KTP700F KTP900F Application DOC en
KTP700F KTP900F Application DOC en
https://support.industry.siemens.com/cs/ww/de/view/103497649
Warranty and Liability
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described in this application example will be excluded. Such an exclusion will not
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(“Produkthaftungsgesetz”), in case of intent, gross negligence, or injury of life, body
or health, guarantee for the quality of a product, fraudulent concealment of a
deficiency or breach of a condition which goes to the root of the contract
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Table of Contents
Warranty and Liability ................................................................................................. 2
1 Task ..................................................................................................................... 4
1.1 Introduction ........................................................................................... 4
1.2 Overview of the automation task .......................................................... 4
2 Solution............................................................................................................... 6
2.1 Overview............................................................................................... 6
2.2 Hardware setup .................................................................................... 7
2.3 Description of the core functionality ..................................................... 8
2.4 Hardware and software components ................................................. 10
2.4.1 Validity ................................................................................................ 10
2.4.2 Hardware components ....................................................................... 10
2.4.3 Software components ......................................................................... 11
2.4.4 Sample files and projects ................................................................... 11
3 Basics ............................................................................................................... 12
3.1 Log-off from the safety program ......................................................... 12
3.2 Safety notices ..................................................................................... 12
3.3 Operating modes ................................................................................ 12
3.4 Mobile Panel ....................................................................................... 13
4 Mode of Operation ........................................................................................... 14
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1 Task
1.1 Introduction
The KTP700F/KTP900F Mobile offers versatile application options in an industrial
environment. Thanks to its mobility and ruggedness, it can be used even where
other HMI panels cannot be used or only with considerable effort.
Using an example, the application describes how to implement the
Emergency stop/stop button
and the enabling button
of the KTP700F Mobile in a fail-safe application.
Note Whenever this document talks about the mobile panel, it always relates to the
KTP700F/KTP900F Mobile.
safety fence can be entered through a safety door for adjustment and maintenance
work.
The robot is to be operated with a mobile HMI panel.
In operating mode “Service mode” the safety door can be opened.
When the safety door is open, you must actuate an additional enabling button
to operate the robot.
An emergency stop button must be within reach when operating in the safety
area.
The “Service mode” is selected with a key switch.
There is an external emergency stop button outside the safety fence.
The system requires a PL d for ISO 13849-1 or SIL 2 for IEX 62061
compatibility.
Figure 1-1
Drive on/off
Emergency stop/stop button
Operation with enabling button
2 Solution
2.1 Overview
The KTP700F Mobile (alternatively KTP900F Mobile) is used as an HMI device for
this task.
The mobile panel is connected to a Connection box Advanced.
The connection box and the F-CPU communicate via PROFIsafe.
The emergency stop/stop button and enabling button are evaluated by the mobile
panel directly with the F program of the connected F-CPU.
Fail-safe digital input and output modules (“F-DI” or “F-DO”) are used to
evaluate the following equipment like
external emergency stop button
safety door
key switch for “service mode”.
The system complies with PL d for ISO 13849-1 or SIL 2 for IEX 62061.
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Assumed knowledge
Basic knowledge of the software and hardware used is assumed.
11
7 8 9 10
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1. Fail-safe CPU
2. ET 200SP interface module
3. ET 200SP, fail-safe digital input / output modules
4. ET 200SP, standard digital input / output modules
5. Contactors for fail-safe shutdown of the load circuit
6. Contactor for operational control of the robot (on/off)
7. External key switch for selecting “Service mode”
8. External push button for acknowledging fault messages
9. External emergency stop button
10. Safety door switches
11. Mobile Panel KTP700F with connection box advanced
Figure 2
-A1 -A2 -A3 -A4 -A5 -A6 -A7 -A1 CPU 1516F
-A2 Bus Modul -K100 -K10 / -K11
-A3 IM 155-6PN Drive On/Off Safety circuit
-A4 ET 200SP, 8 F-DI
-A5 ET 200SP, 4 F-DO
-A6 ET 200SP, 8 DI
-A7 ET 200SP, 8 DO
fail-safe signals
No. Action
2. Press enabling button on KTP and keep pressed
3. Press function button “ON” and keep pressed (only jog mode)
4. Preconditions
Emergency stop/stop button on mobile panel and external emergency stop
button not actuated.
Table 2-4
Component Qty Article number Note
KTP700F Mobile 1 6AV2125-2GB23-0AX0
Connection box advanced 1 6AV2125-2AE23-0AX0
Connecting cable PN 5m 5m 6AV2181-5AF05-0AX0
DIN rail 480 mm 1 6ES7390-1AE80-0AA0
Load current supply. PS 307; AC 1 6ES7307-1KA02-0AA0
120/230V, DC 24V, 10A
CPU 1516F-3 PN/DP 1 6ES7516-3FN00-0AB0
SIMATIC S7, memory card for S7-1X00 1 6ES7954-8LF02-0AA0
CPU/SINAMICS, 3.3 V FLASH,
24 MBYTE
Table 2-5
Component Qty Article number Note
STEP 7 Professional V13 SP1 1 6ES7810-4CC10-0YA5 From this version
Update 3
WinCC Advanced V13 SP1 1 6AV6613-0AA51-3CA5 From this version
Update 3
STEP 7 Safety Advanced V13 1 6ES7833-1FA13-0YA5 From this version
SP1
The following list includes all files and projects that are used in this example.
Table 2-6
Component Note
103497649_KTP700F_KTP900F_Application_DOC_en.pdf This document.
103497649_KTP700F_KTP900F_Getting_Started_DOC_en.pdf Brief description
103497649_KTP700F_KTP900F_Application_Code.zip The file contains the program for the
application example and the wiring
diagram
103497649_KTP700F_KTP900F_GettingStarted_Code.zip The file contains the program for the
standard configuration
3 Basics
3.1 Log-off from the safety program
Before disconnecting the fail-safe HMI device from a connection box, you must log
off the HMI device from the safety program using the system function
“TerminatePROFIsafe” (1) or close the current project.
After logging off, the emergency stop button and enabling button are no longer
active.
Abbildung 3-1
1
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If the safety door is opened during manual mode, the drives are
immediately shut down.
Service mode (operating mode 3 → process monitoring in production)
– In contrast to the previous operating modes, the user can monitor and
control the processing with open safety device (door).
To operate the robot, an additional enabling button is required. When the
enabling button is let loose, the robot drive is stopped immediately.
In all three operating modes, the stationary emergency stop button and
the emergency stop/stop button of the mobile panel are active.
There are three different connection boxes for the mobile panel.
The connection box advanced used in the application can be integrated in an
existing emergency stop circuit.
The assigned emergency stop circuit is not opened when unplugging the mobile
panel from the connection box.
When used together with PROFIsafe, the mobile panel must be logged off the
network beforehand.
Enabling button
The enabling button signal from the mobile panel can be further processed via
PROFIsafe or via suitable external evaluation devices, e.g. safety relays.
Note
The enabling button is only required if prescribed by the operating mode. This
would be the case, for example, in operating mode 3 “Service mode”.
4 Mode of Operation
4.1 Wiring diagram/hardware plan
4.1.1 Preliminary considerations
Considering the task described in chapter 1.2 “Overview of the automation task“,
the hardware plan must cover three functions.
Function 1: Automatic/manual mode.
Function 2: Service mode. The enabling button evaluation from the
mobile panel must be active in this operating mode.
Function 3: The external emergency stop button and the emergency stop/stop
button of the
mobile panel must be active in every operating mode.
The task is now to integrate these three individual functions together in one
application and to achieve PL d or SIL 2.
Two contactors (-K1 and -K2) that are controlled via the evaluation
of the external emergency stop button and the emergency
stop/stop button of the mobile panel.
Note
Two serial contactors in the load circuit are required for the safe
shutdown of the drive and to achieve PL d or SIL 2.
-K100
-K10
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-K11
Description
With the F-CPU together with the fail-safe digital input and output modules, only
three contactors are required in the load circuit.
The fail-safe modules provide safe evaluation and shutdown of contactors -K10
and -K11.
Contactor -K100 is used to turn the drive on and off.
Table 4-1
No. Device Together with an F program
1. Stationary A 2-channel button must be used
emergency stop (two break contacts).
button The signals are read with a fail-safe
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Note
To acknowledge a message with the mobile panel is only possible
together with an F-CPU and STEP 7 Safety Advanced together with
the “FB187” (F_ACK_OP).
Note
The mobile panel features one key switch. This cannot be used for
mode switching. The key switch is not fail-safe.
4.3 Hardware
4.3.1 Mobile Panel, connection box advanced
Figure 4-3
Note The application evaluates the emergency stop/stop button and the enabling
button via PROFIsafe.
The digital electronic module 8 F-DI DC24V is, among others, used for acquisition
of the safety-related signals.
The evaluation of the signals from the
external emergency stop button
key switch for “service mode”
are connected with 2 channels to the corresponding opposing digital module inputs
(2oo2 evaluation).
The two safety door contact elements are evaluated with one channel; they are
assigned one digital input each (1oo1 evaluation).
Pin assignment
1
Channel 0, 4: DI0 – DI4 (1 ) DI0 + (9) VS0 – (5) DI4 + (13) VS4
Channel 1, 5: DI1 – DI5 (2) DI1 + (10) VS1 – (6) DI5 + (14) VS5
Channel 2, 6: DI2 – DI6 (3) DI2 + (11) VS2 – (7) DI6 + (15) VS6
Channel 3, 7: DI3 – DI7 (4) DI3 + (12) VS3 – (8) DI7 + (16) VS7
The diagram below shows the pin assignment of the “key switch” for implementing
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1
The value in brackets is the terminal at the module
5 Configuration Instruction
5.1 Circuit diagram
General information
The circuit diagram contains the data for implementing the automation task
presented in chapter 1.2.
The circuit diagram corresponds to the test setup that was used to test the
functionality of the automation task.
Notes The circuit diagram is also included in this application as a separate document.
Depending on the required automation task, further evaluation devices and protective
measures are necessary.
Overview of the hardware and the signal exchange between each other.
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Figure 5-1
Figure 5-2
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connect the safety door switch (switch -S10 and -S11) to the F-DI module.
Figure 5-5
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The HMI panel can also be used to acknowledge fault messages. The
acknowledgement is done in the control program via the standard function
block FB187 “F_ACK_OP”.
Figure 5-6
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Figure 5-7
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Figure 5-8
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Figure 5-9
5.2 Configuration
5.2.1 General information
STEP 7 program
The STEP 7 program contains a standard STEP 7 program and an F program.
The standard program is used to control the robot drive.
The F program is used to evaluate the safety-related functions.
An F_FB_KTP_Mobile must be parameterized for each Mobile Panel.
An F_FB_KTP_RNG must be parameterized for each connection box.
HMI configuration
The HMI configuration contains all required functions for robot control. The robots
movements are animated with a graphics list.
Program information
The following measures have been implemented in the STEP 7 program to avoid
the risk of misuse by forbidden fixation of the enabling button.
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The enabling button must be released within a specified time frame and then
be returned to the “enabling” position.
The time frame must be specified based on the activity of the monitoring
system.
It is forbidden to use the enabling button to start the drive.
– The enabling button must always be pressed before starting the drive.
– When the “Drive on” button is pressed and the enabling button is pressed
next, the drive will not be activated.
Note Please note the safety information and general information in the Mobile Panel
manual. (You can find the operating instructions under the following link
https://support.industry.siemens.com/cs/de/en/ps/14746/man)
Excerpts from STEP 7 and from HMI configuration are described below in more
detail.
Table 5-1
No. Description
1. F CPU
To add an F-CPU, click the “Add new device” button in the project tree.
In this case, select a “CPU 1516F-3 PN/DP”.
Open the F-CPU device configuration and click on the F-CPU once. The CPU properties are
shown.
Open the “PROFINET interface [X1]” property in the area navigation.
– Ethernet addresses
- Interface: Use the drop-down list to select a subnet or to add a new one.
- IP protocol: Enter the IP address here.
- PROFINET: Here, you can specify your custom PROFINET device name.
The name will not be evaluated.
The default settings were applied to the F parameters F-CPU. Check each parameter and adjust
if necessary.
The list entries containing F parameters are marked with yellow rectangles.
2. ET 200SP
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No. Description
4. Configuring the F-DI module
6. DI and DO modules
Parameterization of DI and DO modules is not described in detail. Please adjust the default I/O
addresses, if required.
No. Description
7. Mobile Panel
F-destination address:
The F-destination address set here must be identical to the PROFIsafe
address at the Mobile Panel under “Settings > PROFIsafe” (Link).
Open the “PROFINET interface [X1]” property in the area navigation.
– Mode
- I-Device communication: You can now edit the transfer areas for the input and output
areas for “IO failsafe”.
The addresses are evaluated in the “F_FB_KTP_Mobile”
block in the F program (Link).
HMI connection
Go to the network view.
Create an HMI connection between the F-CPU and the Mobile Panel.
No. Description
8. Connection box
9. Assigning an IO controller
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To change the default addresses of the ET 200SP, the station must be assigned to an IO
controller (in this case the F-CPU). Otherwise, the entry field is grayed out.
Program structure
Figure 5-10
TON
SFB4
Simu_Robo_01 InstanceDB_FB11
FB11 DB11
HMI_Message InstanceDB_FB12
FB12 DB12
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DataExchange
DB100
FB10, Prog_Robot-01
FB10 contains the essential program steps to control the robot drive.
Table 5-3
No. Description
1. Network 4, automatic mode
To ensure that the function button for switching on the drive cannot be “fixated”, the signal is
polled via a positive edge.
2. Network 5, manual mode
To ensure that the function button for switching on the drive cannot be “fixated”, the signal is
polled via a positive edge.
In “Manual mode”, the system is switched on/off with a function button -> jog mode.
3. Network 6, service mode
To ensure that the function button for switching on the drive cannot be “fixated”, the signal is
polled via a positive edge.
In “Service mode”, the system is switched on/off with a function button -> jog mode.
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The network monitors possible functional errors of contactor –K100 “Robot drive on/off”. To do
this, one make contact was wired from the contactor to one input. When the drive is off and the
input signals a “1 signal”, for example, then there is a malfunction.
Note
The monitoring is not a safety-relevant function. It is not used to safely shut down the drive.
Safe shutdown is evaluated by the F program.
5. Network 9, output of the selected operating mode
The current operating mode is output in a text list at the HMI panel. The evaluation is performed
in this network.
6. Network 10, output of Safety door open/closed
The HMI panel shows an animation of the open or closed safety door. The evaluation is
performed in this network.
FB11, Simu_Robot-01
FB11 simulates the robot movements and the elevator.
The robot movements are simulated on the HMI panel via a graphics list.
Depending on the selected operating mode, the execution is displayed with
different speeds.
The speed of the execution is preset with a clock memory.
Table 5-4
No. Description
1. Network 1, movement in “Automatic” mode.
FB12, HMI_Message
FB12 evaluates fault messages and warning messages that are output via the HMI
panel.
It does not use special functions.
F program structure
Figure 5-11
FB1, FB20,
OB123 FB185
DB1 DB121
F_ESTOP1 F_TOF
FB215,
FB186
DB122
F_FDBACK F_TOF
FB216,
FB186
DB123
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F_SFDOOR
FB217,
DB124
F_Prog_Mobile F_FB_KTP_Mobile
FB22, FB198,
DB127 DB128
F_FB_KTP_RNG
FB199,
DB129
ACK_Execution F_ACK_OP
FB21, FB187,
DB125 DB126
No. Description
2. FB1, DB1
FB1 serves to coordinate the subsequent F block calls. All subsequent FBs are called with this
FB.
3. FB20, DB120
FB20 evaluates
if the safety circuit is closed
– Emergency stop OK
– Safety door closed
– F-DI and F-DO modules OK
– etc.
if the enabling button is being pressed
“Service mode” is activated.
FB22 evaluates the emergency stop/stop button and the enabling button of the Mobile Panel.
The following failsafe HMI blocks are called for evaluation.
F_FB_KTP_Mobile (monitors the assigned operator panel)
– An F_FB_KTP_Mobile is required for each Mobile Panel.
No. Description
9. DB120
DB120 contains the data for the data exchange
between the standard program and the F program
within the F program.
10. DB1, DB121, DB122, DB123, DB124, DB125, DB126, DB127, DB128, DB129
Instance data block for the assigned function blocks.
11. OB82, OB83, OB86
These blocks are required in connection with the F program.
The blocks do not contain program elements.
Note Please refer to the online help for more information on the standard function
blocks used.
Main_Safety [FB1]
Main_Safety_DB [DB1])
Figure 5-12
FB1, Main_Safety_RTG1
FB1 calls all F function blocks and parameterizes them according to the
input/output parameters.
There are not “logic connections” in this FB.
Note Please make sure that the acknowledgement, in this case FB21, is always called
up at the end.
FB20, F-Prog_Robot-01
FB20 connects the safety circuit signals and the enabling button signals.
Table 5-6
No. Description
1. Network 1
The network evaluates whether the safety chain is OK (emergency stop, etc.). At what point the
safety door may be open during operation and when not is considered in the evaluation.
2. Network 3
The time period in which the enabling button is being pressed is monitored to avoid the risk of
misuse by forbidden fixation of the enabling button.
The preset time period is transferred to the block as “IN parameter”.
In this case, the enabling button must be released after 10 seconds (see FB20 call in FB1,
network 1).
This is monitored by SFB4 “TON” switch-on delay.
SFB4 can be parameterized with a FB,DB call (instance DB) or, like in this example, with a multi
instance call (multi instance DB).
FB21, ACK_Execution
FB21 evaluates the acknowledgement.
Table 5-7
No. Description
1. Network 1
The standard function block “FB187” (F_ACK_OP) makes safe acknowledgement via the panel.
For this, two buttons are required at the HMI panel (see Link).
Detailed information on fail-safe acknowledgement can be found in the STEP 7 online help.
2. Network 2
The acknowledgement signal from the “external acknowledgement button” and the
“Acknowledgement” from the panel are combined via the network.
It is output to three outputs.
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FB22, F-Prog_MobilePanel
FB22 evaluates the emergency stop/stop button and the enabling button.
Table 5-8
No. Action
1. Network 1
Calling F_FB_KTP_Mobile
The FB can be found in the “Instructions” task card. Select the “Communication” tab.
For detailed description on how to parameterize the FB, refer to the online Help.
Note
Parameter “MP_Data / MP_Data_Q”
- For a SIMATIC S7-1500, use an “INTEGER” type tag.
- For a SIMATIC S7-300, use a “WORD” type tag.
2. Network 2
Calling F_FB_KTP_RNG
The FB can be found in the “Instructions” task card. Select the “Communication” tab.
For detailed description on how to parameterize the FB, refer to the online Help.
No. Action
3. Connection diagram between F_FB_KTP_Mobile and F_FB_RNG
Transfer areas
F-IO data blocks, QBAD
F-IO data blocks, ACK_REQ
FB1
Main_Safety_RTG1
The following functions have been included in the Mobile Panel configuration.
“Manual mode”
– The operating mode can only be selected via the Mobile Panel with a
password protected button.
– The drive can only be activated in “jog mode”.
“Service mode”
– This operating mode is selected with an external key switch. The key
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switch integrated in the Mobile Panel must not be used for this.
– The drive can only be activated in “jog mode”.
Table 5-9
No. Description
1. Acknowledging using the panel
In connection with FB187 (F_ACK_OP), the panel can be used for fail-safe acknowledgement.
For this, two buttons are required.
Button 1
– Assign the “SetValue” function to this button under “Events > Press”.
– This tag is from a “Standard DB”.
In the example, the “DB100.DBW6” tag is assigned the value “6” via the button.
Button 2
– Assign the “SetValue” function to this button under “Events > Press”.
– This tag is from a “Standard DB”.
In the example, the “DB100.DBW6” tag is assigned the value “9” via the button.
Connection box ID
The connection box is uniquely identified by the ID preset at the connection box.
The ID must be unique throughout the system.
The ID must be identical with the address stored in the Mobile Panel (Link) and the
address assigned to the F block “F_FB_KTP_RNG” (Link).
Notes
The rotary coding switches can set values
from “00” to “ff” (0 to 255 in decimal
format).
The value “00” must only be used for the
“Stop button evaluated by safety relay”
operating mode.
The value “FF” (255) is reserved and must
not be used.
General information
It is assumed that the Mobile Panel is connected to the connection box and the box
ID has been set.
Table 5-11
No. Action
1. Opening the control panel
Open the control panel through the “Start Center” and the “Settings” button.
2. Setting the Ethernet address
4. Assign password
The password is required/used for the “Safety Operation” function (Link). In addition, the access to
the control panel is protected (Link).
In this example: 1
No. Action
7. Safety Operation
Confirm the entry with the “Save” button. A password prompt window opens.
Enter the stored password (Link).
When the entered box ID and the password match, this is indicated with a green “check
mark”.
Close the window with the “Close” button.
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No. Action
8. The hardware settings are now complete.
Close the control panel.
Note
After a password has been assigned, the start screen will display “secure mode”.
The “Settings” and “Taskbar” buttons can only be accessed after the password has been entered.
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Slide-in bars
Slide-in bar on the right (navigation panel)
Slide-in bar at the top (fault message window)
Pop-up screens
Pop-up ACK_HMI
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Pop-up alarm
Fault acknowledgment
When there is a fault during operation, e.g. because the emergency stop/stop
button was activated at the Mobile Panel, the cause of the fault must be
rectified (unlock emergency stop/stop button) and the message must be
acknowledged.
Use the “ACK” button or the “Pop-up-ACK_HMI” pop-up screen to
acknowledge the fault.
After the CPU voltage supply is switched off and switched back on again, the
safety door must be opened completely and closed again (integrated safety
function of the door). The, the system must be acknowledged.
A PROFIsafe communication error requires double acknowledgement.
– Fault acknowledgment of PROFIsafe communication.
– Fault acknowledgment of further messages.
4. Plant screen
Automatic mode
Table 6-2
No. Description
1. Selecting automatic mode
When the safety door is opened or an emergency stop is triggered during operation, the drive (-
K100) and the safety circuit (-K10 /-K11) are shut down immediately.
Manual mode
Table 6-6
No. Description
1. Selecting manual mode
This selection is protected with a password. After pressing the function button, the log in dialog
box is shown.
User: user
Password: 111
The operating mode can only be selected after entering the correct password.
No. Description
2. Drive on/off
When the safety door is opened or an emergency stop is triggered during operation, the drive (-
K100) and the safety circuit (-K10 /-K11) are shut down immediately.
Service mode
Table 6-6
No. Description
1. Selecting service mode
This operating mode cannot be selected via the Mobile Panel; it must be selected with a
separate key switch.
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The safety door may be opened in this operating mode. Depending on the status, the door is
displayed as open or closed.
2. Drive on/off
Before the drive is switched on with the “On” button, the enabling button at the Mobile Panel
must always be pressed first and kept pressed.
The drive is switched on using the “On” function button.
The drive is switched off when the “On” function button is released.
The enabling button must only be pressed for a maximum of 10 seconds (F program preset).
When it is pressed longer, the drive (-K100) and the safety circuit (-K10 /-K11) are shut down
immediately.
The same is the case when the enabling button is released during operation or when an
emergency stop is triggered.
7 Error detection
The following notes are intended to support you when troubleshooting.
Why is the “PROFIsafe” function grayed out in the Mobile Panel configuration
and cannot be activated?
– To activate the PROFIsafe option, activate “IO device” under “Operating
mode” first (see Link).
In which PII word can the emergency stop/stop button and enabling button be
evaluated?
– Word 0 0010-0010 emergency stop/stop button
Word 1 0010-0010 enabling button
Word 2-5 Reserved
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Why are the I/O addresses of the ET200 SP modules (DI /DO modules) grayed
out and cannot be adjusted?
– To change the default addresses of the ET 200SP, the station must be
assigned to an IO controller (in this case the F-CPU). Otherwise, the entry
field is grayed out.
How can I set the box IDs of several connection boxes at the Mobile Panel?
– Always use the same menu. Go to each connection box and plug in the
Mobile Panel. Open the “Safety Operation” menu and enter the
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Why does the drive shut down when I remove the Mobile Panel from the
connection box?
– Make sure to disconnect the PROFIsafe connection before unplugging the
panel. Use the system function “PROFIsafeDisconnect” to do this; you can
configure it in a button, for example.
Alternatively, terminate the Mobile Panel runtime and confirm the
PROFIsafe disconnection in the logoff dialog.
9 History
Table 9-1
Version Date Modifications
V1.0 06/2014 First version
V1.1 02/2016 S7 Distributed Safety -> STEP 7 Safety Advanced