Indraworks Safelogic 15Vrs: First Steps

IndraWorks
SafeLogic 15VRS
First Steps
Commissioning Manual Edition 02

R911400170
IndraWorks SafeLogic 15VRS First Steps
Title IndraWorks
SafeLogic 15VRS
First Steps
Type of Documentation Commissioning Manual
Document Typecode DOK-IWORKS-SL*STEP*V15-CO02-EN-P
Internal File Reference RS-f0428d34854d08040a347e863c306e8e-2-en-US-4
Change Record Edition 02, 2021-04

Refer to tab. 1-1 "Change Record" on page 1
Copyright © Bosch Rexroth AG 2021
All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial prop‐
erty rights.
Liability The specified data is intended for product description purposes only and shall
not be deemed to be a guaranteed characteristic unless expressly stipulated
in the contract. All rights are reserved with respect to the content of this docu‐
mentation and the availability of the product.
Editorial Department Engineering Automation Systems Solution Integration PLC, Safety controls,
AnSt (MiNi/PiaSt)
IndraWorks SafeLogic 15VRS First Steps I
Table of Contents
Table of Contents
Page
1 About this documentation.............................................................................................. 1

1.1 Validity of the documentation.................................................................................................................. 1
1.2 Documentation structure......................................................................................................................... 2
1.3 Required and supplementing documentation......................................................................................... 2
1.3.1 SafeLogic/Safe Motion........................................................................................................................ 2
1.3.2 SafeLogic hardware............................................................................................................................. 3
1.3.3 IndraWorks/WebAssistant................................................................................................................... 5
1.3.4 SafeLogic compact.............................................................................................................................. 6
1.4 Using safety instructions......................................................................................................................... 8
1.4.1 Structure of the safety instructions...................................................................................................... 8
1.4.2 Explaining signal words and safety alert symbol................................................................................. 8
1.4.3 Symbols used...................................................................................................................................... 9
1.4.4 Explaining the signal alert symbol on the device................................................................................. 9
1.5 Names and abbreviations....................................................................................................................... 9
1.6 Customer feedback................................................................................................................................. 9
2 Project goal "First Steps - Safety"................................................................................ 11
3 Installation.................................................................................................................... 13
4 Configuring hardware I/Os........................................................................................... 15

4.1 PROFIsafe............................................................................................................................................ 15
4.1.1 Inline Profibus coupler R-IL PB BK DI8 DO4/CN.............................................................................. 15
4.1.2 Inline Profibus coupler R-IL PN BK DI8 DO4.................................................................................... 17
4.1.3 Inline PSDI 8 and PSDI 16 (PROFIsafe data input).......................................................................... 19
4.1.4 Inline PSDO 8 and PSDOR 4 (PROFIsafe data output).................................................................... 20
4.1.5 S20 Profibus coupler S20-PB-BK...................................................................................................... 21
4.1.6 S20 Profinet coupler S20-PN-BK+.................................................................................................... 23
4.1.7 S20-PSDI 8/4 (PROFIsafe data input)............................................................................................... 25
4.1.8 S20-PSDO 8/3 (PROFIsafe data output)........................................................................................... 26
4.2 CSos..................................................................................................................................................... 26
4.2.1 General information........................................................................................................................... 26
4.2.2 CSos S20 I/Os................................................................................................................................... 27
4.2.3 S20-SSDI 8/4 (CSos data input)........................................................................................................ 28
4.2.4 S20-SSDO 8/3 (CSos data output).................................................................................................... 28
4.2.5 IndraDrive.......................................................................................................................................... 29
5 Commissioning............................................................................................................ 31
5.1 Introduction and overview..................................................................................................................... 31
5.2 Creating an IndraWorks project............................................................................................................ 31
5.3 PROFIsafe............................................................................................................................................ 32
5.3.1 Creating and configuring PROFIsafe Inline terminals at the Profibus............................................... 32
5.3.2 Creating and configuring PROFIsafe Inline terminals at the Profinet................................................ 37
R911400170_Edition 02 Bosch Rexroth AG

II/81 IndraWorks SafeLogic 15VRS First Steps
Table of Contents
Page
5.4 CSos..................................................................................................................................................... 43
5.4.1 Creating and configuring CSos S20 terminals................................................................................... 43
5.4.2 IndraDrive with CSos......................................................................................................................... 46
5.5 Exchanging variables with standard PLC............................................................................................. 50
5.6 Safety network variables....................................................................................................................... 51
5.7 Programming example.......................................................................................................................... 55
5.8 Loading and starting projects on the control......................................................................................... 59
5.9 Modifying projects................................................................................................................................. 60
6 Troubleshooting........................................................................................................... 61
6.1 SafeLogic interface............................................................................................................................... 61
6.2 SafeLogic function module................................................................................................................... 62
6.3 PROFIsafe............................................................................................................................................ 62
6.4 CIP Safety on Sercos........................................................................................................................... 63
6.5 Safety PLCopen function blocks........................................................................................................... 64
6.6 Converting variables (safe ⇔ not safe)................................................................................................. 64
7 Diagnostics.................................................................................................................. 67
7.1 Overview............................................................................................................................................... 67
7.2 Status of the Safety function module.................................................................................................... 67
7.3 Log of the Safety function module........................................................................................................ 68
7.4 Log of the standard control................................................................................................................... 69
7.5 Device diagnostics of the standard control........................................................................................... 70
7.6 Diagnostic outputs of the ProfisafeHost and CSosOriginator function blocks...................................... 71
7.7 Diagnostics on the standard PLC control............................................................................................. 71
8 Style guide Safety programming.................................................................................. 75

8.1 Introduction........................................................................................................................................... 75
8.2 Application structure............................................................................................................................. 75
8.3 Variable names..................................................................................................................................... 75
9 Service and support..................................................................................................... 77
Index............................................................................................................................ 79
Bosch Rexroth AG R911400170_Edition 02

IndraWorks SafeLogic 15VRS First Steps 1/81
About this documentation
1 About this documentation

Editions of this documentation
Edition Release Notes

date
01 2020-11 First edition for version 15VRS
02 2021-04 Revision for version 15V12
● "Prerequisites" on page 13
● chapter 7.1 "Overview" on page 67
Tab. 1-1: Change Record
1.1 Validity of the documentation

Overview on target groups and In the following illustration, the framed activities, product phases and target
product phases groups refer to the present documentation.
Example: In the product phase "Mounting (assembly/installation)", the "me‐
chanic/electrician" can execute the activity "unpack, mount and install" using
this documentation.
Product- Mounting De-

Selection Engineering Commissioning Operation
phases (assembly/installation) commissioning
Presales Aftersales
Design engineer
Mechanic/
electrician
Programmer Programmer
Technologist Commissioning engineer
Target Process Technologist
groups specialist
Process specialist
Machine
operator
Maintenance Mechanic/
technician electrician
Service Disposal company
Select Unpack Parameterize Optimize Operate Dismount
Prepare Mount Program Test Maintain Dispose
Activities Design Install Configure Remove
faults
Construct Simulate
Create
the NC program
Fig. 1-1: Assigning the present documentation to the target groups, product
phases and activities of the target group
Purpose
This documentation contains a description for the creation of a 15VRS control
project to commission a SafeLogic control. Furthermore, this documentation
includes information on diagnostics and troubleshooting.
In this documentation, the term "control" is used for the following

control variants:
● XM21
● XM22
● XM42
● VPx

2/81 IndraWorks SafeLogic 15VRS First Steps
1.2 Documentation structure

For information on the required hardware and the description of the individual
subtasks for the project, refer to chapter 2 "Project goal First Steps - Safety"
on page 11.
For notes on hardware and software installation, refer to chapter 3 "Installa‐
tion" on page 13.
For information on how to configure the hardware I/Os under ProfiSafe, refer
to chapter 4 "Configuring hardware I/Os" on page 15 .
For the commissioning of the safety control and the connected periphery, re‐
fer to chapter 5 "Commissioning" on page 31.
For information on troubleshooting, refer to chapter 6 "Troubleshooting" on
page 61.
For the diagnostic options, refer to chapter 7 "Diagnostics" on page 67.
For programming under SafeLogic, refer to chapter 8 "Style guide Safety
programming" on page 75.
For information on the customer service helpdesk, refer to chapter 9 "Serv‐
ice and support" on page 77.
1.3 Required and supplementing documentation

1.3.1 SafeLogic/Safe Motion
Document Part number, document type Description
SafeLogic documentation
IndraWorks R911400170 This documentation contains a description for
SafeLogic 15VRS Commissioning Manual the creation of a 15VRS control project to com‐
mission a SafeLogic control.
First Steps
IndraWorks R911398635 This documentation describes the creation and
SafeLogic 15VRS Application Description the programming of SafeLogic projects in
IndraWorks Engineering
Project Configuration
ILC R911400164 This project planning manual describes the
MLC 15VRS Project Planning Manual SafeLogic compact Safety control and the Safe‐
ty extension module when using an IoT-compat‐
SafeLogic System Overview ible PLC system ILC SafeLogic and Motion
Control system MLC SafeLogic
MTX 15VRS R911398637 This project planning manual describes the
SafeLogic System Overview Project Planning Manual SafeLogic compact Safety control and the Safe‐
ty extension module when using a CNC system
MTX
Safe Motion documentations


Rexroth IndraDrive R911332634 This documentation describes the "Safe Torque
Integrated safety technology Application Description Off" safety technology integrated in IndraDrive
"Safe Torque Off" (from MPx-16)

IndraDrive R911338920 This documentation describes the "Safe Motion"
Integrated safety technology Application Description safety technology integrated in IndraDrive
"Safe Motion" (from MPx-18)
Tab. 1-2: SafeLogic/Safe Motion documentations
1.3.2 SafeLogic hardware

Safety extension module

IndraControl R911376654 This operating instructions provides information
XFE01.1-SY-01 Operating Instructions on the safe mounting and the electric installa‐
tion of the Safety extension module for XM con‐
Safety extension module for XM devi‐ trols to the technical staff of the machine manu‐
ces facturer or the machine operator
IndraControl R911373152 This operating instructions provides information
PFC01.1-SY-01 Operating Instructions on the safe operation of the Safety extension
module in the IndraMotion MLC VPx control to
Safety extension module for VPx devi‐ the technical staff of the machine manufacturer
ces or the machine operator
Standard controls
IndraControl XM21/XM22 R911340667 This documentation describes the IndraControl
Operating Instructions XM21/XM22 controls.
IndraControl XM42 R911345566 This documentation describes the IndraControl

Operating Instructions XM42 controls.
IndraControl VPx R911383090 This documentation describes the MLC

(based on VPB40.4) Operating Instructions IndraControl VPx controls on the basis of the
box PC VPB40.4
Bus coupler
Rexroth Inline Bus Coupler for R911324349 This documentation describes the Rexroth In‐
PROFIBUS-DP Application Description line bus coupler R-IL PB BK DI8 DO4/CN-PAC
R-IL PB BK DI8 DO4/CN-PAC

Rexroth Inline Bus Coupler for R911324351 Contains the technical data of the Rexroth Inline
Profibus DP with Digital Data Sheet bus coupler R-IL PB BK DI8 DO4/CN-PAC
Inputs and Outputs

R-IL PB BK DI8 DO4/CN-PAC
Rexroth Inline Bus Coupler for R911328682 Contains the technical data of the Rexroth Inline
PROFINET with digital Data Sheet bus coupler R-IL PN BK DI8 DO4-PAC
Inputs and Outputs

R-IL PN BK DI8 DO4-PAC


Rexroth IndraControl R911342784 This documentation describes the Rexroth S20
S20 Bus Coupler for Profinet Data Sheet Profinet bus coupler S20-PN-BK+
IndraControl R911342782 This documentation describes the Rexroth S20

S20 bus coupler for Data Sheet Sercos bus coupler S20-S3-BK+
Sercos
IndraControl R911343914 This documentation describes den Rexroth S20
S20 bus coupler for Application Description PROFIBUS-DP bus coupler S20-PB-BK
PROFIBUS-DP
I/O modules with safe inputs/outputs
Rexroth Inline Module with R911326026 This documentation describes the Rexroth In‐
Safe Digital Inputs Application Description line module R-IB IL 24 PSDI 8-PAC
R-IB IL 24 PSDI 8-PAC

Safe Digital Outputs Application Description line module R-IB IL 24 PSDO 8-PAC
R-IB IL 24 PSDO 8-PAC

Safe Digital Outputs Application Description line module R-IB IL 24 PSDO 4/4-PAC
R-IB IL 24 PSDO 4/4-PAC

Rexroth Inline Module with Safe R911336651 This documentation describes the Rexroth In‐
Digital Relay Outputs Application Description line module R-IB IL 24 PSDOR 4-PAC
R-IB IL 24 PSDOR 4-PAC

S20 module with safe digital Application Description module S20-PSDO-8/3 (PROFIsafe)
Outputs
S20-PSDO-8/3
S20 module with safe digital Application Description module S20-PSDI 8/4 (PROFIsafe)
Inputs
S20-PSDI-8/4
S20 module with safe digital Application Description module S20-SSDO-8/3 (CSoS)
Outputs
S20-SSDO-8/3
S20 module with safe digital Application Description module S20-SSDI 8/4 (CSoS)
Inputs
S20-SSDI-8/4
Tab. 1-3: SafeLogic hardware documentations

1.3.3 IndraWorks/WebAssistant
IndraWorks R911393450 This documentation describes the IndraWorks

15VRS Commissioning Manual installation.
Software Installation
IndraWorks R911393303 This documentation describes the use of
15VRS Application Description IndraWorks in which the Rexroth Engineering
tools are integrated. It includes instructions on
Engineering how to work with IndraWorks and how to oper‐
ate the oscilloscope function.
IndraWorks R911396137 This documentation describes the PLC pro‐
15VRS Application Description gramming tool IndraLogic 2G and its use. The
documentation includes the basic use, first
PLC Programming System IndraLogic steps, visualization, menu items and editors.
2G
IndraWorks R911398633 This documentation describes the system-com‐
15VRS Library prehensive PLC libraries.
Basic Libraries, IndraLogic 2G

IndraWorks R911393284 This documentation describes the field bus and
15VRS Application Description local periphery connections supported by the
MLC and MTX systems. The focus of this docu‐
Field buses mentation lies in the configuration, parameteri‐
zation, commissioning and diagnostics of differ‐
ent periphery connections. It is the basis for the
online help.
IndraWorks R911393275 This documentation describes the field bus li‐
15VRS Library braries for the IndraLogic ILC, IndraMotion MLC
and IndraMotion MTX systems
Field Bus Libraries
IndraWorks R911343569 This documentation describes the functions,
14VRS Application Description configuration and operation of the user interfa‐
ces IndraWorks HMI Engineering and
HMI IndraWorks HMI Operation.
WebAssistant R911381469 This documentation describes the WebAssist‐
Application Description ant. The WebAssistant is a web-based diagnos‐
tic tool used to access a control system via an
Ethernet high-speed connection. The WebAs‐
sistant allows OEMs, end users and service en‐
gineers to access and to remotely diagnose a
system.
Tab. 1-4: IndraWorks/WebAssistant documentations

1.3.4 SafeLogic compact

IndraControl R911332749 Instructs technical staff of the machine vendor

SafeLogic compact Operating Instructions on how to configure the software and on how to
operate and diagnose a SafeLogic compact
Designer software system with the SafeLogic Designer software
IndraControl R911332746 Instructs the technical staff of the machine ven‐
SafeLogic compact Operating Instructions dor and the machine operator on safe assem‐
bly, electrical installation, commissioning as well
Hardware as maintenance of the SafeLogic compact Diag‐
nostic Gateway
Rexroth IndraControl R911332752 Describes the SafeLogic compact diagnostic
SafeLogic compact Operating Instructions gateways and their functions in detail
Diagnostic Gateways
IndraControl R911338436 Instructs the technical staff of the machine ven‐
SafeLogic compact Project Planning Manual dor and the machine operator on safe assem‐
bly, configuration, electrical installation, com‐
Sercos Gateway missioning as well as maintenance of the Safe‐
Logic compact Sercos Gateway
Safety controls network solutions Safe‐ R911332754 These safety instructions provide information to
Logic compact Safety instructions the planner, developer and operator as well as
persons installing the protective equipment in a
machine/system, and initially commission and
operate it


SLC-3-GS3S00300 R911339570 This assembly instruction describes the assem‐
SafeLogic compact Assembly Instructions bly of the modules of the SafeLogic compact
Safety control
Sercos Gateway
SLC-0-GPNT00300 R911334404
SafeLogic compact Assembly Instructions
Ethernet Gateway Profinet I/O
SLC-0-GPRO00300 R911334403
Profibus Gateway
SLC-3-MOC000300 R911343758
Motion Control Module
SLC-3-CPU000300/ R911334402
SLC-3-CPU130302/ Assembly Instructions
SLC-3-CPU320302
SafeLogic compact
Main Modules
SLC-3-XTDI80302/SLC-3-XTIO84302/ R911334401
SLC-3-XTDS84302/SLC-0-STIO68302 Assembly Instructions
SafeLogic compact
Extension modules
SLC-A-UE410-2RO4/ R911334400
SLC-A-UE410-4RO4 Assembly Instructions
SafeLogic compact
Digital Output Modules
SLC-A-MOC-MFSB-RX/ R911343761
SLC-A-MOC-DECB-RX Assembly Instructions
SafeLogic compact
Encoder Junction Boxes
Tab. 1-5: SafeLogic compact documentation

1.4 Using safety instructions

1.4.1 Structure of the safety instructions
The safety instructions are structured as follows:
Safety alert symbol Consequences and

Signal word source of danger
CAUTION Burns and chemical burns due to wrong
battery treatment!
Do not open the batteries and do not heat them over 80 °C.
Avoiding danger
Fig. 1-2: Structure of the safety instructions
1.4.2 Explaining signal words and safety alert symbol

The safety instructions in this documentation contain specific signal words
(danger, warning, caution, notice) and, if necessary, a safety alert symbol
(according to ANSI Z535.6-2006).
The signal word draws attention to the safety instruction and indicates the
risk potential.
The safety alert symbol (triangular safety reflector with exclamation marks),
preceding the signal words Danger, Warning, Caution indicates hazards for
persons.
DANGER
In case of non-compliance with this safety instruction, death or serious injury
will occur.
WARNING
In case of non-compliance with this safety instruction, death or serious injury
can occur.
CAUTION
In case of non-compliance with this safety instruction, minor or moderate
injury can occur.
NOTICE
In case of non-compliance with this safety instruction, material damage can
occur.

1.4.3 Symbols used

Pointers are displayed as follows:
This is a note.
Tips are displayed as follows:
This is a tip.
1.4.4 Explaining the signal alert symbol on the device

If this symbol is on your device, you have to observe the
documentation on the device. The respective
krax
documentation informs on the type of hazard as well as

the steps required to avoid this hazard.
1.5 Names and abbreviations

Term Explanation
MLC Compact Motion Logic systems with Motion, Robot and
Logic Control functionalities
MTX Universal CNC control
IndraWorks Engineering Project planning and commissioning tool of Bosch Rexroth
Framework
IndraDrive Drive controller
Wizard Wizard guiding through several dialogs for an ergonomic
data input
Function block Provides application-specific functionalities
IEC International Electrotechnical Commission
Sercos Sercos (serial real-time communication system) interface
is a world-wide standardized interface for the communica‐
tion between controls and drives
CSos Also called CIP Safety on Sercos, is a safe field bus proto‐
col for Sercos devices
PROFIsafe Safe field bus protocol based on Profibus and Profinet
SDDML Sercos Device Description Markup Language. Device de‐
scription language for Sercos III devices. It is an XML de‐
scription for Sercos III devices and follows the Sercos III
device model
Tab. 1-6: Terms and abbreviations
1.6 Customer feedback

Customer requests, comments or suggestions for improvement are of great
importance to us. Please email your feedback on the documentations to
[email protected]. Directly insert comments in the
electronic PDF document and send the PDF file to Bosch Rexroth.


Project goal "First Steps - Safety"
2 Project goal "First Steps - Safety"

The project goal is to facilitate the start into the safety control engineering of
Bosch Rexroth.
One of the following listed control variants (including the Safety function mod‐
ule) is required for practical tasks:
MLC system
● XM2 control
Equipped with the extension module SafeLogic XFE01.1-SY-01.
● XM4 control
Equipped with the extension module SafeLogic XFE01.1-SY-01
● VPx control
Equipped with the extension module SafeLogic PFC01.1-SY-01
MTX system
● XM4 control
Equipped with the extension module SafeLogic XFE01.1-SY-01
Safe hardware I/Os based on "PROFIsafe" are connected via the Profibus/
Profinet standard interface of the control.
Subtasks ● Installing and creating a basis for a SafeLogic project
● Configuring hardware I/Os based on "PROFIsafe" and "CSos"
● Commissioning a safety control and the connected periphery:
– Creating an IndraWorks project
– Creating and configuring PROFIsafe Inline terminals
– Creating and configuring IndraDrive with CSos
– Concept of the exchange variables Standard PLC/Safety PLC
– Programming example
– Loading and the project to the control and starting it
– Modifying the project
● Troubleshooting
● Diagnostic support
● Style guide “Safety programming”


Installation
3 Installation
Prerequisites
The following minimum system requirements apply to smaller IndraWorks
Safety Manager projects with at most 100 blocks, 10 visualizations and 8 field
bus devices:
● 2 GB RAM
● 1 GHz Pentium
● 5 GB available hard drive space
The IndraWorks Safety manager programming system is only released for:
● Operating system: Windows 10, 64 bit
● Screen resolution: 96 dpi
Installing the device description Drive firmware

files
To use the safety functions of the drive, the IndraDrive firmware MPx18V08
or higher is required. To use the safe switches of the drive, use the drive firm‐
ware 20V08 or higher.
SDDML file
To correctly control the safety-related functions of the IndraDrive, an SDDML
file is required.
The SDDML files for Rexroth IndraDrive and CSos S20 I/Os are already in‐
stalled in IndraWorks.
GSD and GSDML files
The GSD files for Rexroth Inline Profibus I/Os with PROFISafe are already in‐
stalled in IndraWorks.
The GSDML files for Rexroth Inline Profibus I/Os with S20 Profinet I/Os with
PROFIsafe are already installed in IndraWorks.
Installing the SafetyManager li‐ There are two types of SafetyManager licenses:
cense
● IndraWorks SafetyManager (R911322463)
This license is required to develop Safety programs.
It allows the following:
– Logging into the Safety control including all debugging actions
– Setting passwords
– Downloading Safety programs
– Creating boot projects
– Retrieving control log
– Updating firmware
● IndraWorks SafetyManager Lite (R911383338)
This license is required for the remote support and for the servicing of
Safety applications.
It allows the following:
– Logging into the control via remote support access
– Debugging without the option to change values
– Retrieving control log

Installation
1. Open license overview

For the license overview, go to Tools ▶ Options..., General ▶ Software
licenses.
Fig. 3-1: License overview

2. Licensing
For the license dialog, click on the Licensing... button. Enter the activa‐
tion key.
Fig. 3-2: License dialog

To verify the activation key and to apply the license, press Next >>.
The IndraWorks SafetyManager license (Lite) is now installed and acti‐
vated.

Configuring hardware I/Os
4 Configuring hardware I/Os

4.1 PROFIsafe
4.1.1 Inline Profibus coupler R-IL PB BK DI8 DO4/CN
Maximum extension stage Only a limited number of Safety Inline terminals can be operated at an Inline
Profibus coupler of the type R-IL PB BK DI8 DO4/CN. Depending on the de‐
sign, up to six safe Inline terminals can be connected.
The Inline Profibus coupler provides a Profibus parameter channel for up to
230 bytes to parameterize the Inline terminals.
The Safety Inline terminals are assigned to the following number of bytes in
the Profibus parameter channel:
Safety Inline terminal Process data in bits1) Number of bytes in the

Profibus parameter chan‐
nel
R-IB IL 24 PSDI 8 8 54
R-IB IL 24 PSDI 16 16 36
R-IB IL 24 PSDO 8 8 60
R-IB IL 24 PSDO 4/4 8 48
R-IB IL 24 PSDOR 4 8 48
1) 4 bytes of process data are additionally assigned in the input
and output range for each PSDx module (status/control byte,
CRC)
Tab. 4-1: Assigning Profibus parameter channel using Safety Inline terminals
When equipping the Inline Profibus coupler, ensure that the maxi‐
mum number of 230 bytes is not exceeded in the Profibus param‐
eter channel.
Non-safe Inline terminals are also assigned to the Profibus pa‐
rameter channel.
Use the Inline Builder from 1.3VRS to configure the PROFIsafe

Inline terminals.
Example:
Equipping the Profibus coupler with one PSDI8 and two PSDO8 modules
The number of assigned bytes in the Profibus parameter channel is in total:
1 x 54 bytes + 2 x 60 bytes = 174 bytes
56 bytes are thus available.
Setting the DIP switches The DIP switches have to be set as follows:
● Mode: Mode1
● Baud rate: 500 kBauds if grey or yellow Inline terminals are operated at
a coupler; otherwise 2 MBauds
● F-address: Corresponds to the F_Dest address in the configuration dia‐
log. PROFIsafe addresses between 1 and 1022 are permitted

CAUTION This F-address has to be unique in the

complete project
Refer to the chapter "PROFISafe F-parameters" in the "IndraWorks
15VRS SafeLogic Project Configuration" manual.
Fig. 4-1: DIP switch of a PROFIsafe Inline terminal
● The imprint on the housing is valid. The digits directly printed

on the switch can be ignored
● Upon delivery, all switches for the F_Dest address are "on"
To obtain a uniform and unique numbering, set the F_Dest ad‐

dress as follows:
F_Dest = 10*ProfiBusAddr + SlotNo
ProfiBusAddr: Profibus slave address of the bus coupler
SlotNo: Slot of the Inline terminal at the bus coupler
The DIP switches of the Inline terminal have to be set to the Inline
coupler before mounting them.
Note the set F_Dest addresses.
The DIP switches cannot be accessed anymore after integrating
the Inline terminal.

Fig. 4-2: Numbering the slots at the Profibus Inline coupler R-IL PB BK DI8
DO4/CN
4.1.2 Inline Profibus coupler R-IL PN BK DI8 DO4

Maximum extension stage Up to 16 parameterizable Inline terminals (PCP devices) can be connected to
one Inline Profinet coupler of the type R-IL PN BK DI8 DO 4. PROFIsafe In‐
line terminals can be parameterized. To ensure the voltage supply of the
PROFIsafe Inline terminals, always provide a power feed of logic supply volt‐
age after every five modules.
Use the Inline Builder from 1.3VRS to configure the PROFIsafe

Inline terminals.
● Mode: Mode1
● Baud rate: 500 kBauds if grey or yellow Inline terminals are operated at
a coupler; otherwise 2 MBauds

complete project

Fig. 4-3: DIP switch of a PROFIsafe Inline terminal

on the switch can be ignored
● Upon delivery, all switches for the F_Dest address are "on"
To obtain a uniform numbering, set the F_Dest address as fol‐

lows:
F_Dest = 10*IPAddr + SlotNo
IPAddr: Last part of the 4-digit IP address separated by points
(example: 192.168.2.4 ⇒ IPAddr = 4)
SlotNo: Slot of the Inline terminal at the bus coupler
The DIP switches of the Inline terminal have to be set to the Inline
coupler before mounting them.
Note the set F_Dest addresses.
The DIP switches cannot be accessed anymore after integrating
the Inline terminal.

Fig. 4-4: Numbering the slots at the Profinet Inline coupler R-IL PN BK DI8
DO4
4.1.3 Inline PSDI 8 and PSDI 16 (PROFIsafe data input)

Parameterization Single-channel
All channels can be operated individually. For the PSDI 8, both channels of
one input have to be set to "single channel" and "used"/"not used".
Dual-channel
Both channels of one input are interconnected. For PSDI 8, both channels of
an input (channel pair) have to be parameterized to "double channel" and
"used".
Channel 1 Channel 2
Assignment Evaluation Symmetry Assignment Evaluation Symmetry
Single-channel: Both channels ena‐ Used Single channel Disabled Used Single channel Disabled
bled
Single-channel: Channel 1 active Used Single channel Disabled Not used Single channel Disabled
Single-channel: Channel 2 active Not used Single channel Disabled Used Single channel Disabled
Channel 1 + channel 2 redundant Used Double channel Disabled Used Double channel Disabled
Channel 1 + channel 2 redundant Used Double channel Enabled Used Double channel Enabled
with symmetry monitoring
Tab. 4-2: Parameterization for R-IB IL 24 PSDI 8

SAFEBYTE
Bit 7 6 5 4 3 2 1 0
Single- IN3_Ch2 IN3_Ch1 IN2_Ch2 IN2_Ch1 IN1_Ch2 IN1_Ch1 IN0_Ch2 IN0_Ch1
channel
Dual-chan‐ IN3_Ch1&2 IN2_Ch1&2 IN1_Ch1&2 IN0_Ch1&2
nel
Terminal 8.1 7.1 6.1 5.1 4.1 3.1 2.1 1.1
name
Tab. 4-3: I/O mapping of input data with regard to the channel configuration
with R-IB IL 24 PSDI 8 as example
SAFEBYTE
Bit 7 6 5 4 3 2 1 0
channel
Dual-chan‐ 0 IN3_Ch1&2 0 IN2_Ch1&2 0 IN1_Ch1&2 0 IN0_Ch1&2
nel
Terminal 4.4 3.4 4.1 3.1 2.4 1.4 2.1 1.1
name
with R-IB IL 24 PSDI 16 (byte 0) as example
SAFEBYTE
Bit 15 14 13 12 11 10 9 8
channel
Dual-chan‐ 0 IN7_Ch1&2 0 IN6_Ch1&2 0 IN5_Ch1&2 0 IN4_Ch1&2
nel
Terminal 8.4 7.4 8.1 7.1 6.4 5.4 6.1 5.1
name
with R-IB IL 24 PSDI 16 (byte 1) as example
4.1.4 Inline PSDO 8 and PSDOR 4 (PROFIsafe data output)

All channels can be operated individually. Both channels of an output have to
be set to "single channel" and "used" / "not used".
Dual-channel
Both channels of one output are interconnected. Both channels of an output
(channel pair) have to be parameterized to "double channel" and "used".

Channel 1 Channel 2
Assignment Output Assignment Output
Single-channel: Both channels enabled Used Single channel Used Single channel
Single-channel: Channel 1 active Used Single channel Not used Single channel
Single-channel: Channel 2 active Not used Single channel Used Single channel
Channel 1 + channel 2 redundant Used Double channel Used Double channel
Tab. 4-6: Parameterization for R-IB IL 24 PSDO 8
SAFEBYTE
Bit 7 6 5 4 3 2 1 0
Single- OUT3_Ch2 OUT3_Ch1 OUT2_Ch2 OUT2_Ch1 OUT1_Ch2 OUT1_Ch1 OUT0_Ch2 OUT0_Ch1
channel
Dual-chan‐ OUT3_Ch1 OUT2_Ch1 OUT1_Ch1 OUT0_Ch1&
nel &2 &2 &2 2
Terminal 8.1 7.1 6.1 5.1 4.1 3.1 2.1 1.1
name
Tab. 4-7: I/O mapping of output data with regard to the channel configuration
with R-IB IL 24 PSDO 8 as example
SAFEBYTE
Bit 7 6 5 4 3 2 1 0
Single- OUT1_Ch2 OUT1_Ch1 OUT0_Ch2 OUT0_Ch1
channel
Dual-chan‐ OUT1_Ch1 OUT0_Ch1&
nel &2 2
Terminal 4.2 3.2 2.2 1.2
name
Tab. 4-8: I/O mapping of output data with regard to the channel configuration
with R-IB IL 24 PSDOR 4 as example
Bit 4 to bit 7 may not be used. Otherwise, the module R-IB IL 24 PSDOR 4
goes into the safe state: Error message 0x1F4 "At least one reserved bit was
set in the process data image".
4.1.5 S20 Profibus coupler S20-PB-BK

Maximum extension stage Up to 63 S20 terminals can be connected to an S20 Profibus coupler of the
type S20-PB-BK. The S20 Profibus coupler provides a Profibus parameter
channel for up to 230 bytes to parameterize the S20 terminals. The limits the
number of the PROFIsafe S20 terminals.

The Safety S20 terminals are assigned to the following number of bytes in
the Profibus parameter channel:
Safety S20 terminal Process data in bits1) Number of bytes in the

Profibus parameter chan‐
nel
S20-PSDI 8/4 8 8
S20-PSDO 8/3 8 8
1) 4 bytes of process data are additionally assigned in the input
and output range for each PSDx module (status/control byte,
CRC)
Tab. 4-9: Assigning Profibus parameter channel using Safety S20 terminals
When equipping the S20 Profibus coupler, ensure that the maxi‐
mum number of 230 bytes is not exceeded in the Profibus param‐
eter channel.
Non-safe S20 terminals are also assigned to the Profibus param‐
eter channel.
It is recommended not to use more than 16 PROFIsafe S20 terminals per

S20 Profibus coupler S20-PB-BK. To ensure the voltage supply of the termi‐
nals, always provide a power feed of logic supply voltage for all six PSDx
modules.
To operate S20-PSDx modules, the PROFIBUS S20 bus coupler

S20-PB-BK (R911173247) from "AB1" is required.
Electronic damage due to overload

When projecting an S20-PB-BK station, observe the logic current
consumption of each device!
It is specified in each module-specific data sheet. It can differ
module-specifically. Thus, the potential number of devices that
can be connected depends on the specific setup of the station in
question.
If required, use the logic voltage feed-in terminals!

complete project

Fig. 4-5: DIP switch of a PROFIsafe S20 terminal
The imprint on the housing is valid. The digits directly printed on

the switch can be ignored.
To obtain a uniform and unique numbering, set the F_Dest ad‐

dress as follows:
F_Dest = 10*ProfiBusAddr + SlotNo
ProfiBusAddr: Profibus slave address of the bus coupler
SlotNo: Slot of the S20 terminal at the bus coupler
The set address is only applied at a power-up.

If the address is changed at runtime, the module responds with
FailureState.
The positions 10 and 11 of the 12-pin DIP switch are reserved for
the operation mode of the module and preset on off, off upon de‐
livery. The two positions may not be changed.
4.1.6 S20 Profinet coupler S20-PN-BK+

Maximum extension stage Up to 63 S20 terminals can be connected to an S20 Profinet coupler of the
type S20-PN-BK+. The number of the PROFIsafe S20 terminals is not limi‐
ted. However, it is recommended not to use more than 16 PROFIsafe S20
terminals per S20 Profinet coupler S20-PN-BK+. To ensure the voltage sup‐
ply of the terminals, always provide a power feed of logic supply voltage for
all six PSDx modules.

Electronic damage due to overload

When projecting an S20-PN-BK+ station, observe the logic cur‐
rent consumption of each device!
It is specified in each module-specific data sheet. It can differ
module-specifically. Thus, the potential number of devices that
can be connected depends on the specific setup of the station in
question.
If required, use the logic voltage feed-in terminals!

complete project
Fig. 4-6: DIP switch of a PROFIsafe S20 terminal

on the switch can be ignored.
To obtain a uniform numbering, set the F_Dest address as fol‐

lows:
F_Dest = 10*IPAddr + SlotNo
IPAddr: Last part of the 4-digit IP address separated by points
(example: 192.168.2.4 ⇒ IPAddr = 4)
SlotNo: Slot of the S20 terminal at the bus coupler

The set address is only applied at a power-up.

If the address is changed at runtime, the module responds with
FailureState.
The positions 10 and 11 of the 12-pin DIP switch are reserved for
the operation mode of the module and preset on off, off upon de‐
livery. The two positions may not be changed.
Fig. 4-7: Numbering the slots at the Profinet S20 coupler S20-PN-BK+
4.1.7 S20-PSDI 8/4 (PROFIsafe data input)

Both channels of an input can be operated individually. Parameterize in the
safe parameters for the "Both single channel" input.
Dual-channel

Both channels of one input are interconnected. Parameterize in the safe pa‐
rameters for the input "double channel- equivalent" or for the input "double
channel- antivalent".
SAFEBYTE
Bit 7 6 5 4 3 2 1 0
channel
nel
Terminal 07 06 05 04 03 02 01 00
name
Tab. 4-10: I/O mapping of the input data with regard to the channel configura‐
tion with S20-PSDI 8/4 as example
4.1.8 S20-PSDO 8/3 (PROFIsafe data output)

Both channels of an output can be operated individually. Parameterize in the
safe parameters for the "Both single channel" output.
Dual-channel
Both channels of one output are interconnected. Parameterize in the safe pa‐
rameters for the "double channel" output.
SAFEBYTE
Bit 7 6 5 4 3 2 1 0
channel
nel &2 &2 &2 2
Terminal 07 06 05 04 03 02 01 00
name
Tab. 4-11: I/O mapping of the output data with regard to the channel configura‐
tion with S20-PSDO 8/3 as example
4.2 CSos
4.2.1 General information
CSos, also called CIP-Safety on Sercos, is a safe field bus protocol for
Sercos devices.
One CSos connection is established between the safety control and each
CSos device at the Sercos bus for each direction of communication. The
safety control is the originator. The CSos device is called "target".
Addressing Each CSos device in a Sercos bus as well as the safety control have to be
provided with the same SNN (Safe Network Number). Each CSos device at
the Sercos bus additionally requires a unique SDID (Safety Device ID). The
SDID should have no reference to the Sercos address or the device position
in the ring.

SNN and SDID result together in the TUNID (Target Unique Network Identifi‐
er) of the bus device. The safety control is also provided with an SNN and
SDID together resulting in OUNIT (Originator Unique Network Identifier).
Sercos communication phases A connection can only be established when the Sercos bus is in P4. If the
bus is switched to P2 or P0, the CSos connections are canceled.
Signal propagation delay The propagation time mainly depends on the Sercos cycle time and the cycle
time of the SafeLogic PLC. As the Sercos cycle time is low compared to the
SafeLogic cycle time, it is not considered for the calculation.
The following settings have to be made:
EPI = 0 (default)
TiMu = 1 (default)
NTE ≥ (TiMu+3) * Safety cycle time
Use the NTE (Network Time Expectation) to calculate the signal

propagation delay.
4.2.2 CSos S20 I/Os

Maximum extension stage To operate CSos I/Os, the Sercos S20 bus coupler of type S20-S3-BK+ is
used. Up to 63 S20 terminals can be connected. The number of the Csos
S20 terminals is not limited. However, it is recommended not to use more
than 16 CSos S20 terminals per S20 Sercos coupler S20-PN-BK+. To ensure
the voltage supply of the CSos terminals, always provide a power feed of log‐
ic supply voltage for all six SSDx modules.
● SDID: Corresponds to the SDID in the configuration dialog. The SDIDs
1 - 127 are permitted
● SNN: The set value + 600000000hex corresponds to the SNN in the
“Configuration” dialog. The SNNs from 600000001hex to 60000001Fhex
are permitted
● The combination from SNN and SDID is TUNID (Target Unique Network
Identifier). This address has to be unique in the complete project
Fig. 4-8: DIP switch of a CSos S20 terminal

The imprint on the housing is valid. The digits directly printed on

the switch can be ignored.
SNN = 1Fhex and SDID = 127 may not be set at the same time, as
this combination is a test state.
The terminal always goes into a safe state when there is a

change at the DIP switches at runtime.
After setting the DIP switches, the current supply has to be inter‐
rupted once for the terminal to apply the new settings.
4.2.3 S20-SSDI 8/4 (CSos data input)

Both channels of an input can be operated individually. Parameterize in the
safe parameters for the "Both single channel" input.
Dual-channel
Both channels of one input are interconnected. Parameterize in the safe pa‐
rameters for the input "double channel- equivalent" or for the input "double
channel- antivalent".
SAFEBYTE
Bit 7 6 5 4 3 2 1 0
channel
nel
Terminal 07 06 05 04 03 02 01 00
name
Tab. 4-12: I/O mapping of the input data with regard to the channel configura‐
tion with S20-SSDI 8/4 as example
4.2.4 S20-SSDO 8/3 (CSos data output)

Both channels of an output can be operated individually. Parameterize in the
safe parameters for the "Both single channel" output.
Dual-channel
Both channels of one output are interconnected. Parameterize in the safe pa‐
rameters for the "double channel" output.
SAFEBYTE
Bit 7 6 5 4 3 2 1 0
channel


nel &2 &2 &2 2
Terminal 07 06 05 04 03 02 01 00
name
Tab. 4-13: I/O mapping of the output data with regard to the channel configura‐
tion with S20-SSDO 8/3 as example
4.2.5 IndraDrive
IndraDrive control sections of the second generation (CSxx2.x) can be equip‐
ped with a safety module. To control safety-related functions, use the firm‐
ware MPx18V08 or higher.
Depending on the safety engineering option, different safety functions are
available. The following table provides an overview on the available safety
functions for each safety engineering option:
Safety engineering option

L3 L4 S3 S4
STO Safe Torque Off SIL3 SIL3 SIL3 SIL3

SBC Safe Brake Control SIL3 SIL3 SIL3
SS1 SafeStop 1 (time monitored) SIL3 SIL3
SS1 SafeStop 1 (monitoring delayed) SIL2/3 SIL2/3
SS2 Safe Stop 2 SIL2/3 SIL2/3
SI functions
SLS Safe Limited Speed SIL2/3 SIL2/3
EN 61800-5-2
SDI Safe Direction SIL2/3 SIL2/3
SLI Safely Limited Increment SIL2/3 SIL2/3
SLT Safely Limited Torque
SLP Safely Limited Position SIL2 SIL2
SCA Safe CAM SIL2 SIL2
SMS Safe Maximum Speed SIL2/3 SIL2/3
SI functions
SMD Safely Monitored Deceleration SIL2/3 SIL2/3
Rexroth
SDL Safe Door Locking SIL3 SIL3
2 x 24 V input (OnBoard) SIL3 SIL3
Selection and 16 x 24 V input (zone module optional) SIL3

feedback 4 x 2 x 24 V output (zone module optional) SIL3
CIP Safety on Sercos SIL3 SIL3
Tab. 4-14: Overview on the functional scope of IndraDrive Safety

The following table provides an overview on the available safety options for
different drive control sections:
L3 L4 S3 S4
Economy CSE02.1A X X
Basic CSB02.1A X X

L3 L4 S3 S4
Basic CSB02.1B X X X
Advanced CSH02.1B X X X
Basic double-axis type CDB02.1B X X X
HCS 1.1 X
KSM 02.1 X
Tab. 4-15: Availability of the safety options in the drive control sections

Commissioning
5 Commissioning
5.1 Introduction and overview
This chapter describes the commissioning of a safety control and the connec‐
ted periphery.
5.2 Creating an IndraWorks project

The "IndraWorks SafetyManager" license is installed
1. Create a new IndraWorks project.
2. Create a control
Open the context menu of the project node and select a control with
Add... (an MLC XM2 in this example).
3. Control settings
"Safety CPU" has to be selected as function module.
Fig. 5-1: Selecting the Safety function module

The standard control as well as the safety control were created.

Commissioning
Fig. 5-2: Newly created Safety project
In the screen, the empty programs CSos_PRG (Sercos drives), EDM_PRG (a

little program example) and Profisafe_PRG (PROFIsafe I/Os based on
Profibus-DP) were created additionally.
5.3 PROFIsafe
5.3.1 Creating and configuring PROFIsafe Inline terminals at the Profibus
PROFISafe Inline terminals can only be operated at one Profibus coupler of
type "R-IL PB BK DI8 DO4/CN-PAC" (ordering no. R911172194). This bus
coupler has to be created below the "Profibus DP master" node in the project.
1. Inserting PROFIsafe Inline terminals
The PROFIsafe Inline terminals are inserted at the slave via the context
menu item "Add" , in this example below the bus coupler
"2 - R_IL_PB_BK…".
The logic I/O belonging to a PROFIsafe Inline terminal is automatically
created below the "Logic I/Os" node.

Commissioning
Fig. 5-3: PROFIsafe I/O on the standard control and on the safety con‐
trol
To which logic I/O the physical I/O is linked, can be seen in the "I/O
mapping" of the DP Inline terminal and changed if necessary.
There has to be at least one entry to use the Safety I/Os in the safety
control.
The order of the PROFIsafe Inline terminals at the bus coupler

has to correspond to the order in the project tree.
2. Parameterizing Safety Inline terminals
Fig. 5-4: Assigning logic and physical I/Os to a PROFIsafe Inline termi‐
nal
The PROFIsafe Inline terminals are parameterized in the dialogs "Safe
configuration" and "Safe parameterization" below the "Logic I/O" node.
The following parameters for the initial commissioning are important in
the log parameters of the "Safe configuration":
● F_Source_Add: Address of the PROFIsafe master. This address
has to be identical for all devices

Commissioning
● F_Dest_Add: PROFIsafe address of the PROFIsafe Inline terminal

set at the DIP switches of the PROFIsafe Inline terminal (see "Set‐
ting the DIP switches" on page 15)
The following addresses result from the example fig. 5-4 "Assign‐
ing logic and physical I/Os to a PROFIsafe Inline terminal" on page
33:
R_IB_IL_24_PSDI_8: F_Dest_Add= 22
R_IB_IL_24_PSDO_8: F_Dest_Add= 23
● F_iPar_CRC: Checksum of the "Safe parameterization"
The checksum has to be applied always after changing the config‐
uration of the safe I/Os
● F_WD_Time: This parameter is the monitoring period within a
Safety telegram has to be answered
If this time elapses, the Inline terminal goes into the "Safe state". A
default value of 150 ms is generally sufficient for "smaller bus sys‐
tems". The value should to be at least 2*SafetyTask time
The actual time for the response times can be determined at the Profi‐
safeHost instances of each connection in the Safety application.
Fig. 5-5: Setting the safe configuration of a PROFIsafe Inline terminal

The parameters set in the "Safe parameterization" dialog are device-
specific. For the settings, refer to the documentation of the correspond‐
ing I/O Inline terminal.
The following parameters are relevant for the initial commissioning:
The address has to be identical to the F_DEST_Add set in the
"Safe configuration" tab
● I_Par_CRC32: It is automatically calculated and has to be updated
manually in the "Safe configuration" after changing the safe param‐
eters

Commissioning
Fig. 5-6: Setting the safe parameterization of a PROFIsafe Inline termi‐

nal
The Inline terminals can be operated as single channel or double chan‐
nel. That means that four to eight I/Os are available for each Inline ter‐
minal. Each channel has to be enabled separately.
For more information on the parameterization, refer to chapter 4.1.3 "In‐
line PSDI 8 and PSDI 16 (PROFIsafe data input)" on page 19 and chap‐
ter 4.1.4 "Inline PSDO 8 and PSDOR 4 (PROFIsafe data output)" on
page 20.
After the parameterization, "I_Par_CRC32" has to be copied from

the "Safe parameterization" dialog to the "Safe configuration"
(F_iPar_CRC) dialog.
Note that F_Dest_Add and F_Source_Add may not have the

same value.
The safe inputs and outputs are parameterized (offline).

These parameters are only loaded and thus applied to the control
after logging into the standard control and into the safety control!
3. Creating a program
Create the “Profisafe_PRG” program via the context menu item "Add" at
the "SafetyApp". Decide whether to work on "Basic level" (Safety Basic‐
POU) or on "Extended level" (Safety ExtendedPOU).
We work on "Extended level".

"Basic level" does not permit writing on WORD variables for ex‐
ample. Thus, diagnostics ("DiagCode" output) cannot be issued at
the Safety PLCopen function blocks.
Fig. 5-7: "Profisafe_PRG" program with declaration part and a network

Commissioning
4. Inserting "ProfisafeHost" function blocks into the program

The "ProfisafeHost" function block monitors the safe communication.
The function block is automatically created for each PROFIsafe Inline
terminal.
To activate the function block, a reference has to be set to the instance
of the function block in a Safety program or a Safety function block.
A function block has to be inserted via the context menu item Insert FB
call. After selecting the menu item, the input assistant is displayed. The
"ProfisafeHost" function block can be selected in this input assistant.
Fig. 5-8: Selecting the "ProfisafeHost" function block

After creating the function block, connect the function block with an in‐
stance.
Fig. 5-9: Setting the "ProfisafeHost" instance
Fig. 5-10: Selecting the "ProfisafeHost" instance in the input assistant

Activate as shown in the following figure.
The inputs "activate_FV_C", "ipar_EN_C" and "AutoOA" are preas‐
signed with "FALSE". The "StartOA" input is preassigned with "TRUE".
Attach the F_Dest address to variable names to obtain a unique assign‐
ment.
The outputs can be summarized to group status messages using OR
operations.

Commissioning
Fig. 5-11: Created and activated "ProfisafeHost" instance
5.3.2 Creating and configuring PROFIsafe Inline terminals at the Profinet

PROFISafe Inline terminals can only be operated at one Profinet coupler of
type "R-IL PN BK DI8 DO4" (ordering no. R911171944). This bus coupler has
to be created below the "Profinet I/O controller" node in the project.
The easiest method to apply the bus configuration to the project is to scan
the Profinet bus and to apply the devices found to the project. This is also ap‐
plicable to the S20-PROFIsafe and to any Profinet devices. The prerequisite
is that the GSDML was imported in IndraWorks before. If there is no hard‐
ware when projecting, proceed as for the PROFIsafe terminals under
Profibus.
1. Searching devices at the Profinet
Starting the search via the menu item "Scan devices…" in the context
menu of the node "PROFINET_IO_Controller".
Fig. 5-12: Starting the Profinet search

A list is displayed containing the Profinet devices found at the Profinet
controller.
2. This step is only required for PROFIsafe Inline modules.

The "R-IL PN BK DI8 DO4" bus couplers have to be searched and ex‐
panded in the list of the Profinet devices found. The found PROFIsafe
modules are located below the bus coupler. As the ident number of all

Commissioning
PROFIsafe Inline modules is identical, assign the module types manual‐

ly. Click on the selection in the "Device type" field.
Fig. 5-13: Selection lists for PROFIsafe Inline device types in the Profinet
search result
Select the correct device type in the window.
Fig. 5-14: Selecting the Inline device type for PROFIsafe modules
3. Click on “Copy all devices to project” to apply the found Profinet devices
to the project.
The logic I/O belonging to a PROFIsafe Inline terminal is automatically
created below the "Logic I/Os" node.

Commissioning
Fig. 5-15: Inserted Profinet devices including the PROFIsafe terminals
4. Parameterizing PROFIsafe terminals
Fig. 5-16: Assigning logic and physical I/Os to a PROFIsafe terminal

The PROFIsafe terminals are parameterized in the dialogs "Safe config‐
uration" and "Safe parameterization" below the "Logic I/O" node. The
following parameters for the initial commissioning are important in the
log parameters of the "Safe configuration":
● F_Source_Add: Address of the PROFIsafe master. This address
has to be identical for all devices

Commissioning
The following addresses result from the example fig. 5-4 "Assign‐
ing logic and physical I/Os to a PROFIsafe Inline terminal" on page
33:
R_IB_IL_24_PSDI_8: F_Dest_Add= 22
R_IB_IL_24_PSDO_8: F_Dest_Add= 23
● F_iPar_CRC: Checksum of the "Safe parameterization"
The checksum has to be applied always after changing the config‐
uration of the safe I/Os
● F_WD_Time: This parameter is the monitoring period within a
Safety telegram has to be answered
If this time elapses, the Inline terminal goes into the "Safe state". A
tems". The value should to be at least 2*SafetyTask time
The actual time for the response times can be determined at the Profi‐
safeHost instances of each connection in the Safety application.
Fig. 5-17: Setting the safe configuration of a PROFIsafe Inline terminal

ing I/O terminal.
set at the DIP switches of the PROFIsafe terminal (see "Setting the
DIP switches" on page 15)
The address has to be identical to the F_DEST_Add set in the
"Safe configuration" tab
● I_Par_CRC32: It is automatically calculated and has to be updated
manually in the "Safe configuration" after changing the safe param‐
eters

Commissioning
Fig. 5-18: Setting the safe parameterization of a PROFIsafe terminal

The PROFIsafe terminals can be operated as single channel or double
channel. That means that four to eight I/Os are available for each Inline
terminal. Each channel has to be enabled separately.
For more information on the parameterization, refer to chapter 4.1.3 "In‐
line PSDI 8 and PSDI 16 (PROFIsafe data input)" on page 19 and chap‐
ter 4.1.4 "Inline PSDO 8 and PSDOR 4 (PROFIsafe data output)" on
page 20.
After the parameterization, "I_Par_CRC32" has to be copied from

the "Safe parameterization" dialog to the "Safe configuration"
(F_iPar_CRC) dialog.
Note that F_Dest_Add and F_Source_Add may not have the

same value.

These parameters are only loaded and thus applied to the control
after logging into the standard control and into the safety control!
5. Creating a program
Create the “Profisafe_PRG” program via the context menu item "Add" at
the "SafetyApp". Decide whether to work on "Basic level" (Safety Basic‐
POU) or on "Extended level" (Safety ExtendedPOU).
We work on "Extended level".

"Basic level" does not permit writing on WORD variables for ex‐
ample. Thus, diagnostics ("DiagCode" output) cannot be issued at
the Safety PLCopen function blocks.

Commissioning
Fig. 5-19: "Profisafe_PRG" program with declaration part and a network
6. Inserting "ProfisafeHost" function blocks into the program

The "ProfisafeHost" function block monitors the safe communication.
The function block is automatically created for each PROFIsafe Inline
terminal.
To activate the function block, a reference has to be set to the instance
of the function block in a Safety program or a Safety function block.
A function block has to be inserted via the context menu item Insert FB
call. After selecting the menu item, the input assistant is displayed. The
"ProfisafeHost" function block can be selected in this input assistant.
Fig. 5-20: Selecting the "ProfisafeHost" function block

After creating the function block, connect the function block with an in‐
stance.
Fig. 5-21: Setting the "ProfisafeHost" instance
Fig. 5-22: Selecting the "ProfisafeHost" instance in the input assistant

Activate as shown in the following figure.

Commissioning
The inputs "activate_FV_C", "ipar_EN_C" and "AutoOA" are preas‐

signed with "FALSE". The "StartOA" input is preassigned with "TRUE".
Attach the F_Dest address to variable names to obtain a unique assign‐
ment.
The outputs can be summarized to group status messages using OR
operations.
Fig. 5-23: Created and activated "ProfisafeHost" instance
5.4 CSos
5.4.1 Creating and configuring CSos S20 terminals
1. Inserting CSos S20 terminals
CSos S20 terminals are inserted at the slave via the context menu item
"Add" below the Sercos node, here "S20-S3-BK+".
The CSos S20 terminals are automatically created below "Logic I/Os".
Fig. 5-24: CSos I/O on the standard control and on the safety control
To which logic I/O the physical I/O is linked, can be seen in the "I/O
mapping" of the CSos S20 terminal and changed if necessary.
There has to be at least one entry to use the Safety I/Os in the safety
control.

Commissioning
The order of the CSos S20 terminals at the bus coupler has to
correspond to the order in the project tree.
2. Parameterizing CSos S20 terminals
Fig. 5-25: Assigning logic and physical I/Os to a CSos S20 terminal
The CSos S20 terminals are parameterized in the dialogs "Safe configu‐
ration" and "Safe parameterization" below the "Logic I/Os" node. The
following parameters for the initial commissioning are important in the
log parameters of the "Safe configuration":
● Safety Network Number (SNN): Uniquely identifies the network via
all safety systems. The default value is 0x600000001. The maxi‐
mum value for CSos S20 I/Os is 0x6000001F (see "Setting the DIP
switches" on page 27)
● Safety Device ID (SDID): Logical address of the CSos S20 I/Os.
The default value is 1, the maximum value for CSos S20 I/Os is
127 (see "Setting the DIP switches" on page 27)
● Safety Configuration CRC (SCCRC): Checksum of the "Safe pa‐
rameterization".
The checksum always has to be applied after changing the param‐
eterization of the safe I/Os
● Network Time Expectation (NTE): This parameter is the monitoring
period within which a Safety telegram has to be answered.
If this time elapses, the S20 terminal goes into the "Safe state". A
tems".
The required NTE can be calculated as follows: NTE ≥ (TiMu+3) *
Safety cycle time [ms].
The actual time for the response can be determined via the CSo‐
sOriginator function block of the connection in the Safety applica‐
tion. The signal propagation delay is only available for connections
receiving data. No signal propagation time is available for sending
connections.

Commissioning
Fig. 5-26: Setting the safe configuration of a CSos S20 terminal

ing CSos S20 terminal.
● SNN/SDID: TUNID of the CSos S20 terminal set at the DIP
switches of the CSos S20 terminal (see "Setting the DIP switches"
on page 27)
● SCCRC: It is automatically calculated and has to be updated after
changing the safe parameters manually in the "Safe configuration"
Fig. 5-27: Setting the safe parameterization of a CSos S20 terminal

The CSos S20 terminals can be operated as single channel or double
channel. Thus, four to eight I/Os are available for each CSos S20 termi‐
nal.
After the parameterization, "SCCRC" has to be copied from the

"Safe parameterization" dialog to the "Safe configuration" dialog.

These parameters are only loaded to the control by logging into
the standard control and into the safety control!
3. Inserting "CSosOriginator" function blocks into the program
The "CSosOriginator" function block monitors the safe communication to
the CSos S20 terminals.

Commissioning
One CSosOriginator instance is created for each CSos terminal. To acti‐

vate the function block, a reference has to be set to the instance of the
function block in a Safety program or a Safety function block.
The procedure is analog to that of the "ProfisafeHost" function blocks
(see fig. 5-9 "Setting the "ProfisafeHost" instance" on page 36).
The "CSosOriginator" is located under "SafetyCSos". The inputs "acti‐
vate_FV_C" and "AutoOA" are preassigned with "FALSE". The "Star‐
tOA" input is preassigned with "TRUE".
Fig. 5-28: Activating the CSos instances of a CSos S20 terminal
5.4.2 IndraDrive with CSos

The drive firmware supports CSos
1. Creating drives
Drag IndraDrive on the "Sercos" node in the Project Explorer and drop
it.
The drive was inserted below the Sercos node and below Motion ▶ Real
axes.
Existing drives can also be scanned at the Sercos bus.
2. Configuring CIP Safety on Sercos

After selecting the item Configuration CIP Safety on Sercos... in the con‐
text menu of the node Sercos ▶ Drive name ▶ Axis, the configuration di‐
alog opens. The desired safety function of the drive is selected in the
configuration dialog.

Commissioning
Fig. 5-29: CSos dialog

Both logic I/Os for the CSos functionality were created below the safety
control.
Fig. 5-30: Logic I/Os of the drive "Drive1"
"Control" stands for the information from the safety control to the drive.
"Status" stands for the information from the drive to the safety control.
The information can be accessed bit by bit (always "I/O mapping" tab).
3. Parameterizing the "Logic I/Os"

See step 2 in chapter 5.4.1 "Creating and configuring CSos S20 termi‐
nals" on page 43.
4. Inserting "CSosOriginator" function blocks into the program
The "CSosOriginator" function block monitors the safe communication to
the drives.
It is automatically created twice for each CSos drive. A CSos-capable
drive is always provided with two channels: One status channel and one
control channel. One instance of the "CSosOriginator" function block is
created for each channel. To activate the function block, a reference has
to be set to the instance of the function block in a Safety program or a
Safety function block.
The procedure is analog to that of the "ProfisafeHost" function blocks
(see fig. 5-9 "Setting the "ProfisafeHost" instance" on page 36).
The "CSosOriginator" is located under "SafetyCSos".
Note on the activation: The inputs "activate_FV_C" and "AutoOA" are
preassigned with "FALSE". The "StartOA" input is preassigned with
"TRUE".

Commissioning
Fig. 5-31: Activating CSos instances of a drive
Controlling the SafeMotion via Different safe motion modes can be controlled via bits in the control word/
control bits byte:
Fig. 5-32: Control bits of a drive with Safe Motion

Commissioning
Input combination Value SafeMotion Function

function
EmergencyStopSignal 1 None Normal mode

ModeSelectionSignal 1
EmergencyStopSignal 0 SMES Safe Motion Emergency Stop
EmergencyStopSignal 1 SMSS1 Safe Motion Safe Stop 11)
Enabling Control 0 SMSS2 Safe Motion Safe Stop 21)
EmergencyStopSignal 1 SMM1 Safe Motion Mode 12)
Enabling Control 1
SMM1 1
...
EmergencyStopSignal 1 SMM16 Safe Motion Mode 162)
Enabling Control 1
SMM16 1
1) Depending on the configuration in the drive, either Safe Stop 1
or Safe Stop 2
2) The enabled operation modes as well as their parameters are
specified in the drive configuration
Tab. 5-1: Enabling the Safe Motion mode in the drive
Controlling the SafeMotion via Instead of using the bit of the SafeMotion control word, controlling via Safe‐
function blocks Motion function blocks is also possible. Variables in the control word and in
the status word do not have to be used at all. The drive is referenced via an
"AxisID" corresponding to the SDID configured in the SafeMotion.
The SafeMotion function block is in the SafetyDriveMotion library. The follow‐
ing function blocks are available:
● SF_MotionEmergencyStop: Controlling the EmergencyStop functionality
of the drive
● SF_MotionSafeStop: Controlling the SafeStop functionality of the drive
● SF_SMMSelector: Controlling an SMM (SafeMotionMode)
● SF_AxisGroup: Summarizes multiple axes to one group.
There are the following advantages when using the function blocks:
● Controlling the SafeMotion functionality is monitored. It is checked
whether the drive actually reaches the required state.
● No variables have to be created and interconnected in the control word
and in the status word.
● The functions can be modularized easier when using the “AxisID” as on‐
ly reference.
● By grouping axes with the same safety function, multiple axes can be
commanded simultaneously using SafeMotion function blocks.
All function blocks can be operated individually. However, the function block
"SF_MotionEmergencyStop" always has to be available if the functionality is
used.

Commissioning
Fig. 5-33: Example program to control one axis with two SafeMotion function
blocks
5.5 Exchanging variables with standard PLC

The SafeLogic safety control supports logic exchange variables in order not
to exchange safety-relevant information between the standard and the safety
control. These can be created with the following steps.
A lot of information on the safety control and on the connected

safe field bus devices can be retrieved on the standard PLC also
directly via the global variable SafetyData (see chapter 7.7 "Diag‐
nostics on the standard PLC control" on page 71). Thus, only a
small number of logic exchange variables has to be created.
1. Adding the data exchange with the standard application

Use logic exchange devices to exchange variables between the stand‐
ard control (grey PLC) and the safety control (yellow PLC).
To create a logic exchange device, select the required data type and the
direction of the data flow in the context menu of the node Safe‐
tyApp ▶ Logic I/Os below Add ▶ Logic exchange devices.

Commissioning
The variables can subsequently be created on the safe area in the logic
exchange device.
Fig. 5-34: Creating variables in the logic exchange device
Only non-safe variables can be exchanged (see chapter 6.6

"Converting variables (safe ⇔ not safe)" on page 64).
2. In the standard PLC, a Global Variable List has to be subsequently cre‐
ated for the logic data exchange. In the variable list, the corresponding
list has to be selected from the safe PLC below "Logical exchange map‐
ping". The variables entered into the list are applied automatically.
Fig. 5-35: GVL for logic I/Os
If the variable list changes on the safety control, refresh the list.
5.6 Safety network variables

The NVL (Safety NetworkVariable List) contains variable declarations trans‐
ferred to or from another safety control. The Safety network variables can be
used in all safety application programs. The Safety network variables are ac‐
cessed via the objects "Safety network variable list (sender)”" and "Safety
network variable list (receiver)".

Commissioning
Safety network variables can be declared VAR_EXTERNAL like global varia‐

bles in the safety application.
The following data types can be exchanged via network variables:
● SAFEBOOL
● SAFEWORD
● SAFEINT
At the sender, network variables are outputs of the application. That is, one
value has to be assigned once in the cycle. At the receiver, network variables
are inputs of the application. This means that they may be read, but it may
not be written to them.
An NVL sending list can be transferred to multiple receivers simultaneously.
The receivers have to log in at the sender to receive the variables. As an indi‐
vidual connection is created for each configured receiver, reduce the number
of receivers to a minimum.
The connection monitoring of NVLs is performed via the function blocks "Net‐
VarReceiver" and "NetVarSender". The required instances are created auto‐
matically. Function blocks cannot access network variables.
To use Safety network variables, at least two Safety controls have to be con‐
tained in the project. Both controls have to communicate to each other via
Ethernet.
Fig. 5-36: Creating multiple safety controls in one project

Commissioning
The names of the two Safety applications have to be different.

Creating a safe sender GVL
1. Open the context menu of the Safety application on the safe sending
control and select "Safety NVL sender…".
A new Safety NVL sending list is inserted below the Safety application.
2. Set the Safety address of the sender and the required number of receiv‐
ers in the "Safety configuration" tab (by default, the maximum number is
set to 4 receiver).
Fig. 5-37: Setting the Safety address and the maximum number of receiv‐
ers
3. Set the IP address of the receiver controls in the "PLC network" tab
(each receiver control has an individual entry).
Default setting: The controls are addressed via the broadcast address.
However, the default setting generated computational load on all

network devices as the broadcast packages are received by all
devices and have to be processed individually.
Disable the default setting and directly enter the IP address of the
target control.
If standard network variables and Safety network variables are

used on the standard control simultaneously, double assignment
of the "1202" port can occur as port "1202" is the standard config‐
uration of both network variables.
In this case, the network variables do not work!
To prevent double assignment, it is recommended to set the port
configuration of the Safety network variables for receiver and
sender to a different port (e.g. "1209").
Fig. 5-38: Setting the IP address and the port of the receiver control
4. Add the required or desired variable declarations to the Safety NVL
sender.

Commissioning
Fig. 5-39: Inserting a variable declaration into an NVL of the sender

Creating a safe receiving NVL
1. Select the safe receiver control in the Project Explorer and open the
context menu of the Safety application.
Select the context command Add ▶ Safety-NVL receiver….
A new Safety NVL receiving list is inserted below the Safety application.
2. Assign a sender to the receiver in the window of the NVL receiving list.
Fig. 5-40: Selecting the NVL sending list

The sending list is assigned to the receiving list.
The list identifier has to be entered manually in the "PLC network" tab.
Use the identifier of the reserved variable list identifiers of the sender.
Disable the default setting and directly enter the IP address of the
sender control.
All declared variables of the NVL sending list are applied to the
NVL receiving list.
Fig. 5-41: Applying safe network variables of the sending NVL and the re‐
ceiving NVL

Commissioning
To operate the safe NVL, one function block is necessary at the sender and
one at the receiver. This is the function block "NetVarSender" for the sender
NVL and the function block "NetVarReceiver" for the receiver NVL. These are
created with NVLs and have to be implemented into the Safety program as
VAR_EXTERNAL.
● The function block "NetVarSender" controls sending of the variable
list.
● The function block "NetVarReceiver" establishes a connection to the
network variable sender list. The connection is monitored by using the
watchdog time.
Both function blocks have to be created on the respective Safety control.
Fig. 5-42: Example of an interconnection of a “NetVarSender” function block
Fig. 5-43: Example of an interconnection of a “NetVarReceiver” function block
5.7 Programming example

The SafeLogic programming example for a program in the "Extended Level"
is the Two-Hand Control with EDM of the document "PLCopen - Technical
Committee 5 Safety Software Technical Specification Part 2: User Examples
Version 1.01 - Official Release". It is shown as SafeLogic FBD implementa‐
tion.
It is programmed in the "Extended Level" to assign diagnostic in‐

formation from the "DiagCode" outputs of the Safety PLCopen
function blocks to WORD variables. This is not possible in the
current implementation on "Basic Level".
Describing the safety functions The following safety functions are used in this example:
● When pressing the E-STOP button, all dangerous motions have to be
stopped (via SF_EmergencyStop).
E-STOP has the highest priority.
After releasing the E-STOP button, reset via Reset
● The safety output is enabled by pressing both the pushbuttons of the
two-hand control.

Commissioning
Releasing one of the two-hand pushbuttons disables the safety output

and stops the dangerous motion via the switching devices K1 and K2
(via SF_TwoHandControlTypeII)
● The initial state and the operating state of the connected switching devi‐
ces are monitored. If an error is detected, the safety output cannot be‐
come ready for operation (via SF_EDM)
● After activating the safety application or the functional application or af‐
ter an E-STOP condition, the two-hand control has to be released and
pressed again to enable the safety output again (via SF_OutControl).
To ensure this for the functional restart, the process signal of the func‐
tional application is connected to the "Activate" input of the two-hand
control function block "THC_S2_S3".
If the application process is started again while the two-hand control is
enabled, the function block goes into the state 16#C003.
This status signals an error in which both buttons are pressed during ac‐
tivation, thus preventing a restart.
Only one operating state exists in this example.

Commissioning
Fig. 5-44: Declaration for programming example: two-hand control with EDM
Commissioning
Fig. 5-45: Implementation on the example: Two-hand check with EDM
Name Data type Description
S1_S_EStopIn SAFEBOOL E-STOP button S1

S2_S_Switch1 SAFEBOOL Switch S2 connected to pushbutton 1 of the two-hand control
S3_S_Switch2 SAFEBOOL Switch S3 connected to pushbutton 2 of the two-hand control
K1_S_EDM1 SAFEBOOL Feedback of external device K1
K2_S_EDM2 SAFEBOOL Feedback of external device K2
Reset BOOL Reset of standard control
Process BOOL Enabling the motion by the process of the standard control
Tab. 5-2: Function block inputs
S_EDM_Out_EDM_K1_K2 SAFEBOOL Enabling signal for the safety control (safe drives...)
S_EDM_Out_EDM_K1_K2_unsafe BOOL Enabling signal for the standard control (not safe)
Error_EStop_S1 BOOL Error flag of EStop_S1
Error_THC_S2_S3 BOOL Error flag of TCH_S2_S3
Error_OC_K1_K2 BOOL Error flag of OC_K1_K2
Error_EDM_K1_K2 BOOL Error flag of EDM_K1_K2
Diag_EStop_S1 WORD Diagnostic code for EStop_S1
16#8xxx: Regular operation
16#Cxxx if error in EStop_S1
Diag_THC_S2_S3 WORD Diagnostic code for THC_S2_S3
16#Cxxx if error in THC_S2_S3

Commissioning

Diag_OC_K1_K2 WORD Diagnostic code for OC_K1_K2
16#Cxxx if error in OC_K1_K2
Diag_EDM_K1_K2 WORD Diagnostic code for EDM_K1_K2
16#Cxxx if error in EDM_K1_K2
Tab. 5-3: Function block outputs

Additional information The example can also be used with SF_TwoHandControlTypeIII.
For simplicity reasons, the "Activate" input was set to TRUE. In the applica‐
tion, this can be replaced by a variable.
Function block Input Constant val‐ Description

ue
EStop_S1 S_StartReset FALSE No automatic reset if the S-PLC is started

S_AutoReset FALSE No automatic reset. Reset/acknowledgement required by operator
OC_K1_K2 S_StartReset TRUE Automatic reset permitted if the S-PLC is started
S_AutoReset TRUE Automatic reset. No reset/acknowledgement required by operator
Static Control FALSE A dynamic modification of the "Appl_Control" signal (rising edge) is
requested after enabling the function block or a triggered safety func‐
tion (S_SafeControl to FALSE)
EDM_K1_K2 S_StartReset FALSE No automatic reset if the S-PLC is started
MonitoringTime T#200 ms The maximum response time of both feedback signals
S_EDM1 and S_EDM2
Tab. 5-4: Information on the function block parameters used
5.8 Loading and starting projects on the control

1. Logging into the application on the standard control
By logging in, the PLC program is loaded to the control. The data ex‐
change to the safe control is still established.
2. Loading the Motion configuration from PC to control
Create drives using the function "Synchronize -> Download Motion con‐
figuration to the device" in the context menu of the control. The Sercos
bus has to be in P4 or BB.
3. Logging into "SafeApp" on the safety control
When logging into the safety control, the Safety program is loaded to the
RAM of the safety control.
If a new project is loaded to the safety control, press the button on the
Safety function module. It is prompted for the control password at each
login, even if no password is set.
If the Safety program is to remain on the safety control after logout, ap‐
ply the boot project.
Enable the "SafetyApp" via Set active application and generate the boot
project via the menu item Debug ▶ Generate boot application.

Commissioning
4. Starting the PLC (standard application and safety application)

Both controls are started.
The PROFIsafe and the CSos communication start correctly. All yellow
Inline couplers should display green in the status LEDs "D" and "UM".
The "ProfisafeHost" and "CSosOriginator" function blocks do not display
any errors and the "FV_activated_S" output is FALSE.
The data exchange between standard control and safety control is ac‐
tive.
5.9 Modifying projects

The application on the safety control can only be modified if logged off from
the safety control.
With each change at the Safety I/Os (PROFIsafe, CSos, data exchange devi‐
ces), the program on the standard control as well as the program on the safe‐
ty control have to be refreshed (login/download).

Troubleshooting
6 Troubleshooting
This chapter supports the troubleshooting in Safety projects. It lists all typical
problems and their solutions.
6.1 SafeLogic interface

● Problem: When trying to download the SafeLogic program, the following
message is displayed:
Fig. 6-1: SafeLogic compilation error

Cause: SafeLogic program contains syntactic errors.
Solution: Check the error output (in the message window) and debug
the error in the SafeLogic program.
● Problem: When trying to log in to the Safety function module, the follow‐
ing message is displayed:
Fig. 6-2: SafeLogic connection error

Cause: Either the firmware of the Safety function module or the firmware
of the standard control are outdated or there is no Safety module on the
control.
Solution: Check firmware versions and update if required. For the stand‐
ard control, the firmware version can be updated via the connection test
in the "Properties" dialog of the control. For the Safety function module,
the firmware version can be checked in the "Status" dialog of the Safety
function module (double-click on the Safety function module, "Status"
tab).
● Problem: While downloading the PLC program to the standard control, a
message is displayed informing on the different config. IDs.
Cause: The config ID of the standard control is not equal to the one of
the Safety control (see fig. 7-1 "Status tab" on page 68)
Solution: Reload the standard control and the Safety control.

Troubleshooting
6.2 SafeLogic function module

● Problem: After starting up the system, the FS-LED flashes red at the
Safety function module. The Safety application is not running.
Cause: There is no Safety boot application. Thus, no Safety application
could be loaded as well.
Solution: Store a boot application on the Safety function module. Go to
the menu item Create ▶ Generate boot application.
● Problem: Three LEDs are red at the Safety function module. The Safety
application is not running.
Cause: The Safety control is in the safe state due to a fatal error.
Solution: Restart the control and analyze the log of the safety control
(see fig. 7-2 "Safety control logbook" on page 68).
6.3 PROFIsafe
● Problem: Individual PROFIsafe devices (Safety Inline terminals at the
Profibus coupler) loose their connection sporadically. The "Profisafe‐
Host" function block of the corresponding devices displays the error
code C104.
Cause: Profibus is not running stable. Incorrectly set terminal resistan‐
ces are frequently the cause.
Solution: For Profibus, the terminal resistances are only to be activated
at cable ends. All other terminal resistances have to be disabled. Other‐
wise, electrical waves reflect. This corrupts data.
● Problem: Individual PROFIsafe devices (Safety Inline terminals at the
Profibus coupler) do not establish any connection. The "ProfisafeHost"
function block of the corresponding devices displays the error code
C102.
Cause: Data is not exchanged between the Safety control and the
PROFIsafe devices.
Solution:
– Ensure that the IOConfigIDs are identical on the standard control
and on the safety control. Use SafetyData.Safe-
tyFM.State.IOConfigIDState.
– Use the global data structure “SafetyData” to check whether the in‐
puts and the outputs of the respective PROFIsafe devices are
transmitted.
– Check whether the respective device was disabled via "User‐
Defs.cfg".
– Check the I/O addresses of the Profibus/PROFINET device.
– Ensure that the standard PLC does not have write access on the
I/O addresses of the Safety device.
● Problem: The Profibus diagnostics of the coupler does not contain the
slot number (slot of the Inline terminal).
Cause: The IndraWorks Profibus diagnostics identifies only the Profibus
coupler as device.
Solution: The slot number (slot of the Inline terminal) is included in the
"Extended diagnostics" (refer to the following figure). The slot can be
counted. Position the cursor over the diagnostic text and a tooltip with
additional information is provided if available.

Troubleshooting
Fig. 6-3: Slot number of the extended Profibus diagnostics and addition‐
al information as tooltip
● Problem: UT1 and/or UT2 flash(es) at runtime.
Cause: There is a problem with wiring. This problem can be caused as
follows:
1. The supply outputs are short-circuited against another cable.
2. A test pulse clock is selected for the input or for the output. Howev‐
er, the connected device generates its own test pulse clock.
3. The cables for the test pulses were interchanged with other inputs
or outputs.
Solution: Check wiring. Disable test pulses if required.
6.4 CIP Safety on Sercos

● Problem: If projects are applied from 13V08 or 14V02, drives with CSos
do not longer operate. Projects can also not be edited correctly any‐
more.
Cause: In 13V14 and 14V04, the logic CSos devices (below the "Logic
I/Os" node) of the drives were changed. Thus, the logic CSos devices
do not match the CSos devices in the project anymore.
Solution: Create the logic devices of the drives again. Proceed as fol‐
lows for each drive:
1. Cancel the CSos connection: Open the context menu of the drive
in the Project Explorer under Sercos ▶ Drive name ▶ Drive and se‐
lect "CSos settings".
Disable CSos and close the dialog.
2. Rename the logic I/Os belonging to the drive below the "Logical
devices" node. It is recommended to attach "_old".
3. Create a new CSos connection: Open the CSos settings again and
enable CSos for the drive.
A new logic device for the drive is created below the "Logic I/Os"
node of the safety control.

Troubleshooting
4. All settings and variables from the old logic device are applied to
the new device.
5. Delete the old logic device.
● Problem: The CSos connections are interrupted again and again after
timeouts.
Cause: A cyclic data timeout is exceeded, i.e. insufficient number of pro‐
duced data packages.
Solution: Increase the configuration value "NTE" of 4*Safety cycle time
in the CSos settings for the "safe communication".
6.5 Safety PLCopen function blocks

● Problem: The Safety PLCopen function block "SF_GuardMonitoring" re‐
mains in the "State 8002" after the start and cannot be reset via the
"Reset" input.
Cause: The inputs "S_GuardSwitch1" and "S_GuardSwitch2" are direct‐
ly connected to a PROFIsafe Inline terminal. When starting the applica‐
tion, these inputs are sporadically FALSE for one cycle. Due to the state
machine defined in the PLCopen, the function block remains in this
state.
Solution: The "Activate" input of the "SF_GuardMonitoring" function
block may only be enabled after the PROFIsafe data exchange has star‐
ted. OR operate the "FV_activated_S" outputs of the "ProfisafeHost"
function block instances and use them as trigger for the "Activate" input
of the PLCopen function blocks.
Fig. 6-4: OR operation of the "FV_activated_S" outputs
6.6 Converting variables (safe ⇔ not safe)

● Problem: A non-safe variable is to be converted into a safe variable.
Solution: Conversion via an AND operation.
Fig. 6-5: Converting a non-safe variable into a safe variable
A safe variable may only be converted into a non-safe variable for

test purposes. For real machines, further safety actions are re‐
quired.
● Problem: A safe variable is to be applied to the "grey" control via

VAR_EXTERNAL.
Solution: Assign a safe variable to a non-safe variable.

Troubleshooting
Fig. 6-6: Converting a safe variable into a non-safe variable


Diagnostics
7 Diagnostics
7.1 Overview
IndraWorks:
● Safety Function module - Status (see chapter 7.2 "Status of the Safety
function module" on page 67)
● Safety Function module - Logbook (see chapter 7.3 "Log of the Safety
function module" on page 68)
● Standard control - Log (refer to chapter 7.4 "Log of the standard con‐
trol" on page 69)
● Standard control - Device diagnostics (refer to chapter 7.5 "Device di‐
agnostics of the standard control" on page 70)
● SafeLogic - Function blocks (refer to chapter 7.6 "Diagnostic outputs of
the ProfisafeHost and CSosOriginator function blocks" on page 71)
● Diagnostics on the standard PLC control, refer to chapter 7.7 "Diagnos‐
tics on the standard PLC control" on page 71
● Sercos I/O diagnostics
● Sercos ▶ HCS02.x ▶ Parameter editor
● Sercos ▶ HCS02.x ▶ Axis_x ▶ Error/diagnostic memory
● MTX debug menu (show functions)
7.2 Status of the Safety function module

For the status of the Safety function module, go to the Project Explorer, dou‐
ble-click on the function module and select the "Status" tab.
No Safety license is required for this display. The Safety connec‐

tion does not have to be confirmed via the button of the safety
control.
To obtain the current module status, press the Refresh button.

Diagnostics
Fig. 7-1: "Status" tab
7.3 Log of the Safety function module
Fig. 7-2: Safety control logbook
The license "IndraWorks SafetyManager Lite" is at least required

for this display. This connection is possible via "remote access".

Diagnostics
The logbook is displayed in the Log tab of the Safety control and is used as
protocol and to diagnose runtime errors of the application and system errors.
The log can be used to find the error cause in the PLC or in the application.
Two logs are available in SafeLogic:
● Device logbook
● Application log
The device log is part of the device and is intended for entries concerning the
device, such as system errors or generating new boot applications.
The application log is part of the IEC application and is intended for entries
concerning the application, such as runtime errors, errors while loading the
boot application and errors during online communication.
The application log is the default log of the Safety control. The device log is
only available if the default log (application log) has been loaded.
Press the button to load all available logs (device log and application
log) cyclically from the control. They can then be subsequently selected in the
Logger window.
The information shown in the logs is structured as follows:
● Weighting (information, warning, error, exception)
● Time stamp
● Error description
● Component (generator)
7.4 Log of the standard control

For example, the logbook of the standard control logs problems occurring
when trying to establish a connection and during the data transfer from or to
safe bus devices. To go to the log, double-click on the standard control and
select the Log tab.
The log of the standard PLC is in the RAM of the control. The log is not lost
when switching off and on the control.
Fig. 7-3: Device editor – Log
To enable the log, go to Tools ▶ Options... and subsequently to

IL2G ▶ General settings.

Diagnostics
7.5 Device diagnostics of the standard control

MLC system The "Error/diagnostic memory" dialog provides an overview on all diagnostic
messages of the control and the connected devices. The diagnostic messag‐
es are sorted automatically. The latest messages are on top of the list. The
messages of the standard PLC are also stored in a shortened version.
The log entries are remanently stored on the control and are thus still availa‐
ble after switching off and on the control. The memory of the device diagnos‐
tics is limited to 100,000 entries.
Fig. 7-4: Example of an MLC diagnostic logbook representation

This dialog can be opened online and offline. Some functions are disabled in
offline mode.
MTX system The "Device diagnostics" dialog shows messages, warnings and errors gen‐
erated by the MTX system.
These messages can be applied to a log. The data is persistently stored in a
database on the PC. Multiple logs can be created with 1,000 entries each.
Fig. 7-5: Example of the MTX device diagnostics

Diagnostics
7.6 Diagnostic outputs of the ProfisafeHost and CSosOriginator

function blocks
To monitor the connection to safe field bus devices, the function blocks "Pro‐
fisafeHost" and "CSosOriginator" are provided. Both function blocks provide
the "DiagCode" output. The "CSosOriginator" additionally provides the "Dia‐
gCodeExt" output. If there is a connection problem to the save field bus devi‐
ces, these outputs point directly towards the error cause.
The license "IndraWorks SafetyManager Lite" is at least required

for this display. This connection is possible via "remote access".
For the error codes, refer to the function blocks in the online helps.
Fig. 7-6: Error information at the ProfisafeHost and CSosOriginator

function blocks
7.7 Diagnostics on the standard PLC control

For many applications, it is required that the standard control is provided with
a read-only access to the safe I/Os of the safety control. Additionally, more
status information is required from the Safety control to operate the machine.
This information is provided via the global variable SafetyData on the
standard PLC. This variable design is structured. It is automatically created
and updated when compiling the standard PLC application.
Fig. 7-7: Elements of the global variable “SafetyData”

Diagnostics
The global variable SafetyData allows to access the following diagnostic in‐
formation:
● SafetyFM - Status information of the Safety control:
This information is mostly identical to the information given in the "status
of the function module" (chapter 7.2 "Status of the Safety function mod‐
ule" on page 67)
● LogicalIO - Access to safe connections:
This entry facilitates access to safe connections. It hierarchically maps
the devices below the "Logic I/Os" node and the Safety control. Connec‐
tion information is also available in addition to the access to the trans‐
mitted variables
● SafeNetVars - Access to safe network variables:
This entry provides all safe network variable lists known to the control.
Each configured connection is individually visible in case of sender lists.
The connection status is displayed in addition to the access to the trans‐
mitted safe variables
● IoConfig - Disables safe devices:
This entry maps the functionality to teach disabled safe devices. Apart
from the checksum (CRC) of the current configuration, the access to de‐
activation bits is also possible
Information mapped in the global variable “SafetyData” is suitable for the fol‐
lowing areas of application.
● Check the connection status of the safe devices
● Electrical commissioning of safe I/Os
● Status and diagnostic information for HMI devices
● Use safe signals to control the standard PLC program
● Access to diagnostic data without logging into the safety control
The global variable SafetyData does not generate any additional comput‐
ing load in the standard PLC. Only when an entry is accessed, required data
is provided and causes computational load. Entries that are not accessed, do
not generate any computing load.
Entries below the global variable “SafetyData” are provided with the following
properties:
● All entries are always read-only
● The information read has to be considered as unsafe variables
● Information is also updated if the standard PLC is in the "Stop" state
● Data can be recorded via the PLC trace
● The signals are sampled at the access point in time of the standard PLC
program or the monitoring in the debugger. Thus, they do not have to be
synchronous
Example of accessing input data of a safe I/O module:

Diagnostics
Fig. 7-8: Variable definition of a logic I/O (in this example” Modul1In”)
Fig. 7-9: Resulting image under SafetyData.LogicalIO.Modul1In


Style guide Safety programming
8 Style guide Safety programming

8.1 Introduction
Programming under SafeLogic differs from programming the standard control
with regard to new data types, graphic editors, a changed color representa‐
tion of safe variables and the option to verify program parts.
Data can be exchanged with the safe I/Os and the standard control.
For the Safety programming, the standard programming guidelines are al‐
ways applied. Special guidelines for Safety are noted down in the following.
They are based on the PLCopen Safety.
A uniform approach significantly facilitates the readability of the program
code when specifying function block names, types, variables, etc. Thus, oth‐
ers become quicker familiar with the code and troubleshooting can be re‐
duced.
Reference documents ● IEC 61131-3
● PLCopen - Technical Committee 5: Safety Software
Part 1: Concepts and Function Blocks Version 1.0 - Official Release
(2007-01-31)
Part 2: User Examples Version 0.9 - Working Document (2007-06-14)
● CoDeSys Safety - Functional specification programming system
Part 2: Language scope - Version 1.0 (2007-03-06)
8.2 Application structure

The Safety application has to be structured according to safety-relevant func‐
tion groups. Status and error messages are to be output individually for each
function group.
Basic Level The Basic Level is suitable to interconnect I/Os and to create simple logic op‐
erations.
Only FBD is permitted as IEC language.
Additionally, the number of usable function blocks is strictly limited. Only AND
and OR as well as certified function blocks are permitted.
Safety applications are to be created simply by instantiating and interconnect‐
ing existing function blocks. Thus, they can also be easily connected.
Extended Level The Extended Level allows calling complex function blocks.
Only FBD is permitted as IEC language.
Certifying the application is more demanding due to the bigger instruction set.
Note further restrictions on the Safety programming. A POU in "Safety FBD"
may not exceed 50 networks in the default setting for example. This value
can be set via the properties of the "SafetyApp" node.
8.3 Variable names

● Label safe variables with the prefix "S_". This identifies variables easily.
The graphic support (yellow marking) is no safety function. Continue us‐
ing the standard prefixes for data types, such as "S_bSafetyActive"
● Label mapped variables (e.g. to PROFIsafe, Csos or logic exchange de‐
vices) either with the suffix "_IN" or "_OUT"

Style guide Safety programming
The direction is defined with reference to the safety control:

– IN: to the safety control (input)
– OUT: from the safety control (output)

Service and support
9 Service and support

Our worldwide service network provides an optimized and efficient support.
Our experts offer you advice and assistance should you have any queries.
You can contact us 24/7.
Service Germany Our technology-oriented Competence Center in Lohr, Germany, is responsi‐
ble for all your service-related queries for electric drive and controls.
Contact the Service Hotline and Service Helpdesk under:
Phone: +49 9352 40 5060

Fax: +49 9352 18 4941
E-mail: [email protected]
Internet: http://www.boschrexroth.com
Additional information on service, repair (e.g. delivery addresses) and training

can be found on our internet sites.
Service worldwide Outside Germany, please contact your local service office first. For hotline
numbers, refer to the sales office addresses on the internet.
Preparing information To be able to help you more quickly and efficiently, please have the following
information ready:
● Detailed description of malfunction and circumstances
● Type plate specifications of the affected products, in particular type co‐
des and serial numbers
● Your contact data (phone and fax number as well as your e-mail ad‐
dress)


Index
Index
A N
Abbreviations........................................................ 9 Names................................................................... 9
ANSI Z535.6-2006................................................ 8 Names and abbreviations..................................... 9
C P
Commissioning................................................... 31 Product phases..................................................... 1
Create CSos S20 terminals........................... 43 Programming example
Create IndraWorks project............................. 31 Safety, two-hand control with EDM func‐
Create PROFIsafe Inline terminals at the tion block........................................................ 55
Profibus.......................................................... 32 Project goal First Steps - Safety......................... 11
Create PROFIsafe Inline terminals at the Purpose of the documentation.............................. 1
Profinet........................................................... 37
Exchange variables........................................ 50 S
IndraDrive with CSos..................................... 46 Safe network variables
Load and start project.................................... 59 NVL................................................................ 51
Modify project................................................. 60 Safety
Safety network variables................................ 51 Safe variables................................................ 51
Complaints............................................................ 9 Safety instructions................................................. 8
Configuring hardware I/Os.................................. 15 Service hotline.................................................... 77
CSos.............................................................. 26 Signal alert symbol................................................ 8
PROFIsafe..................................................... 15 Signal words......................................................... 8
Criticism................................................................ 9 Style guide application structure......................... 75
Customer Feedback.............................................. 9 Style guide Safety programming......................... 75
Style guide variable names................................. 75
D Suggestions.......................................................... 9
Diagnostics......................................................... 67 Support............................................................... 77
Device diagnostics of the standard control.... 70 Symbols................................................................ 9
Log of the Safety function module................. 68
Log of the standard control............................ 69 T
SafeLogic function blocks.............................. 71 Target groups........................................................ 1
Standard control............................................. 71 Troubleshooting.................................................. 61
Status of the Safety function module............. 67 CIP Safety on Sercos..................................... 63
Documentation Convert variables........................................... 64
Change record................................................. 1 PROFIsafe..................................................... 62
Documentation overview....................................... 1 SafeLogic function module............................. 62
Documentation structure....................................... 2 SafeLogic interface........................................ 61
Documentation, overview...................................... 1 Safety PLCopen function blocks.................... 64
Documentation, purpose....................................... 1
Documentation, structure...................................... 2 V
Documentation, validity......................................... 1 Validity of the documentation................................ 1
F W
Feedback.............................................................. 9 Warnings............................................................... 8
H
Hazard warnings................................................... 8
Helpdesk............................................................. 77
Hotline................................................................. 77
I
Installation........................................................... 13
Device description files.................................. 13
Install the SafetyManager license.................. 13
System prerequisites..................................... 13
Notes
Notes
Bosch Rexroth AG
P.O. Box 13 57
97803 Lohr a.Main, Germany
Bgm.-Dr.-Nebel-Str. 2
97816 Lohr a.Main, Germany
Phone +49 9352 18 0
Fax +49 9352 18 8400
www.boschrexroth.com/electrics
*R911400170*
R911400170
DOK-IWORKS-SL*STEP*V15-CO02-EN-P

Indraworks Safelogic 15Vrs: First Steps

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IndraWorks

Commissioning Manual Edition 02

Type of Documentation Commissioning Manual

Document Typecode DOK-IWORKS-SL*STEP*V15-CO02-EN-P

Internal File Reference RS-f0428d34854d08040a347e863c306e8e-2-en-US-4

Change Record Edition 02, 2021-04

1 About this documentation.............................................................................................. 1

2 Project goal "First Steps - Safety"................................................................................ 11

4 Configuring hardware I/Os........................................................................................... 15

R911400170_Edition 02 Bosch Rexroth AG

8 Style guide Safety programming.................................................................................. 75

9 Service and support..................................................................................................... 77

Bosch Rexroth AG R911400170_Edition 02

About this documentation

1 About this documentation

Edition Release Notes

Tab. 1-1: Change Record

1.1 Validity of the documentation

Product- Mounting De-

In this documentation, the term "control" is used for the following

R911400170_Edition 02 Bosch Rexroth AG

About this documentation

1.2 Documentation structure

1.3 Required and supplementing documentation

Bosch Rexroth AG R911400170_Edition 02

About this documentation

Document Part number, document type Description

"Safe Torque Off" (from MPx-16)

"Safe Motion" (from MPx-18)

Tab. 1-2: SafeLogic/Safe Motion documentations

1.3.2 SafeLogic hardware

Safety extension module

IndraControl XM42 R911345566 This documentation describes the IndraControl

IndraControl VPx R911383090 This documentation describes the MLC

R-IL PB BK DI8 DO4/CN-PAC

Inputs and Outputs

Inputs and Outputs

R911400170_Edition 02 Bosch Rexroth AG

About this documentation

Document Part number, document type Description

IndraControl R911342782 This documentation describes the Rexroth S20

R-IB IL 24 PSDI 8-PAC

R-IB IL 24 PSDO 8-PAC

R-IB IL 24 PSDO 4/4-PAC

R-IB IL 24 PSDOR 4-PAC

Tab. 1-3: SafeLogic hardware documentations

Bosch Rexroth AG R911400170_Edition 02

About this documentation

IndraWorks R911393450 This documentation describes the IndraWorks

Basic Libraries, IndraLogic 2G

Tab. 1-4: IndraWorks/WebAssistant documentations

R911400170_Edition 02 Bosch Rexroth AG

About this documentation

1.3.4 SafeLogic compact

IndraControl R911332749 Instructs technical staff of the machine vendor

Bosch Rexroth AG R911400170_Edition 02

About this documentation

Document Part number, document type Description

Tab. 1-5: SafeLogic compact documentation

Document Typecode DOK-IWORKS-SLSTEPV15-CO02-EN-P