Safe communication

This is the web edition of the original ‎⮫ AC500-S safety user manual, version 1.3.2. This web edition is provided for quick reference only. The original safety user manual must be used to meet functional safety application requirements.

Safety data are transferred between safety CPU and safety I/Os using PROFIsafe profile⮫ [2]. SM560-S / SM560-S-FD-1 / SM560-S-FD-4 safety CPU needs a non-safety CPU to communicate to safety I/O modules. All safety-related communication takes place through the non-safety CPU using a "black channel" principle of data transmission⮫ [2].

The communication of safety CPU to remote safety I/O modules is done using PROFINET IO field bus with a PROFIsafe profile for safe data transmission⮫ [2]. Safety and non-safety I/O modules can be mixed on a local I/O bus both in central and remote configuration. PROFINET IO controller communication module (CM579-PNIO) shall be used on non-safety CPUs as a part of the "black channel" to transfer safety data to PROFINET IO devices. PROFINET devices CI501-PNIO, CI502-PNIO, CI504-PNIO and CI506-PNIO can be used to attach safety I/O modules in remote configurations.

02.12.008_system setup — Fig. 387: AC500-S system setup with PROFINET/PROFIsafe for remote safety I/Os, sensors and actuators

PROFINET/PROFIsafe communication between AC500-S safety CPUs is supported using CM589-PNIO and/or CM589-PNIO-4 PROFINET IO device communication modules together with SM560-S-FD-1 and/or SM560-S-FD-4 safety CPUs with F-Device functionality on one side and CM579-PNIO with any AC500-S safety CPU with F-Host functionality on the other side (Fig.388). SM560-S-FD-1 and SM560-S-FD-4 safety CPUs are able to exchange a large amount of safety data with F-Hosts (3rd party PROFIsafe F-Hosts are supported as well) using PROFINET/PROFIsafe by configuring up to 32 F-Submodules.

If using PROFIsafe short frame F-Submodules (supported for PROFIsafe V2.4 and V2.6), a maximum of 384 bytes can be exchanged (max. 32 F-Device instances with 12 bytes safety data for each input/output direction).

If using PROFIsafe long frame F-Submodules (supported for PROFIsafe V2.6 only), a maximum of 1353 bytes can be exchanged (max. 11 F-Device instances with 123 bytes safety data for each input/output direction).

SM560-S-FD-1 with F-Device(s) supports safe communication to maximum one F-Host. SM560-S-FD-4 with F-Device(s) supports safe communication to maximum four F- Hosts. Fig. 388 shows that using SM560-S-FD-1 and SM560-S-FD-4 safety CPUs with additional F-Device functionality one can establish safe CPU to CPU communication between different control stations on PROFINET/PROFIsafe. SM560-S-FD-4 safety CPUs can simultaneously communicate not only with 1 PROFINET IO controller/F-Host (Master) but with up to 4 PROFINET IO controllers/F-Hosts (Masters). In addition to SM560-S-FD-1 and SM560-S-FD-4 safety CPUs, CM589-PNIO and CM589-PNIO-4 PROFINET IO device communication modules are needed to establish PROFINET connectivity as "black channel", respectively, to 1 or up to 4 PROFINET IO controllers.

02.12.009_Exemplary_setup_for_safe_CPU_to_CPU_communication — Fig. 388: Exemplary setup for safe CPU to CPU communication between various safety CPUs (SM560-S / SM560-S- FD-1 / SM560-S-FD-4)

The following communication requirements shall be fulfilled for using AC500-S safety PLC:

Safety data cannot be transferred over public networks, e.g., internet. If safety data is transferred across company/factory networks, ensure that sufficient protection is provided against manipulation (firewall or router for network separation).
Equipment connected to communication devices shall feature safe electrical isolation.

NOTICE

You can use AC500-S safety I/O modules and SM560-S-FD-1 / SM560-S-FD-4 safety CPUs with 3rd party F-Hosts on PROFINET. Download and install valid ABB GSDML files in your 3rd party F-Host engineering environment from ‎⮫ www.abb.com/plc.

After this, you can configure and use these AC500-S modules with 3rd party F-Host. Contact ABB technical support on how to obtain F_iPar_CRC values of AC500-S safety I/O modules for 3rd party F-Hosts.

Validate that all iParameters (input delay, channel configuration, etc.) for all AC500-S safety I/Os and other F-Devices are correct with a given F_iPar_CRC value using appropriate functional validation tests or verification procedure for those parameters⮫ “Verification procedure for safe iParameter setting in AC500-S safety I/Os”.

Default F_iPar_CRC values used in GSDML files for AC500-S safety I/O modules do not correspond to default iParameter configurations for AC500-S safety I/O modules and have to be re-calculated in the engineering tools before their usage. It was done to avoid unintended use of AC500-S safety I/O with 3rd party F-Hosts.