Safety I/O Terminal Unit and its functionality.

3.6.1 Functionality

Describes the functionality of the TU582-S terminal unit for safety I/O modules.

3.6.2 Mounting, dimensions and electrical connection

Instructions for physical installation and electrical connections of the terminal unit.

3.6.3 Technical data

Lists technical specifications for the TU582-S terminal unit.

3.6.4 Ordering data

Provides part numbers and order codes for the TU582-S terminal unit.

4 Configuration and programming

4.1 Overview

General overview of the configuration and programming process for AC500-S Safety PLCs.

4.2 Workflow

Outlines the engineering workflow for configuring and programming safety and non-safety modules.

4.3 System configuration and programming

Provides a step-by-step explanation for configuring and programming the AC500-S Safety PLC.

4.3.1 Installation

Instructions for installing the necessary software tools like Control Builder Plus.

4.3.2 License activation

Details the process for activating software licenses for AC500-S Safety features.

4.3.3 Creation of new project and user management

Steps for creating projects and managing user access to safety modules.

4.3.4 Working with PROFINET / PROFIsafe F-Devices

Guidance on configuring and integrating third-party PROFINET/PROFIsafe F-Devices.

4.3.5 Instantiation and configuration of safety modules/Definition of variable names

Steps for adding safety modules and defining variable names per guidelines.

4.3.6 Programming of AC500-S Safety CPU

Instructions and guidelines for programming the SM560-S Safety CPU.

4.3.7 Checking of program and system configuration

Steps to verify the program and system configuration against checklists.

4.4 CoDeSys Safety programming guidelines

Rules and best practices for programming safety applications using CoDeSys Safety.

4.4.1 Overview

General introduction to the CoDeSys Safety programming guidelines.

4.4.1.1 Target group

Identifies the intended audience for the programming guidelines.

4.4.1.2 Requirements

Lists necessary knowledge for understanding the CoDeSys programming guidelines.

4.4.1.3 Terms

Defines key terms used within the CoDeSys programming guidelines.

4.4.2 Framework

Describes the general framework and components for CoDeSys Safety programming.

4.4.2.1 Safety Integrity Level (SIL)

Discusses the SIL levels supported by CoDeSys V2.3 for safety applications.

4.4.2.2 Approved CoDeSys version

Lists the approved CoDeSys versions for creating safety-oriented applications.

4.4.2.3 Control-specific application notes

Provides important notes specific to safety controller applications in CoDeSys.

4.4.2.4 Application creation procedure

Details the standard procedure for creating safety applications.

4.4.2.5 Settings

Specifies the required system settings within CoDeSys for safety programming.

4.4.2.6 Classification

Discusses the classification of language constructs used in safety applications.

4.4.3 Language-specific programming guidelines

Guidelines tailored to specific programming languages like ST, FBD, and LD.

4.4.3.1 Safety-related restrictions for developers

Lists safety-related restrictions and recommendations for developers.

4.4.3.2 Language

Details the approved IEC 61131-3 languages for safety programming.

4.4.3.3 Task system

Discusses the task system and its implications for safety applications.

4.4.3.4 Variable declarations

Rules and best practices for declaring variables in safety applications.

4.4.3.5 Direct addresses

Guidelines for using direct addresses and marker addresses in program code.

4.4.3.6 Data types

Lists suitable simple and complex data types for safety-oriented applications.

4.4.3.7 Blocks

Guidelines for using programs, functions, and function blocks in safety applications.

4.4.3.8 Libraries

Information on approved external and user libraries for safety applications.

4.4.3.9 Expressions

General rules for programming expressions, including complexity and data types.

4.4.3.9.1 General

General rules that must be followed when programming expressions.

4.4.3.9.2 Constants

Recommendations for declaring constants for better semantic transparency.

4.4.3.9.3 Assignments

Guidelines for variable assignments, including implicit and explicit conversions.

4.4.3.9.4 Parentheses

Guidance on using parentheses for defining expression priorities and readability.

4.4.3.9.5 Bit access

Approved method for accessing bits in safety applications.

4.4.3.9.6 Conversions

Rules regarding implicit and explicit type conversions in assignments.

4.4.3.10 Operators

Suitability of various operators for use in safety-oriented applications.

4.4.3.11 Language constructs

Approved ST language control elements for safety applications.

4.4.4 General programming guidelines

General rules to avoid errors, including states, warnings, and variable usage.

4.4.5 Safety-oriented and non-safety-oriented parts of the application

Measures for separating safety and non-safety parts of complex applications.

4.5 Safety code analysis tool

Information on the ABB SCA tool for automatically checking safety rules.

4.6 AC500-S Libraries

Overview of the available safety libraries certified for AC500-S Safety PLC.

4.6.1 Overview

Introduction to the safety libraries certified by TÜV.

4.6.2 Safety_Standard.lib

Description of standard CoDeSys POUs included in Safety_Standard.lib.

4.6.3 SafetyBase_PROFIsafe_AC500_V22_Ext.lib

Details on the PROFIsafe Stack implementation (PROFISAFESTACK POU).

4.6.4 SafetyExt_AC500_V22.lib

Lists the POUs available in the SafetyExt_AC500_V22.lib library.

4.6.4.1 SF_E_ERR_LED_SET

Function to set the state of the E-ERR LED (ON or OFF).

4.6.4.2 SF_MAX_POWER_DIP_SET

Function to control the maximum number of restarts after power dip.

4.6.4.3 SF_WDOG_TIME_SET

Function to set the maximum allowed cycle time for the Safety CPU.

4.6.4.4 SF_APPL_MEASURE_BEGIN

Defines the start point for time profiling within the safety application program.

4.6.4.5 SF_APPL_MEASURE_END

Defines the end point for time profiling within the safety application program.

4.6.4.6 SF_MAX_POWER_DIP_GET

Retrieves the current number of restarts after a power dip.

4.6.4.7 SF_SAFETY_MODE

Reads out the current operating mode (DEBUG or SAFETY) of the Safety CPU.

4.6.4.8 SF_SM5XX_OWN_ADR

Gets the value of the hardware switch address on the Safety CPU.

4.6.4.9 SF_RTS_INFO

Displays the firmware version of the Safety CPU.

4.6.4.10 SF_FLASH_DEL

Deletes a selected data segment from the flash memory.

4.6.4.11 SF_FLASH_READ

Reads a data set from a flash memory segment.

4.6.4.12 SF_FLASH_WRITE

Writes user data to a data segment in the flash memory.

4.6.4.13 SF_DPRAM_PM5XX_S_REC

Receives data from the PM5xx Non-safety CPU to the Safety CPU.

4.6.4.14 SF_DPRAM_PM5XX_S_SEND

Sends data from the SM560-S Safety CPU to the PM5xx Non-safety CPU.

4.6.5 DPRAM_SM5XX_SEND and DPRAM_SM5XX_REC in SysInt_AC500_V10.lib

POUs for data exchange between PM5xx and SM560-S Safety CPU via DPRAM.

4.6.6 SafetyBlocks_PLCopen_AC500_v22.lib

List of supported PLCopen Safety POUs and their basis.

4.6.6.1 Introduction

Introduction to generic parameters and diagnostic codes of PLCopen Safety POUs.

4.6.6.2 SF_Equivalent

Function block for converting two equivalent BOOL inputs to one BOOL output.

4.6.6.3 SF_Antivalent

Function block for converting two antivalent BOOL inputs to one BOOL output.

4.6.6.4 SF_ModeSelector

Function block that selects the system operation mode.

4.6.6.5 SF_EmergencyStop

Function block for monitoring an emergency stop button.

4.6.6.6 SF_ESPE

Function block for monitoring electro-sensitive protective equipment (ESPE).

4.6.6.7 SF_GuardMonitoring

Function block that monitors the safety guard status.

4.6.6.8 SF_TwoHandControlTypeII

Provides two-hand control functionality according to EN 574, Section 4 Type II.

4.6.6.9 SF_TwoHandControlTypeIII

Provides two-hand control functionality according to EN 574, Section 4 Type III.

4.6.6.10 SF_GuardLocking

Controls access to hazardous areas via interlocking guards.

4.6.6.11 SF_TestableSafetySensor

Detects sensor failures and monitors response time for safety sensors.

4.6.6.12 SF_MutingSeq

Specifies sequential muting procedures with four muting sensors.

4.6.6.13 SF_MutingPar

Specifies parallel muting procedures with four muting sensors.

4.6.6.14 SF_MutingPar_2Sensor

Specifies parallel muting procedures with two muting sensors.

4.6.6.15 SF_EnableSwitch

Evaluates signals from a three-position enable switch for safety functions.

4.6.6.16 SF_SafetyRequest

Provides interface to control actuators and place them in a safe state.

4.6.6.17 SF_OutControl

Controls a safety output based on application and safety signals.

4.6.6.18 SF_EDM

Controls safety output and monitors actuators via feedback signals.

5 Safety times

5.1 Overview

Introduces the topic of safety times and error reactions in the system.

5.2 Fault reaction time

Defines fault reaction time and provides a table of maximum fault reaction times.

5.3 Safety function response time

Explains SFRT, its calculation, and factors affecting it.

6 Checklists for AC500-S Commissioning

6.1 Overview

Explains the purpose of the checklists for AC500-S commissioning.

6.2 Checklist for creation of safety application program

Checklist for ensuring proper creation and documentation of safety programs.

6.3 Checklist for configuration and wiring

Checklist for verifying correct system configuration and wiring.

6.4 Checklist for operation, maintenance and repair

Checklist for ensuring proper operation, maintenance, and repair procedures.

6.5 Verification procedure for safe iParameter setting in AC500-S Safety I/Os

Procedure to verify safe iParameter settings and confirm F_iPar_CRC calculation.

6.5.1 Verification procedure workflow

Step-by-step workflow for performing the iParameter verification procedure.

6.5.2 Verification tables for iParameter settings in AC500-S Safety I/Os

Tables for cross-checking iParameter values in AI581-S, DI581-S, and DX581-S modules.

6.5.2.1 AI581-S Safety I/O tables

Specific verification tables and calculation examples for AI581-S module parameters.

6.5.2.2 DI581-S Safety I/O tables

Specific verification tables and calculation examples for DI581-S module parameters.

6.5.2.3 DX581-S Safety I/O tables

Specific verification tables and calculation examples for DX581-S module parameters.

7 Safety application examples

7.1 Overview

Introduction to application examples using PLCopen Safety POUs.

7.2 Example 1: Diagnostics concept

Demonstrates diagnostic concepts using safety functions like emergency stop and light curtains.

7.2.1 Functional description of safety functions

Explains the safety functions used in the diagnostics example.

7.2.2 Graphical overview of safety application interface

Provides a visual representation of the safety application interface with inputs and outputs.

7.2.3 Declaration of used variables

Lists the input and output variables used in the diagnostics example.

7.2.4 Program example

Shows a sample program illustrating the diagnostics concept.

7.2.5 Additional notes

Provides extra information and considerations for the diagnostics example.

7.3 Example 2: Muting

Illustrates safety functions related to muting for production cell safeguarding.

7.3.1 Functional description of safety functions

Describes the safety functions for muting, including door monitoring and emergency stop.

7.3.2 Graphical overview of the safety application interface

Visual overview of the muting application interface, showing connections.

7.3.3 Declaration of used variables

Lists the input and output variables used in the muting example.

7.3.4 Program example

Shows a sample program illustrating the muting application.

7.3.5 Additional notes

Provides extra information and considerations for the muting example.

7.4 Example 3: Two-hand control

Demonstrates a two-hand control safety function for machine operation.

7.4.1 Functional description of safety functions

Describes the safety functions for two-hand control, including emergency stop.

7.4.2 Graphical overview of the safety application interface

Visual overview of the two-hand control application interface.

7.4.3 Declaration of used variables

Lists the input and output variables used in the two-hand control example.

7.4.4 Program example

Shows a sample program illustrating the two-hand control application.

7.4.5 Additional notes

Provides extra information and considerations for the two-hand control example.

Appendix

A System data for AC500-S-XC

Contains system-specific data for the AC500-S-XC version.

A.1 Environmental conditions

Details operating temperature, humidity, air pressure, and immunity to gases/mist.

A.2 Mechanical data

Provides specifications on wiring method, dimensions, mounting, and protection.

A.3 Environmental tests

Summarizes results from storage, humidity, insulation, vibration, shock, and EMC tests.