VersaSafe Integration Guide, GFK-2735
Contents
1. Element Type Signal Status 0 X 11 BOOL OAR Operator Acknowledge Required Status 0 X 12 BOOL PUR Power Up Requested Status 0 X 13 BOOL Error Any Device Error Status 0 X 15 BOOL COK Communication OK Status i X 00 07 BOOL Module Type 1 Byte Status i X 16 27 BOOL Module error code See individual module manual Status i X 28 31 BOOL Module comm status 0000 OK 0001 OK but not yet started 0010 DIP switch error 0011 not connected 0100 Invalid module type detected 1000 not configured 3 3 2 2 2 2 2 2 2 2 2 J2 J1 f4 1 Ja 1 14 1 1 1 1 fo jo Jo Jo Jo Jo Jo Jo Jo Jo 1 lo l9 8 I7 le 5 4 3 2 l1 Jo 9 8 7 le 5 4 3 2 1 Jo jo l8 7 J6 5 4 I3 2 1 JO Status Module Error Code Unused Module Type Data Element Type Signal Data i X 00 15 BOOL Error Code See individual module manual Data i X 16 23 BOOL Output Enable Only LPSDO and PSDO Data i X 24 31 BOOL lO data DevAck Element Description DevAck 0 Error acknowledge for LPSDO DevAck 1 5 Error acknowledge for Satellites 1 5 DevAck 6 Reserved DevAck 7 Operator acknowledge for failsafe communication DevAck 8 Restart download of safety logic from GE IP Controller to LPSDO DevAck 9 Confirm download of different2. All parameters are passed to VS_Island Additionally the UDT based structure Conf which contains the compiled safety logic is passed to VS_Island 8 4 2 VS_ Island The block VS_Island manages one island Each island needs its own instance It is automatically created within VS_call_ lt Island number gt _ lt SafeProjName gt Functions of this block e insert island number in compiled logic required as part of the safety policy e check module address DIP setting for each module e Call VS_Download to communicate with LPSDO e Map GE IP Controller and HMI data to VersaSafe data e Move data from to LPSDO lt gt PSD 27 VersaSafe Integration Guide February 2012 GFK 2735 Input Parameters Parameter Type LPSDOin BYTE 48 24 Words input from LPSDO module fieldbus PSDx1in BYTE 4 2 Words input from PSDx satellite 1 fieldbus PSDx2in BYTE 4 2 Words input from PSDx satellite 2 fieldbus PSDx3in BYTE 4 2 Words input from PSDx satellite 3 fieldbus PSDx4in BYTE 4 2 Words input from PSDx satellite 4 fieldbus PSDx5in BYTE 4 2 Words input from PSDx satellite 5 fieldbus PLCin WORD 4 4 Words input from GE IP Controller application Island INT Number of safety island 1 31 Diag UDT Diagnostic data shall be published external for HMI Conf UDT Compiled safety logic Output Parameters Parameter Type LPSDOout BYTE 48
3. In Output O 7 PLCout 3 X 00 07 LPSDO App Diag 0 7 App Diag Signals 8 bit can be inserted in the safety logic so that the GE IP Controller logic is aware of internal safety signals Data to VersaSafe Parameter Device Signal PLCin 0 X 00 07 LPSDO Enable Output 0 7 PLCin 0 X 08 15 PSDx Satellite 1 Enable Output 0 7 PLCin 1 X 00 07 PSDx Satellite 2 Enable Output 0 7 PLCin 1 X 08 15 PSDx Satellite 3 Enable Output 0 7 PLCin 2 X 00 07 PSDx Satellite 4 Enable Output 0 7 PLCin 2 X 08 15 PSDx Satellite 5 Enable Output 0 7 PLCin 3 X 00 07 LPSDO App Ack 00 07 PLCin 3 X 08 15 LPSDO App Ack 08 15 Enable Output signals do have only an effect for output modules LPSDO PSDO App Ack signals 16 bit can be used as additional enable signals within the safety logic 24 VersaSafe Integration Guide February 2012 GFK 2735 8 2 lO Data VersaSafe Modules represent an analog IO module within the given fieldbus They can have either 4 or 16 or 24 words of input and output The input size is always equal to the output size Do not use this data directly it is only shown for reference here Use the GE IP Controller interface instead The logic module referred to as LPSDO has 16 or 24 words of lO depending on DIP switch setting All IO modules referr
4. 32 48 64 PSDOR PSDO 4 4 ByteOffset ByteOffset 20 End Case End_For 29 VersaSafe Integration Guide February 2012 GFK 2735 8 4 4 Conversion Subroutines 30 PB Purpose convi0DW2Bytes converts 10 DWORDS to 40 byte convByte2Int convert one byte to an integer convBytes2DW converts 4 Bytes to a DWORD convDW2Byte extracts one byte from a DWORD convDW2Ws converts one DWORD to two WORDs VersaSafe Integration Guide February 2012 GFK 2735 9 VersaSafe HMI Reference 9 1 Data Exchange GE IP Controller HMI Data exchange between GE IP Controller and HMI is performed by arrays of structures On GE IP Controller side the structure is implemented as UDT The variable name is PH_VSafe Array member index zero is unused Island 1 uses array member index 1 and so on All variables except unused index 0 must have their Publish property equal External to be able to communicate by symbolic SRTP On HMI side it is a corresponding toolchest structure The variable name is H_VSafe Array member index zero is used as indirect variable to animate the screen elements Higher indices are connected to the corresponding GE IP Controller variables as GE IP Controller Access variables Members of communication structure Element PLC Type HMI Type ComDiag WORD 6 DINT 6 Island communication Status Ack DWORD DINT Applic
5. 4 E gl Drawers 88 Favorites tt AAO Aaa OP MAAD AD OP AAAA 5 2 Import UDTs Logic Blocks and Variables Open the drawer VersaSafe Integration in the toolchest window 1 Drag all items from the UDT folder to the UDT folder of the RX3i target 2 Inthe RX3i target s Program Blocks folder add a folder VersaSafe 3 Drag all logic blocks from the toolchest Logic folder to the VersaSafe folder Start with conv blocks and then add VS_ Data VS_CheckAddr VS_ Download VS_Island and then VS_System 12 VersaSafe Integration Guide February 2012 GFK 2735 4 Import one of the PH_VSafe_xx csv files to the RX3i target variables xx depends on the maximum number of islands you want to support It is possible to upgrade the number islands at any time later This step will add the diagnostic interface to QuickPanel View Control for up to four safety islands 5 Import the csv file VS_1 csv to the RX3i target variables This step will add the fieldbus interface for the first safety island If you need more than one island import also VS_2 3 4 csv 6 Include an unconditional call of VS_System in MAIN Connect the Enable input to a condition that reflects the OK status of the fieldbus communication If you are not sure just connect an ALW_ON 5 3 Import HMI Panels and Scripts If you work with separate PME projects open the QuickPanel View Control project now and open the drawer VersaSafe I
6. Guide February 2012 10 VersaSafe Performance The time to exchange process data between the controller and the devices of VersaSafe islands are as follows 10 1 Transit Time from RX3i Controller to LPSDO The time to transfer data from RX3i Controller to LPSDO output is calculated according to the below formula trespo Econtroer tProtibus tniu X 1 5 tsatetyLogic where LPsDO Transit time from RX3i controller to LPSDO output in ms controller GE IP Controller sweep time in ms terotibus Profibus cycle time in ms tniu NIU reaction time in ms tsatetyLogic Safety logic scan time tsatetytogic 8 MS Max lmu 2Xt 2Xtc t Station transmission time in ms to NIU Conversion time tc 2 ms t 1 15 x 13 x 8 n 3a X tp ts 2tp n Number of user data bytes Number of modules on NIU th Bit duration t 0 002ms at 500 kbit s ls Software runtime t 0 7 ms lo Runtime on cable t 0 016 ms km 10 2 Transit Time from PSDI to RX3i Controller The time to transfer data from PSDI input to RX3i Controller when the safety input transitions from ON to OFF is calculated according to the below formula tespn o f i tcontrotter Protibus tniu X 1 5 ritter where tespi1 0 Transit time from PSDI input 1 to 0 to RX3i controller in ms tcontroller GE IP Controller sweep time in ms terofibus Profibus cycle time in ms tniu NIU reaction time in ms Refer Section 10 1 Filter Input filter time in ms con
7. Note As a safety requirement it is mandatory that ConfirmDownload input should not be turned ON programmatically and it has to be turned ON manually using a physical push button input or HMI push button input from user AppAck WORD Application acknowledge bits 0 15 EnableOut BYTE Enable output signals for LPSDO module PLCIn WORD 4 Configured PLCIn parameter of VS_Call_xx block in VS_System for specified island number Output Date Type Description Parameter Invalidisland BOOL Input island number is invalid OutStatus BYTE LPSDO output status AppDiag BYTE Status of application diagnostic bits O 7 PLCLogicActive BOOL VersaSafe integration logic is executed DownloadActive BOOL Download of safety logic from GE IP Controller to LPSDO is in progress DownloadProgress INT Download progress percentage DiffLogicDetected BOOL Safety logic in LPSDO is different from loaded project in GE IP Controller RoutingEnabled BOOL Communication between VersaSafe modules is executed by GE IP controller RoutingStatus BOOL Communication status between VersaSafe modules CommErr BOOL Communication error is detected by the integration logic PowerCycleReq BOOL Power cycle of LPSDO is required AnyDeverr BOOL Any device error OpAckReq BOOL Operator acknowledge is required SysStatus WORD Island status 9000H Running 9001H No project 9002H Loading 9003H Stopped ModErrorCode WORD Module Error Code Refer LPSDO module manual 17 Ver
8. Panels and Scripts ccccccceceeseeceeeeeceeeeeceaeeseneeseeeeceaeeesaaeeseaeeseaeeesaaeeseaeeeenees 13 5 4 Create Modify Safety Logic with VersaConf Safety oooococnnnccccononoccconononcconononnnnnnnonncnnannnnnnnno 13 SS Import XML Gs consti tt fanved ace aa dida bitadir 14 5 6 Comfigure XSL LOG ICt rara rc a a a 14 51 LPSDO and PSDX interfaces ia om ag ea ae a E CREARA Daba iaa datan 16 STel COMUN eaa a a e a Ea A E E E e E a S 16 De PS DO siai e a e a a aras 17 ETS ot O A ac aute 18 O ta ennai a E a EE A T E N 18 5 8 Download Targets and run Application oonnnccccnninicnnnnncccnnnneccconnnerccnnnnrrccnnnnrccrnnnrrrcnnnrc 19 A o NA O O AEAT 19 Operating the VersaSafe HMI cccccccsssseeeeeneeeeeeeeeeeseeeeneeeeeeeeeseseeeeeeeeeeeeesenees 21 VersaSafe general Reference sssssseeeeeeeeeeeeeneeeeeneeeeeeeeeseneeeeeeeeeeeeeeseneeseneeeeeeeees 23 VersaSafe GE IP Controller Logic Reference cccccccssesesseeeeeeeeeeeseeeeeneeeeeeeees 24 8 1 Data Exchange VersaSafe GE IP Controller cccceesseeeeeeeeeeeeeeeaeeeeeeeseeeeeseaeeeeaeeeeaees 24 82 OND at cial ate cil Can ddan E E OE basset eect 25 338 UD ara AE tac cis Cesena En AA TO O E ido 26 A ollo siea A 26 8 4 1 VS_call_ lt Island number gt _ lt SafeProjNaMe gt ooccoococcccconoconononononcconononcnnnnnnnccnnnnnncnnnnnns 26 84 27 VS a o vert oot Sls ck ees ete clic cl ete 27 8 4 3 WS Download old iaa 28 8 4 4 Conve
9. lt SafeProjName gt This ST block is created by VersaConf Safety as XML and is imported into PME Never change this block in any way The contents of the block are e Safety project documentation as comments e Initialisation of compiled safety logic e Call an instance of VS_ Island 26 VersaSafe Integration Guide February 2012 GFK 2735 Input Parameters Parameter Type LPSDOin BYTE 48 24 Words input from LPSDO module fieldbus PSDx1in BYTE 4 2 Words input from PSDx satellite 1 fieldbus PSDx2in BYTE 4 2 Words input from PSDx satellite 2 fieldbus PSDx3in BYTE 4 2 Words input from PSDx satellite 3 fieldbus PSDx4in BYTE 4 2 Words input from PSDx satellite 4 fieldbus PSDx5in BYTE 4 2 Words input from PSDx satellite 5 fieldbus PLCin WORD 4 4 Words input from GE IP Controller application Island INT Number of safety island 1 31 Diag UDT Diagnostic data shall be published external for HMI Output Parameters Parameter Type LPSDOout BYTE 48 24 Words output to LPSDO module fieldbus PSDx1 out BYTE 4 2 Words output to PSDx satellite 1 fieldbus PSDx2out BYTE 4 2 Words output to PSDx satellite 2 fieldbus PSDx3out BYTE 4 2 Words output to PSDx satellite 3 fieldbus PSDx4out BYTE 4 2 Words output to PSDx satellite 4 fieldbus PSDx5out BYTE 4 2 Words output to PSDx satellite 5 fieldbus PLCout WORD 4 4 Words output to GE IP Controller application
10. 0 LPSDO 32 VersaSafe Integration Guide February 2012 GFK 2735 8 VersaSafe GE IP Controller Logic Reference The VersaSafe application logic is designed to support the following data exchanges e Download compiled safety logic to the LPSDO e Cyclic data exchange between LPSDO and safety IO modules e Data exchange between GE IP Controller application logic and safety logic e Data exchange between VersaSafe system and an HMI for diagnostic and user acknowledge purpose 8 1 Data Exchange VersaSafe GE IP Controller The GE IP Controller application shall never write directly into VersaSafe lO data see IO Data There is a very high probability that in this case the safety goes into a safe state switching off all outputs Instead the GE IP Controller application shall use the input parameter PLCin and the output parameter PLCout of the VersaSafe integration block to communicate with the safety logic Both parameters are 4 word arrays The following tables show the assignment of signals Data from VersaSafe read only for GE IP Controller Parameter Device Signal PLCout 0 X 00 07 LPSDO Output 0 7 PLCout 0 X 08 15 PSDx Satellite 1 In Output O 7 PLCout 1 X 00 07 PSDx Satellite 2 In Output 0 7 PLCout 1 X 08 15 PSDx Satellite 3 In Output 0 7 PLCout 2 X 00 07 PSDx Satellite 4 In Output 0 7 PLCout 2 X 08 15 PSDx Satellite 5
11. 24 Words output to LPSDO module fieldbus PSDx1 out BYTE 4 2 Words output to PSDx satellite 1 fieldbus PSDx2out BYTE 4 2 Words output to PSDx satellite 2 fieldbus PSDx3out BYTE 4 2 Words output to PSDx satellite 3 fieldbus PSDx4out BYTE 4 2 Words output to PSDx satellite 4 fieldbus PSDx5out BYTE 4 2 Words output to PSDx satellite 5 fieldbus PLCout WORD 4 4 Words output to GE IP Controller application 8 4 3 VS Download This block does the communication with LPSDO for download of compiled logic and LPSDO status 28 VersaSafe Integration Guide February 2012 GFK 2735 State Machine 0 Reset Status NO PROJ 310 Read Header not equal 320 Download LPSDO initiated 315 Wait for confirmation 330 reload header accepted Download complete Pseudo Code for extracting the module ID t is assumed the logic block consists of a zero based DW array LogicBlockDW ByteOffset LogicBlockDW 2 WO LogicBlockDW 2 W1l 13 DWoffset ByteOffset 4 ByteNr ByteOffset Mod 4 ModuleCount BYTE TO_INT LogicBlockDW DWoffset B ByteNr ByteOffset ByteOffset 4 For i 0 To ModuleCount 1 Do DWoffset ByteOffset 4 ByteNr ByteOffset Mod 4 ModuleID i BYTE _TO INT LogicBlockDW DWoffset B ByteNr Case ModuleID i Of 16 PEDI t ByteOffset ByteOffset 16 32 80 PSDO LPSDO ByteOffset ByteOffset
12. GE Intelligent Platforms Programmable Control Products VersaSate Integration Guide GFK 2735 February 2012 GFL 002 Warnings Cautions and Notes as Used in this Publication Warning notices are used in this publication to emphasize that hazardous voltages currents temperatures or other conditions that could cause personal injury exist in this equipment or may be associated with ts use In situations where inattention could cause either personal injury or damage to equipment a Warning notice is used Caution notices are used where equipment might be damaged if care is not taken Note Notes merely call attention to information that is especially significant to understanding and operating the equipment This document is based on information available at the time of its publication While efforts have been made to be accurate the information contained herein does not purport to cover all details or variations in hardware or software nor to provide for every possible contingency in connection with installation operation or maintenance Features may be described herein which are not present in all hardware and software systems GE Intelligent Platforms assumes no obligation of notice to holders of this document with respect to changes subsequently made GE Intelligent Platforms makes no representation or warranty expressed implied or statutory with respect to and assumes no responsibility for the accuracy complet
13. HMI target VS_Language csv Language grid entries Additional files to speed up integration might be present You can use any existing PME RX3i QuickPanel View Control project to integrate VersaSafe or you can start a new project or you can use the start up project The RX3i target and the QuickPanel View Control target might be in same project or in different projects For the steps in the next chapters it is assumed we have already an RX3i target in a PME project and a 12 QuickPanel View Control target within the same or in different project The following steps describe how to add VersaSafe to an existing project Open the common or the RX3i project and proceed as described below 11 VersaSafe Integration Guide February 2012 GFK 2735 5 1 Import VersaSafe integration Drawer Locate the file VersaSafe Integration zdrw and import it into the PME toolchest F All Drawers m E e VersaSafe Integration E E MessageGrids Message Group VS_ErrorCode Message Group VS_Location Message Group VS_ErrorCodeDL Message Group VS_Status Panels F Panel Header P Panel VS_Diag F Panel VS_DiffLogic F Panel Language P Panel Footer LIBs Script VS_LIB Struct ME HL_Language 8 HL_Footer E H_VSafe Logic ff convDW2Ws VS_Data VS_Island convDW2Byte convBytes2DW VS_System conv10DW2Bytes WS_CheckAddr E VS_Download convByte2Int LPSDO UDT y VS_CfoLB By VS_PH_VSafe Bh VS_Cfo
14. addresses It is recommended to create a scheme for addressing For example you may reserve AI101 to AI199 for safety island number 1 and the same for AQ Then the first 24 Words 101 124 are for the LPSDO Always reserve 24 Words even in case of a 16 Word 3 satellites configuration Then address 125 to 128 is for satellite 1 address 129 to 132 is satellite 2 and so on Use the same scheme for island two with addresses 201 upward see table below Example Island LPSDO 0 Sat 1 Sat 2 Sat 3 Sat 4 Sat 5 1 101 124 125 128 129 132 133 136 137 140 141 144 2 201 224 225 228 229 232 233 236 237 240 241 244 3 301 324 325 328 329 332 333 336 337 340 341 344 4 401 424 425 428 429 432 433 436 437 440 441 444 You will need these addresses to complete the software configuration later A csv file with variables using the above scheme for island 1 to 4 is provided for convenience 10 VersaSafe Integration Guide February 2012 GFK 2735 5 Detailed Software Integration Steps The integration package includes at least the following files File Contents VersaSafe_Vxxx zip Start up PME project VersaSafe Integration zdrw PME drawer PH_VSafe_xx csv variables to import in the GE IP Controller target VS_1 csv VS_2 csv VS_3 csv VS_4 csv variables to import in the GE IP Controller target H_VSafe csv variables to import in the
15. any No Checks Wiring fifo Besse Input Signals Not checked Output Signals Not checked Timing e Output Signals Not checked ah Devices ff maandas Compliancy Not checked Device Parameters Not checked History Previous Project LAS ERE RR RASO Predecessor exists No Project CRC CRCs Ee sass Project Header CRC 90D01AD7 Logical Block CRC F75C11D3 Address Block CRC 0D27D1B3 Project Header Time Stamp 28 03 2011 11 34 27 20 VersaSafe Integration Guide February 2012 lication Name VersaConf Safety 2 7 GFK 2735 6 Operating the VersaSafe HMI VersaSafe modules do not have any user operational controls and they have only a few LEDs to indicate the current state Moreover they are often hidden somewhere in a cabinet A convenient tool to watch the status and operate the modules is the HMI screen which is included in the integration package It shows the status of the modules itself of all physical lO and of GE IP Controller interface signals In case of any safety event it will show a text message to indicate the location and the cause of the event VersaSafe status screen elements for module status Module status Unconfigured Module type and error display satellite LPSDO 8 PSDI 8 PSDI 8 PSDO 8 wit
16. ation data from Island HeaderLPSDO DWORD 10 DINT 10 Project Header actually stored in LPSDO HeaderProj DWORD 10 DINT 10 Project Header from compiled safety logic Data DWORDJ 6 DINT 6 Data from modules 1 DWORD per Sat Status DWORDJ 6 DINT 6 Status from modules 1 DWORD per Sat DevAck BOOL 16 BOOL 16 Device acknowledge signals ComDiag Element Type Signal ComDiag 0 X 0 BOOL PLC Logic Active VersaSafe integration logic is executed ComDiag 0 X 1 BOOL Download active Download of compiled safety logic from GE IP Controller to LPSDO is in progress ComDiag 0 X 2 BOOL Different logic Safety logic in LPSDO is different from detected loaded project in GE IP Controller ComDiag 0 X 3 BOOL Routing Enabled Communication between VersaSafe modules is executed by the GE IP Controller ComDiag 0 X 4 BOOL Comm error Any error detected by the integration logic ComDiag 1 WORD LPSDO Byte 4 LPSDO communication object or FF error ComDiag 2 WORD LPSDO Byte 5 LPSDO status ComDiag 3 WORD LPSDO Byte 6 LPSDO status ComDiag 4 WORD LPSDO Byte 7 LPSDO status ComDiag 5 INT Progress Download progress Bits 0 7 of ComDiag 0 are dedicated to show the status of GE IP Controller integration logic The rest of ComDiag reflects the status of the LPSDO once the integration logic is executing and the LPSDO is communicating 31 VersaSafe Integration Guide February 2012 GFK 2735 Status
17. be configured by DIP switch for the correct island and satellite number DIP switches are only visible and operable if the module is not installed Make sure switches are set correctly before you install the module DIP switch LPSDO PSDx 0 2 always 0 Satellite number 1 5 3 7 Island number 1 31 Island number 1 31 8 always off always off 9 off normal mode always off on multiplexer mode Mode 1 16 Words IO max 3 satellites Mode 2 2 24 Words lO max 5 satellites Baud rate 500KBD 500KBD Note that multiplexer mode is not explicitly supported by this package However you can use multiplexer mode with some simple GE IP Controller logic Refer to hardware manuals for more information about multiplexer mode VersaSafe Integration Guide February 2012 GFK 2735 4 Fieldbus Configuration 4 1 Profibus A PBM300 Profibus master must exist in the RX3i hardware configuration Add as many NIUs IC220PBI002 as your application requires Add standard and safety modules to the NIUs The distribution of safety modules is completely free Safety modules of the same island can be located at the same or at different NIUs Safety modules of different islands can be located at the same NIU or at different NIUs Note that the one LPSDO requires 16 or 24 words of data This may restrict the number of usable LPSDOs for one NIU due to system limitations Double click on the modules to review and alter the assigned
18. d is compared with the actual logic in the LPSDO As we have modified the logic a difference is found and a dialog pops up at the HMI to show some relevant data of the project loaded in the LPSDO versus the new actual updated project The operator must explicitly confirm that he wants to update the safety logic This is part of the safety policy Additionally the GE IP Controller programmer and the safety engineer can look at any time into the ST block There is a comprehensive comment section showing all relevant parameters of the actual safety logic like time of last change version etc Example ST init block for VersaSafe PACSystem output format V 1 0 Island 2 Project Information 19 VersaSafe Integration Guide February 2012 GFK 2735 Build Number 374 Project Developer Windows Login Name 113004127 Project Project Program and Device Parametrization dle ERRE RE SO ARA A tale aint tet AE Project Name AckTestBig Path to Project D Documents and Settings 113004127 My Documents AppProj Applied Solution VersaSafe SafeConf Last changed 28 03 2011 11 34 27 Project CRC EOB9B5A6 Archival Storage Project and Documentation ias lisa aaa ia aa aa wie Project Printed No Project Archived No Operating Company Address of Application Location A E aa Same as Operating Comp
19. dule 3 PSD4out WORD 4 Output to PSD Module 4 PSD5out WORDIA Output to PSD Module 5 PLCout WORDIA Output to GE IP Controller Mandatory parameters 15 VersaSafe Integration Guide February 2012 GFK 2735 Island Must be the number which is defined in the VersaConf Safety tool and equal to DIP switch setting Island is 1 based Diag Attach the array member of PH_VSafe array with index island number LPSDOin 24 WORD array connected by fieldbus to the LPSDO module as input LPSDOout 24 WORD arrays connected by fieldbus to the LPSDO module as output PSD1in 4 WORD array connected by fieldbus to PSDx module 1 as input PSD1out 4 WORD arrays connected by fieldbus to PSDx module 1 as output Optional parameters PSD2 5in 4 WORD array connected by fieldbus to PSDx modules 2 5 as input PSD2 5out 4 WORD arrays connected by fieldbus to PSDx modules 2 5 as output PLCin 4 WORD array to allow the GE IP Controller to provide enable signals for the safety logic PLCout 4 WORD array to allow the GE IP Controller access to signals of safety logic You can create appropriate arrays and assign the addresses you assigned during hardware configuration or in case the fieldbus supports symbolic variables you use the variables created during fieldbus configuration 5 7 LPSDO and PSDx interface User defined function blocks LPSDO amp PSDx are provided as a part of integration tool chest for easy user interaction wi
20. ed output will be ON if the safety logic in RX3i Controller is different from safety logic in LPSDO module 3 If DiffLogicDetected output is ON turn ON the ConfirmDownload input for one scan so that download starts and the DownloadActive will be ON and the DownloadProgress gives the progress percentage of the download Note As a safety requirement it is mandatory that ConfirmDownload input should not be turned ON programmatically and it has to be turned ON manually using a physical push button input or HMI push button input from user 4 After the completion of download if the OpAckReq output in ON then turn ON the OpAck input till the OpAckReq output turns OFF 5 Now the SysStatus output should be 9000H RoutingEnabled amp RoutingStatus outputs should be ON which indicates that the safety logic of that corresponding island is running and no errors are present If not just turn ON Restart input for one scan 18 VersaSafe Integration Guide February 2012 GFK 2735 6 If the OpAckReq output in ON then turn ON the OpAck input till the OpAckReq output turns OFF 7 Even now if any of RoutingEnabled amp RoutingStatus outputs is OFF then check for any error output being set in LPSDO block outputs and check the individual satellite PSDO PSDI status using PSDx block 5 8 Download Targets and run Application Now you can validate downl
21. ed to as PSDI and PSDO have 4 words of lO The following tables show the usage of the 4 words of IO modules and the first 4 words of an LPSDO Further words of the LPSDO are used for data exchange between lO and logic module or for download of safety logic to the logic module depending on the state of the system For more information see chapter Safety Bridge System of module manuals VersaSafe is a big endian system while PACSystem is a little endian system so care must be taken when accessing bytes Input Data big endian ordered The second column shows the byte for a little endian Intel system Byte LPSDO PSDI PSDO 0 1 Dev Diag hi Dev Diag hi Dev Diag hi 1 0 Dev Diag lo Dev Diag lo Dev Diag lo 2 3 App Diag Input Data Protocol 3 2 Output Data Protocol Protocol 4 5 Comm Protocol Protocol Protocol 5 4 Comm Protocol Protocol Protocol 6 7 Comm Protocol Protocol Reserved 7 6 Comm Protocol Reserved Output Data Output Data big endian ordered The second column shows the byte for a little endian Intel system Byte LPSDO PSDI PSDO 0 1 Dev Ack Dev Diag hi Dev Diag hi 1 0 App Ack Dev Diag lo Dev Diag lo 2 3 App Ack Protocol Output Data 3 2 Enable Out Protocol Protocol 4 5 Comm Protocol Protocol Protocol 5 4 Comm Protocol Protocol Protocol 6 7 Comm Protocol Reserved Res
22. eness sufficiency or usefulness of the information contained herein No warranties of merchantability or fitness for purpose shall apply indicates a trademark of GE Intelligent Platforms Inc and or its affiliates All other trademarks are the property of their respective owners Copyright 2011 GE Intelligent Platforms Inc All Rights Reserved 2 VersaSafe Integration Guide February 2012 GFK 2735 Contact Information If you purchased this product through an Authorized Channel Partner please contact the seller directly General Contact Information Online technical support and http www ge ip com support GlobalCare Additional information http www ge ip com Solution Provider solutionprovider ip O ge com Technical Support If you have technical problems that cannot be resolved with the information in this guide please contact us by telephone or email or on the web at www ge ip com support Americas International Americas Direct Dial Europe the Middle East and Africa Phone 800 1 433 2682 EMEA Direct Dial 352 26 722 780 if toll free 800 option is unavailable or if dialing from a mobile telephone Technical Support Email support emea ip ge com Customer Care Email customercare emea ip ge com Primary languages of support English French German Italian Czech Spanish Asia Pacific 86 400 820 8208 86 21 3217 4826 India Indonesia and Pakistan Technical Support Email support cn ip ge c
23. ers and HMI designers 1 2 References VersaSafe VersaPoint Module C220SDL543 User s Manual GFK 2730 VersaSafe VersaPoint Module IC220SDL953 User s Manual GFK 2731 VersaSafe VersaPoint Module IC220SDL 753 User s Manual GFK 2732 VersaSafe VersaPoint Module IC220SDL 752 User s Manual GFK 2733 VersaSafe VersaPoint Module IC2205DL840 User s Manual GFK 2734 VersaSafe Integration Guide February 2012 GFK 2735 2 Overview 2 1 What is VersaSafe VersaSafe is a configurable machine safety solution designed for mid sized machine safety applications in the range of approximately 32 128 safety lO VersaSafe is based on VersaPoint Network Interface Units NIUs For the first step VersaSafe will support Profibus Other NIUs will follow step by step 2 2 VersaSafe Integration Overview VersaSafe needs a GE IP Controller application logic and a fieldbus to perform communication between main GE IP Controller and VersaSafe modules as well as for communication between the safety modules amongst each other This is referred to also as host environment There is no safety related requirement neither to application logic nor to fieldbus However the host environment must provide a cyclic deterministic and device consistent communication Generally any host environment which is supported by a VersaPoint NIU and which is compliant to above requirements is able to run VersaSafe This integration guide describes how to integrate VersaSafe in
24. erved 7 6 Comm Protocol Reserved Enable Out 25 VersaSafe Integration Guide February 2012 GFK 2735 Explanation Item Direction Description Dev Diag VS gt PLC Device diagnostic data see module manual App Diag VS gt PLC Application data generated by safety logic Dev Ack PLC gt VS Device acknowledge see module manual App Ack PLC gt VS Application data from GE IP Controller to safety logic Enable Out PLC gt VS Enable output used if individually enabled by HW configuration Input Data VS gt PLC Status data from safe inputs Output Data VS gt PLC Status data from safe outputs Comm Prot Both Short communication protocol Protocol Both Safety Bridge routing protocol 8 3 UDT UDT Purpose VS _Cfg Compiled safety logic header block address block logic block VS_CfgLB Logic block for VS_Cfg VS_PH_VSafe Communication object for HMI 8 4 Logic Blocks Block Type Lang Purpose VS_call_ lt Island UDFB ST Initialize compiled safety logic and call number gt _ lt SafeProjName gt VS_Island created as XML by VersaConf Safety VS_Island UDFB LD Safety island management block VS_Download UDFB ST Communicate with LPSDO VS_CheckAddr PB LD Verify correct DIP settings VS_Data PB ST Extract data for HMI and GE IP Controller cony PB LD Various auxiliary conversion subroutines 8 4 1 VS_call_ lt Island number gt _
25. figured in VersaConf Safety tool 34 VersaSafe Integration Guide February 2012 GFK 2735 35 The time to transfer data from PSDI input to RX3i Controller when the safety input transitions from OFF to ON is calculated according to the below formula where tpspio 1 t Controller tProfibus tniu Fiter tsatetyTest tespio 1 Econtroller tProtibus tniu X 1 5 tFiter tsatetyTest Transit time from PSDI input 0 to 1 to RX3i controller in ms GE IP Controller sweep time in ms Profibus cycle time in ms NIU reaction time in ms Refer Section 10 1 Input filter time in ms configured in VersaConf Safety tool Safety relevant test time in PSDI tsatetyrest 22 MS Max VersaSafe Integration Guide February 2012 GFK 2735
26. h another Satelite not signal configured 10 0 Ch1 10 LEYAU 76543210 76543210 76543210 76543210 76543210 OE MIS FrEE 76543210 ACK ACK ACK ACK ACK Q PAM ERA Ind eye El PLC Logic active Header Ind HE Download active A G Routing enabled El Routing Status El Any comm Error Island 2 B Any Devi ms Restart Output enable status IO status only for output modules Error acknowledge button For each module we have e Module type display LPSDO PSDI PSDO e Module status display configured communicating safety errors text and location e lO status display physical lO status e Output enable status display only for LPSDO and PSDO e Error acknowledge button to confirm any safety event 21 VersaSafe Integration Guide February 2012 GFK 2735 VersaSafe status screen elements for island status Cross circuit with another signal 76543210 76543210 76543210 76543210 76543210 76543210 16543210 76543210 ACK AK 76543210 76543210 76543210 Island System status flags application data status Island selector button to display header Island status flags button to restart 22 VersaSafe Integration Guide February 2012 GFK 2735 7 VersaSafe general Reference Module Type IDs 23 Module ID Module ID Module Length of I par block hex dec Byte 0x10 16 PSDI 26 0x20 32 PSDO 32 0x30 48 PSDOR 20 0x40 64 PSDO 4 4 20 0x50 8
27. logic DevAck 10 15 Reserved 32 VersaSafe Integration Guide February 2012 GFK 2735 9 2 Screens 9 2 1 Main VersaSafe Diagnostic Screen Element Type Visibility Animation Module Header Text Module Type Error Header 1 Message Anim L_VS_PSDxValid S Data 0 X 14 LPSDO Error Header 1 Message Anim L_VS_PSDxValid S Data S X 15 PSDx Island Nr LPSDO Text Data 0 X 14 a BAND 248 Island Nr PSDx Text Data S X 14 Data S BAND 248 AND NOT 8 Data S X 15 Error Code Text Message Grid L_VS_ErrCode S Error Header 2 Text L_VS _PSDxValid S Data 0 X 14 Satellite Nr LPSDO Text Data 0 X 14 Data 0 BAND 7 Satellite Nr PSDx Text Data S X 14 Data S BAND 7 AND NOT Data S X 15 Error Location Text Message Grid L_VS_ErrLoc S IO Status Rectangle 8 Data S X 24 31 Enable Output Rectangle 8 Data S X 16 23 App Diag Data Rectangle 8 Ack X 00 07 App Ack Data Rectangle 16 Ack X 16 31 Ack Error Button DevAck S Op Ack Button Data 0 X 11 DevAck 07 9 3 Scripts Global Functions script VS_LIB Sub comment DWORD2STRING dw s converts a DWORD to a string ErrorDecodePSDx Status ErrLoc ErrCode decodes error codes from PSDIx ErrorDecodeLPSDO Status ErrLoc ErrCode decodes error codes from LPSDO 9 4 Structures See Data Exchange VersaSafe GE IP Controller 33 VersaSafe Integration
28. ntegration again Otherwise proceed directly 1 Import the H_VSafe csv file to the HMI_QP12 target variables Drag VS_LIB from toolchest LIB folder to project folder Global Functions Drag all items from toolchest folder MessageGrids to project folder Message Grids Drag all panels from toolchest folder Panels to project folder Graphical Panels Include panel VS_Diag into your navigation system You may also want to rename it and adjust vertical size or position according existing conditions 6 Enable language translation add three languages English default German and Italian 7 Open Language csv using MS excel Select all rows first 3 columns Copy open the language grid in PME click with right mouse button into the grid and choose Paste row s OW 03 TO Note Open the screen VS_Diag and check assignment of message grids according the following picture and update manually if it is not done automatically NS Miype 8 Island Nr 10 AEZ ETAK 5 OE HATE NO a BEID ino OED in UREO W Routing Status 5 4 Create Modify Safety Logic with VersaConf Safety This step is only mentioned and briefly described here For more information see online help of VersaConf Safety 13 VersaSafe Integration Guide February 2012 GFK 2735 Note about naming conventions The logic block created by VersaConf Safety has the name VS_call_x_ lt safety logic name gt Where x is
29. oad and start the targets 5 9 Modification cycle If the safety engineer has decided to modify the safety logic and created a new XML file the XML file must be imported again If the number of satellites has changed you may need also to update the parameters If the number of islands has been increased check the following items e The array size of PH_VSafe must be at least number of islands plus two e The array size of H_VSafe must be at least number of islands plus one e f you increase the array size of PH_VSafe make sure all elements have the publish property equal External If you work with separate PME projects open the RX3i project now 1 Click with right mouse button at Program Blocks VSafe and choose Import Block from File 2 Navigate to the VersaConf Safety project folder FileOutput folder open the XML file 3 Ifa Variable Conflict dialog pops up select Use existing variable and confirm After some seconds the ST block with the name VS_call_ lt Island number gt _ lt SafeProjName gt is updated Typically you will be able to do a run mode store now to update the RX3i logic But this will not automatically invoke the updated safety logic To trigger this you have the following options e Stop start or power cycle the RX3i e Power cycle the remote station where the LPSDO is part of e Press restart on the HMI screen In all cases the new safety logic is initialized in RX3i memory an
30. om China support jp ip ge com Japan support in ip ge com remaining Asia customers Customer Care Email customercare apo ip ge com customercare cn ip ge com China 3 VersaSafe Integration Guide February 2012 GFK 2735 10 INTOdU CON cid e La abras 7 SA tity ages ieee eid ee uted aie eee eee ee eee ae 7 1 2 References iei 2 2 tinction dai halal A e a aa 7 AS O Ea araara seuedeiessvatenesstedenetisenaaees 8 2 1 Whatis Vers aa eae aa a a a a a aa aa aa ai 8 2 2 VersaSafe Integration OvVervieW ooonoccnninnnnnnnnnnccconcccnnnnnnncnna cc cnn 8 2 37 recon d ais a the fetes Get O a a eate lel tete he nee ete lean eee iad a 8 2 3 1 Software Requirements ccccccccecceeeseeeeeeee cece eeeeaeeeeaaeegeneeceaeeeeaaeseeaeeseeeesaeeteaeeeeeeees 8 2 3 2 Hardware Requirement eroro sorana o a a EES A E A E 8 Hardware Installation QUICKStA rt ccccssceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeaeeeseeeeeeeeeeeeeneeeeeeeees 9 3111 DIP Switch Setting iii E ee eee ata 9 Fleldbus Gonilguratlonn nico coves cisco ees eee eee ek ee a eee 10 A o to ahie bie et ie ee ede A 10 Detailed Software Integration Steps eeeceeeeeeeeeeeeeeeeeeeeeeeeaeeeeeeeeeeeeeeeeeeeeeeeeees 11 5 1 Import VersaSafe integration Drawer ccccceecceeeeeeeceeeeeseeceeeeecaeeeeeaeseeneeseaeeesaeeseaeeseees 12 5 2 Import UDTs Logic Blocks and Variables 0 ccccceecceceeeeeeeeeeeeeceeeeeeeseceeaeeeeeeeeeeeeeeeaees 12 5 3 Import HMI
31. propriate parameters There are 6 input and 6 output parameters which have to be connected via fieldbus to the safety modules Depending on the used fieldbus it can be by address based variables or by pure symbolic variables You can import the VS_1 csv file with referenced variables for convenience In addition there are some input and output parameter connected to internal GE IP Controller logic and a UDT structure for HMI communication Next picture shows an example for island 2 14 VersaSafe Integration Guide February 2012 GFK 2735 Enable VS CALL 2 ISLA ND2 YS_2_tromLPSD VS_2_toLPSDO Ys_2 tromPSDi YS_2_toPSD VS_2_fromPSD2 VS_2_toPSD2 VS_2_fromPSD3 VS_2_toPSD3 VS_2_tromPSD4 VS_2_toPSD4 VS_2_fromPSD5 VS_2_toPSD5 VS_2_tromPLC YS_2_toPLC 2 PH_VSate 2 Input Parameter Date Type Signal LPSDOin WORD 24 Input from LPSDO Module PSD1in WORD 4 Input from PSD Module 1 PSD2in WORD 4 Input from PSD Module 2 PSD3in WORD 4 Input from PSD Module 3 PSD4in WORD 4 Input from PSD Module 4 PSD5in WORD 4 Input from PSD Module 5 PLCin WORD 4 Input from GE IP Controller Island UINT Island Nr Diag VS_PH_VSafe PH_VSafe Island Communication with HMI Output Date Type Signal Parameter LPSDOout WORD 24 Output to LPSDO Module PSD1out WORD 4 Output to PSD Module 1 PSD2out WORD 4 Output to PSD Module 2 PSD3out WORDIA Output to PSD Mo
32. rsion Subroutines oconocncnncccnnccconocnnoncccconccnnnnnnnnn nn nan c conca n nn n nn nn cnn ca ran ra nann nn nnnccins 30 VersaSafe HMI Reference cms 31 9 1 Data Exchange GE IP Controller HMI ooonnnnnnccnnnnnnnnnconnncccccnccncnrn conca cc rra 31 A EL E E O 33 9 2 1 Main VersaSafe Diagnostic Screen occccninnccnnccinoninnncnnnonnccnnnnnnnrnnnnnn cn nn ca ran rn nannccnnnnnns 33 S PE O IS o A Ri cre ie el ae ec 33 A th iaecde niece ita ees eet ccna cat nee dete CEST ae dee eed 33 VErsasate Perfomance oi A ae ce 34 VersaSafe Integration Guide February 2012 GFK 2735 10 1 Transit Time from RX3i Controller to LPSDO ooccnnnnnnononicincnonononononacinanononononann cnn cnn nono nananns 34 10 2 Transit Time from PSDI to RX3i Controller oooooccccccononnccccnnccnononanacananono nono nacancnnnn ona nnannnns 34 VersaSafe Integration Guide February 2012 GFK 2735 1 Introduction 1 1 Scope This document describes how to integrate a VersaSafe machine safety project into a PACSystems RX3i based automation application using Proficy Machine Edition Creating the safety project itself as well as any safety related assessments is not within the scope of this document This document consists of two parts part one chapters 3 to 6 provides help for a quick start install hardware configure fieldbus GE IP Controller and HMI and operate HMI The second part contains reference information for GE IP Controller programm
33. saSafe Integration Guide February 2012 GFK 2735 5 7 3 PSDx Input Parameter Date Type Description IslandNr UINT Island number configured in LPSDO SatelliteNr UINT Satellite number of the island DevAck BOOL Error acknowledge for PSDx EnableOut BYTE Enable output signals for PSDO module Applicable only for PSDO module For PSDI module provide 0 to this input PLCIn WORDIA Configured PLCIn parameter of VS_Call_xx block in VS_System for specified island number Output Date Type Description Parameter Invalidisland BOOL Input island number is invalid InvalidSatellite BOOL Input satellite number is invalid InOutStatus BYTE PSDI input PSDO output status CommStatus BYTE Bit 0 3 refers to Module Communication Status 0000 OK 0001 OK but not yet started 0010 DIP switch error 0011 not connected 0100 Invalid module type detected 1000 not configured ErrorCode WORD Module Error Code Refer to the individual module manual 5 7 4 Operation Steps to download safety logic from RX3i Controller to Safety logic module LPSDO using LPSDO UDFB Note These steps are not mandatory if HMI View is used as mentioned in above sections 1 The PLCLogicActive output should be ON If it is OFF then either the VersaSafe integration steps is not followed correctly or integration logic is not called 2 Once the PLCLogicActive is ON the DiffLogicDetect
34. th the LPSDO amp PSDx modules These blocks are not mandatory for the Versasafe integration logic to work They are useful in particular if status and confirmation signals shall be processed by PLC logic not only by HMI If required these blocks can be dragged to the application logic used 5 7 1 Configuration 1 Drag the LPSDO block from the Versasafe Integration tool chest to the logic 2 Call the LPSDO UDFB in the logic and assign an instance name to it 3 Pass the required island number to IslandNr input and pass the configured PLCIn parameter of VS_Call_xx block in VS_System for specified island number to PLCIn input 4 All other bool inputs should be OFF and other inputs should be 0 5 Assign coils with appropriate name to the outputs 6 After the download of target and CPU placed in Run IO Enabled mode make sure that VersaSafe integration logic is being called 16 VersaSafe Integration Guide February 2012 GFK 2735 5 7 2 LPSDO Input Parameter Date Type Description IslandNr UINT Island number configured in LPSDO OpAck BOOL Operator acknowledge for failsafe communication DevAck BOOL Error acknowledge for LPSDO Restart BOOL Restart download of safety logic from GE IP Controller to LPSDO Rising edge triggered input ConfirmDownload BOOL Confirm download of different logic to LPSDO Rising edge triggered input
35. the island number and lt safety logic name gt is the name of the VersaConf Safety project Block names in ME are restricted to 31 characters total That means the name of the safety project is limited to 21 characters Keep in mind also restrictions about usable characters for logic blocks in ME and the fact that ME is not case sensitive For each individual island e Create or modify safety logic e Open menu Project Check project When it is finished without error you will find an XML file in the FileOutput folder of VersaConf Safety s project folder 5 5 Import XML file If you work with separate PME projects open the RX3i project now Otherwise proceed directly For each safety island do the following steps 1 Click with right mouse button at Program Blocks VSafe and choose Import Block from File 2 Navigate to the VersaConf Safety project folder FileOutput folder open the XML file 3 Ifa Variable Conflict dialog pops up select Use existing variable and confirm After some seconds a new ST block in VSafe will appear with the name VS_call_ lt Island number gt _ lt SafeProjName gt 4 Open the block VS_System and add the new ST block with instance name lt SafeProjName gt Call it conditionally with an NO contact the input Enable 5 6 Configure RX3i Logic For each safety island block VS_call_ lt Island number gt _ lt SafeProjName gt see previous chapter you have to attach ap
36. to an RX3i QuickPanel View Control host environment Steps to integrate VersaSafe into a PME RX3i QuickPanel View Control project e Import the VersaSafe integration drawer into Machine Edition e Drag UDTs and logic blocks from the integration drawer into the RX3i logic import the csv variable file s e Drag the screens and scripts from the integration drawer into a PME View target and import the csv variable file s and the language grid e Import an XML file into the RX3i logic which was previously created by VersaConf Safety for each safety island e Configure GE IP Controller logic for all individual safety islands 2 3 Preconditions 2 3 1 Software Requirements e Proficy Machine Edition LD PLC and View V 7 0 SIM 7 or higher e VersaConf Safety configurator V 2 7 or higher e VersaSafe Integration Package PME drawer auxiliary files this manual 2 3 2 Hardware Requirements e RX3i controller with Ethernet and Profibus Master e Profibus NIU with VersaSafe modules e QuickPanel View Control 8 VersaSafe Integration Guide February 2012 GFK 2735 3 Hardware Installation Quickstart This chapter shows only some fundamental steps for a quick start For more information refer to the appropriate hardware manuals VersaSafe modules can be installed at any VersaPoint NIU combined with standard VersaPoint modules For currently supported field busses see fieldbus configuration 3 1 DIP Switch setting Each VersaSafe module must
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