Power Distribution & Controls Division SIRIUS Safety Controls AS-Interface Actuator-Sensor-Interface Siemens Energy & Automation 2006 Power Distribution & Controls Division Position in the communications architecture SIRIUS Safety Controls Siemens Energy & Automation 2006 Power Distribution & Controls Division Networked Devices Vs Hardwired SIRIUS Safety Controls 2006 Forecast $308M Networked Components 19% Non Networked Components 81% Source: 2005 VDC Report Currently a very low percent of components are networked The market is open for Siemens to take network share The safety networking battle lines are forming NOW, and Rockwell is leveraging their Device Net position even with very few products on the market Siemens Energy & Automation 2006 Power Distribution & Controls Division Good topics to “lead-in” with Safety Networks? SIRIUS Safety Controls When meeting with your prospects ask the following questions to start the conversation: Do your operators ever jumper out safety systems? How often does you line stop do to safety faults? How long does it take to diagnose and solve the problem? What if you could wire this machine in a fraction of the time by combining your safety and control systems? Engage your support team Call your BDM or Controls Specialist if you have a lead. They will assist you in coordinating the resources to close it! Siemens Energy & Automation 2006 Power Distribution & Controls Division What is AS-Interface? SIRIUS Safety Controls GSD EDS Simple and low cost network for sensors and actuators Open, manufacturer-independent industrial network for the sensor-actuator control level Roughly 300 product vendors globally PLC independent platform Over 10 million nodes have been installed in plants and systems since 1994 Siemens Energy & Automation 2006 Power Distribution & Controls Division AS-Interface Facts SIRIUS Safety Controls Standardization of the AS-Interface system per IEC 62026-2 and EN 50295 Master / slave principal Line, star or tree topology allows easy design and layout Degrees of protection IP65 with products from IP20 to IP69K Basic system with max. 31 slaves with max. 4I/4O each, extendable to up to 62 slaves [version 2.1] with max. 4I/3O each Unshielded cable with 2 x 1.5 mm² Maximum bus cycle time of 5 ms or 10 ms with A/B slaves 100m extension in any tree structure up to 200m by using the Extension Plug 600m by using combined Extension plugs and repeater or extender ASIsafe up to Cat. 4 in acc. with EN 954-1 / up to SIL 3 in acc. with IEC 61508 Siemens Energy & Automation 2006 Power Distribution & Controls Division Customer Benefits of AS-Interface SIRIUS Safety Controls = Sensor = Sensor = Actuator = Actuator Aktor one cable replaces 100‘s Siemens Energy & Automation 2006 Power Distribution & Controls Division Customer Benefits of AS-Interface SIRIUS Safety Controls Easy installation and operation thanks to simple design Cost savings for connection technology and installation due to single-line power and data transmission High degree of operational reliability thanks to continuous monitoring of the connected devices Reduced control cabinet size due to fewer I/O modules and terminals Fewer terminal boxes in the field thanks to the modules‘ degree of protection IP67 Easy and fast commissioning Reduced maintenance in product fault cases due to hot-swap slave replacement without having to re-teach the master Reduced downtime of the AS-i network thanks to easy visualization of the complete network without extra wiring Siemens Energy & Automation 2006 Power Distribution & Controls Division System-based simplicity: The structure SIRIUS Safety Controls An AS-Interface system comprised of a master, an AS-I power supply unit and the nodes – the so-called slaves. The AS-Interface Master The master uses cyclic polling to exchange data with the slaves. In one cycle, four data bits are exchanged in the incoming direction and four data bits in the outgoing direction. The AS-Interface power supply This 30volt unit ensures that data and power can be transferred along one and the same cable. Siemens Energy & Automation 2006 Power Distribution & Controls Division Flexible structure, simple to engineer SIRIUS Safety Controls Line Whether as line, star or tree topology – there are no restrictions regarding the structure or network topology Star Simple and quick Implementation of the system cost-efficient modification or expansion of the network No terminating resistors Tree Siemens Energy & Automation 2006 connect a cable or device wherever you want Power Distribution & Controls Division Network configuration SIRIUS Safety Controls standard 100m with Extension Plug 200m 100 m (109 yd) 200 m (219 yd) with repeater 300m comb. repeater apl. 400m 200 m (219 yd) 300 m (328 yd) 200 m (219 yd) 400 m (437 yd) maximum network range 200 m (219 yd) 600 m (656 yd) 200 m (219 yd) 200 m (219 yd) 200 m (219 yd) Siemens Energy & Automation 2006 Power Distribution & Controls Division Direct or distributed: Flexible connection possibilities SIRIUS Safety Controls direct connection direct connection of AS-Interface to the programmable logic control systems (PLC) The AS-i master is connected just as simply as standard S7 I/O modules distributed connection AS-Interface as sub-system feeder for higher-level bus systems Flexible wiring of AS-i can compliment higher-level systems Can be completely configured and commissioned before the central control has been fully programmed Siemens Energy & Automation 2006 Power Distribution & Controls Division AS-Interface data exchange SIRIUS Safety Controls AS-Interface Master Slave 1 output data input data Slave 2 output data cycle time: -max. 5 ms (standard mode) -max 10 ms (A/B-mode) input data . . . Slave n output data input data master request ST 0 SB A4 A3 A2 A1 A0 ST SB 1 D3 D2 D1 D0 PB … start bit … control bit Siemens Energy & Automation 2006 slave response A0, .., A0 D3, .., D0 EB 1 … adress bit … information ST 0 SB D3 D2 D1 D0 PB PB EB … parity bit … end bit 1 EB Power Distribution & Controls Division AS-Interface addresses SIRIUS Safety Controls 31 or 62 addresses are available per master Addresses can’t be repeated By the A-B technique the addresses are subdivided into A and B subaddresses, for a total of 62 possible addresses standard addresses PLC and master slave 1 slave 2 slave 31 A-B addresses PLC and master mixed addresses PLC and master slave 1A slave 1B slave 1 slave 2 Siemens Energy & Automation 2006 slave 17A slave 25A slave 31B slave 17B slave 31 Power Distribution & Controls Division Assembly and Connection SIRIUS Safety Controls vampire contact Mechanical coding by geometry Fast installation and quick servicing thanks to the piercing technology First install the mounting plate Insert the profiled cable in the mounting plate Clip in the module and screw it together. (vampire terminals of the module break through the insulation of the wire and establish contact with the copper leaders) Sensors are attached to the modules Siemens Energy & Automation 2006 Power Distribution & Controls Division Connection with a K45 Compact Module SIRIUS Safety Controls Simply assembling thanks to K45 compact modules, which are protected against reverse polarity electronic reverse-connect protection in the module mechanical coded (red) in the mounting plate Reverse polarity protection for the yellow cable 3 contacts for the black cable The center contact the „+“ wire the outer two are connected internally and contact the “-” wire Siemens Energy & Automation 2006 Power Distribution & Controls Division Project planning and maintenance SIRIUS Safety Controls At the press of a button: Configuring the system using the hand held programmer An AS-Interface network can be simply and quickly configured – in one of two ways: 1) The nodes are addressed using the AS-I addressing device 2) The nodes are configured by just pressing a button on the master The AS-i modules are automatically assigned to the I/O area of the control. When a single module is replaced, the master automatically reassigns the same address to it. Specialist personnel are not required. Siemens Energy & Automation 2006 Power Distribution & Controls Division AS-Interface Masters SIRIUS Safety Controls Masters for Simatic C 7 for SIMATIC C7 CP142-2 for SIMATIC ET 200X CP 243-2 for SIMATIC S7-200 CP 343-2P for SIMATIC S7-300 Up to 62 AS-Interface slaves can be connected Integrated analog value transmission For an S7-300 master, the AS-Interface can be configured and uploaded in Step 7 Configuring is not required Simple operation in the I/O address range The power supply voltage on the AS-Interface profiled cable is monitored Your advantage: Simple coupling to the SIMATIC S7-300, S7-200, ET 200S or SIMATIC C7 Links to PROFIBUS / PROFINET Link 20E Siemens Energy & Automation 2006 DP/ASi Link Advanced PROFIBUS slave and AS-Interface master Up to 62 AS-Interface slaves can be connected CPs for the AS-Interface do not have to be configured integrated analog value transfer possibility to configure and upload the ASInterface configuration in STEP 7 Your advantage: Optimum transition to PROFIBUS integrated in STEP 7 Power Distribution & Controls Division AS-Interface Power Supplies SIRIUS Safety Controls AS-i Power Supplies in IP 20 5A power supply 3A power supply 8A power supply Siemens Energy & Automation 2006 In the SITOP design Wide range of power ratings (from 3 A to 8 A) Super-wide range input: 120..500V AC Connected using spring-loaded terminals Removable terminal blocks Integrated ground fault detection Integrated overload diagnostics Your advantage: Optimum power for every application Power Distribution & Controls Division AS-Interface Field Modules SIRIUS Safety Controls Compact Modules K45 and K60 Degree of protection IP65/IP67, IP68/69K ATEX-certified modules are available for hazardous Zone 22 M8/M12 connection sockets Up to 8 inputs and 4 outputs Contacts are established that are protected against incorrect polarity Rail mounting and wall mounting are possible The module can be mounted to a baseplate using just one screw Diagnostic LEDs K45 K60 Your advantage: The installation and commissioning times are reduced by up to 40% Analog Modules Degree of protection IP65/IP67 Directly senses or supplies analog signals locally 2/4 channel Input modules for up to 4 current transducers, voltage transducers or thermo-resistance transducers Output modules for current or voltage Your advantage: Analog values easily managed Siemens Energy & Automation 2006 Power Distribution & Controls Division AS-Interface control cabinet modules SIRIUS Safety Controls SlimLine and Flat modules SlimLine F90 Flat module Degree of protection IP20 Up to 16 inputs SlimLine modules starting at a width of 22.5 mm SlimLine modules, removable terminal blocks, that are protected against finger touch and cannot be accidentally interchanged Low-profile flat modules for small control cabinets Connected using either screw or Cage Clamp terminals Rail and panel mounting possible Diagnostic LEDs Your advantage: Modules can be accommodated in control cabinets and small local cabinets in the field Counter modules Degree of protection IP20 They evaluate pulses Connected using either screw or Cage Clamp terminals Your advantage: Pulses can be evaluated that even exceed the clock cycle frequency of AS-Interface Siemens Energy & Automation 2006 Power Distribution & Controls Division AS-Interface motor starters SIRIUS Safety Controls 24 V DC Starters Degree of protection IP65/IP67 Direct starter, double starter or reversing starter Up to 70 W Quick stop function Basic motor starters in a well-proven module design for 24 V DC motors Compact Starters Degree of protection IP65/IP67 Up to 5.5 kW at 400/500 V AC Electromechanical or electronic design Optionally with brake contact pre-wired load feeders in IP65 replace local control cabinets Motor Starters for ECOFAST Degree of protection IP65/IP67 Standardized interface according to the ECOFAST specifications (in conformance with DESINA) starters Switchingcan function – mechanical or electronic either be installed close to for soft starting the motor or plugged-onto the motor Load Feeders complete individual load feeder module Siemens Energy & Automation 2006 Degree of protection IP20 Available either completely pre-wired or as individual components Power range up to max. 7.5 kW Power bus in combination with a busbar system (> 200 A) Complete, pre-assembled load feeders simplify wiring with AS-Interface Power Distribution & Controls Division Integrated ASI slaves SIRIUS Safety Controls Pushbuttons / Indicator Lights Can be mounted in a modular fashion according to individual requirements Metal and plastic versions Extended address mode (A-B technique) With LEDs or incandescent lamps Complete 3SB3 operator system with simple AS-Interface connection Signaling Columns Many optical and acoustic elements can be combined Up to 4 signal elements can be connected using adapter elements With LEDs or incandescent lamps Signaling columns to monitor production sequences and to visually an alarm in emergency situations with a simple ASInterface connection Communications-capable Contactors 55 to 250 kW Contactors from 55 to 250 kW Control and message signals via the ASInterface Indication of remaining lifetime (RLT) via the ASInterfacequickly and simply change over Enables from automatic to local control; this means that automatic control via AS-i can be disabled and a contactor can be manually controlled Siemens Energy & Automation 2006 Power Distribution & Controls Division System components and accessories SIRIUS Safety Controls Increasing network distance Extend an AS-i segment by 100 m with the extension plug Extend one bus segment to another via repeater Extension Plug Repeater / extender Infrastructure costs are reduced and more applications can be addressed Hanheld Prgrammer Addresses all AS-Interface network nodes Reads-out the I/O and ID codes of the slaves Parameterizes the slave (ID1 or analog parameter) Measures the AS-Interface voltage Allows outputs to be directly set and slave inputs to be read-in Extremely Saves the complete configuration simple plant/system way of addressing and parameterizing a slave Analyzer Completely checks the quality and function of an AS-Interface installation Transfers the retrieved data to a PC via RS232 interface – this data is evaluated using software Simple and user-friendly Test logs are automatically generated Advanced trigger functions permit precise analysis Network can be analyzed for faults and preventive maintenance – trace logs simplify remote diagnostics Siemens Energy & Automation 2006 Power Distribution & Controls Division Safety at Work: AS-Interface SIRIUS Safety Controls SAFETY AT WORK Otherwise known as ASIsafeTM Siemens Energy & Automation 2006 Power Distribution & Controls Division Safety Integrated® USA SIRIUS Safety Controls What is AS-Interface Safety at Work (ASIsafeTM)? A communication network based on AS-Interface that…… …… allows the connection of safety related devices such as E-Stops, Guard Switches, Light Curtains, Laser Scanners, Gate Switches to an intelligent safety relay called a Safety Monitor over a network. Siemens Energy & Automation 2006 Power Distribution & Controls Division Traditional Safety Circuit SIRIUS Safety Controls Safety Relay E-Stop E-Stop E-Stop Interlock Switch Interlock Switch Traditional hard wired safety circuits require additional wiring home runs of signaling contacts. This adds cost, labor and complicates maintenance. Siemens Energy & Automation 2006 Power Distribution & Controls Division New Safety Circuit Using ASIsafe SIRIUS Safety Controls E-Stop Safety Monitor E-Stop Interlock Switch Zone 1 Zone 2 With an AS-Interface network, reduced cabling costs, reduced labor and simplified maintenance are just the beginning of the benefits AS-Interface provides. Siemens Energy & Automation 2006 Power Distribution & Controls Division AS-Interface Distributed Configuration Safety at Work SIRIUS Safety Controls Gateway to AS-Interface Safety monitor Standard module AS-i power unit Safe module Safe Light Curtain Safety Limit Switch Safe light barrier Standard module Siemens Energy & Automation 2006 Safe emergency stop button Power Distribution & Controls Division AS-Interface Distributed Configuration Safety at Work SIRIUS Safety Controls Standard PLC and standard master Safety monitor Standard module AS-i power unit Safe module Safe Light Curtain Safety Limit Switch Safe light barrier Standard module Siemens Energy & Automation 2006 Safe emergency stop button Power Distribution & Controls Division AS-Interface Distributed Configuration Safety at Work SIRIUS Safety Controls Standard PLC and standard master Safety monitor Standard module AS-i power unit Safe emergency stop button Safe module Safe Light Curtain Safety Limit Switch Safe light barrier Standard module Can be easily configured with most popular PLC platforms. No Safety PLC required!! Siemens Energy & Automation 2006 Power Distribution & Controls Division Popular Ways To Link to AS-I and ASIsafe SIRIUS Safety Controls SLC 500 DeviceNet to ASI Gateway SST-ASI-SLC BW1116 333009703000 ControLogix With utility SW 333009704000 ASI Master only 333009705000 With utility SW MicroLogix 333009706000 ASI Master only 333009707000 Siemens Energy & Automation 2006 Utility SW only Power Distribution & Controls Division Gateways to most protocols SIRIUS Safety Controls Source: Anybus.com Siemens Energy & Automation 2006 Power Distribution & Controls Division Compelling advantages SIRIUS Safety Controls PLC control platform Safety cabinet Safety relays Standard I/O Standard I/O DeviceNet Siemens Energy & Automation 2006 Power Distribution & Controls Division Compelling advantages SIRIUS Safety Controls PLC control platform Standard I/O Standard I/O Fieldbus Siemens Energy & Automation 2006 Power Distribution & Controls Division Compelling advantages SIRIUS Safety Controls PLC control platform Standard I/O Standard I/O Fieldbus Siemens Energy & Automation 2006 Power Distribution & Controls Division Compelling advantages SIRIUS Safety Controls Cable costs reduced Fault sources reduced Installation time reduced Commissioning time reduced Plant down time reduced Siemens Energy & Automation 2006 Power Distribution & Controls Division Major Components of ASIsafe SIRIUS Safety Controls Major Components Safety Monitor Safety I/O Blocks Configuring Software Siemens Energy & Automation 2006 SAFETY AT WORK Power Distribution & Controls Division Safety Monitor Connections SIRIUS Safety Controls The monitor is available in two versions: Single-channel Dual-channel (Dependent or independent) Enable circuit 1 1.13/1.14 1.23/1.24 Enable circuit (K1,K2) 1.32 Signaling circuit (OUT1) 1.Y1 Contactor monitoring (EDM) 1.Y2 RESET (optional) Enable circuit 2 2.13/2.14 2.23/2.24 Enable circuit (K3,K4) 2.32 Signaling circuit (OUT2) 2.Y1 Contactor monitoring (EDM) 2.Y2 RESET (optional) Siemens Energy & Automation 2006 Power Distribution & Controls Division Safety Monitor Handling SIRIUS Safety Controls System Start Up Safety Slaves are detected and their ID-Code is stored: Once detected, slaves can only be removed with the use of a PC but can be hot-swapped one device at a time. Teach-in-Phase Safety monitor reads the code values of the Slaves into its comparative table (with repeated alignment) No additional programming for standard slaves on the network Configuration of safety functions with ASIMON software by PC via RS 232 interface Siemens Energy & Automation 2006 Power Distribution & Controls Division Easy Grouping of Safety Signals with ASIsafe SIRIUS Safety Controls Standard-PLC and standard-master safety monitor safety monitor standard module AS-i power unit Safe emergency stop button Siemens Energy & Automation 2006 Safe emergency stop button Safe emergency stop button safe module Power Distribution & Controls Division Grouping Allows Zone Control SIRIUS Safety Controls SAFETY AT WORK Area 3 complete line E-STOP Area 2 Siemens Energy & Automation 2006 Area 1 Power Distribution & Controls Division Field Modules K45F and K60F (IP67) SIRIUS Safety Controls K45F: 1 or 2 safe inputs with a category 2 according to EN954 1 safe input with applications of category 3/4 according to EN954 Also available with 2 standard outputs K60F: 1 or 2 safe inputs with a category 2 according to EN954 1 safe input with applications of category 3 or 4 according to EN954 In addition there are 2 standard outputs Siemens Energy & Automation 2006 Power Distribution & Controls Division Wiring Example category 2 SIRIUS Safety Controls For applications in compliance with Category 2, both inputs at the safety module can be used This means that two electromechanical sensors in compliance with Category 2 (positive opening action contacts) can be connected to an individual block. If a single connection is made, the use of a jumper plug is required for the second M12 port Safety monitor Safe Safe module module Category 2 with safety-related modules Siemens Energy & Automation 2006 Power Distribution & Controls Division Wiring Example category 3 / 4 SIRIUS Safety Controls For applications in compliance with Category 3/4, a 2-channel input is used at the safety module. Inputs 1 is assigned a 2-channel sensor. Input 2 is sealed using an M12 cap, in order to guarantee degree of IP67 protection. Safety Safe monitor module Category 3 / 4 with safety-related modules Siemens Energy & Automation 2006 Power Distribution & Controls Division Safety at Work: AS-Interface SIRIUS Safety Controls SAFETY AT WORK Configuration Software Siemens Energy & Automation 2006 Power Distribution & Controls Division Safety at Work: AS-Interface SIRIUS Safety Controls Logic Path In The Safety Monitor E-Stop Gate Switch AND Interlock Switch Light Curtain EDM Standard OR SAW Output Siemens Energy & Automation 2006 Safe Switching Output Power Distribution & Controls Division Safety at Work ASI-Mon Software Version 2.03 Easy Configuration via Drag & Drop SIRIUS Safety Controls Available Devices (placeable by drag and drop to the corresponding column) Devices with direct access to the safe output Expanded Logic devices For complex applications Siemens Energy & Automation 2006 Power Distribution & Controls Division Safety at Work: AS-Interface SIRIUS Safety Controls SAFETY AT WORK Case Studies Siemens Energy & Automation 2006 Power Distribution & Controls Division Examples of converting hard-wire to network safety SIRIUS Safety Controls Roofing line comparison resulted in $43,000 savings or 18% Transfer line comparison resulted in $289,000 savings or 17% Source: Sam Boyter of Fox Controls Elgin, IL Siemens Energy & Automation 2006 Power Distribution & Controls Division Pearson Case Study (source Pearson Packaging) SIRIUS Safety Controls Case Erector Packaging Machine Discretely Wired Machine PLC 4 Electricians more than 1 week to wire 4 x 76 hours = 304 hours Startup 2 day for 2 electricians 2 x 2 x 8 = 32 hours • Category 3 safety system 4x8= Total Siemens Energy & Automation 2006 32 hours 368 hours Power Distribution & Controls Division Pearson Case Study (source Pearson Packaging) SIRIUS Safety Controls Case Erector Packaging Machine Machine built with distributed I/O and distributed safety I/O · · PLC 2 Electricians 1 week to wire No junction boxes No conduit No wire markers No wire terminals Startup less then 1/2 day for 2 Electricians 2 x 40 = 80 hours 2 x 4 = 8 hours Category 3 safety system Eliminate Conduit Significant Labor Reduction Installation Hardware Panel Space 2 x 4 = 8 hours -26% Total Siemens Energy & Automation 2006 96 hours Power Distribution & Controls Division Hollywood Entertainment SIRIUS Safety Controls Distribution Warehouse Wilsonville, OR. 25% reduction in installation cost was realized by replacing traditional control wiring in conduit 30% faster installation time allowing more flexibility in the schedule Pre-engineered cable paths along the system eliminated excess cabling cost Although the cable was installed in Panduit wiring duct mounted on the conveyors, it could have been tie-wrapped along the conveyors and still perform well in the warehouse environment. Using the common I/O blocks kept the system setup simple and straight forward The handheld programming unit saved the engineer time addressing the I/O blocks Siemens Energy & Automation 2006 Power Distribution & Controls Division Selling the Value to an OEM SIRIUS Safety Controls No compromise to Safety Reduction in machine manufacturing costs Increased revenue Increased usage of cut and paste engineering Shorter startups More flexibility All the values of distributed I/O now apply to safety devices Siemens Energy & Automation 2006 Power Distribution & Controls Division Selling the Value to an End User SIRIUS Safety Controls No compromise to Safety Low manufacturing costs means lower machine prices Simpler systems means easier maintenance and increased machine availability Increased diagnostics means reduced down time All the values of distributed I/O now apply to safety devices Siemens Energy & Automation 2006 Power Distribution & Controls Division Components for AS-Interface Safety at Work SIRIUS Safety Controls Optical Safety Safety Monitor Safety Module K45F Safety Module K60F Safety SlimLine S22.5F Rope Pull Switches Siemens Energy & Automation 2006 Push button Station E-Stops Interlock Switches Power Distribution & Controls Division Questions??? SIRIUS Safety Controls Siemens Energy & Automation 2006