PROFIsafe

the easy way to integrate safety

H. Borgmann
Phoenix Contact Electronics GmbH

Hendrik Borgmann
Phoenix Contact Electronics GmbH
Bad Pyrmont, Germany
hborgmann@phoenixcontact.com
+49 5281 946 21 32

Safety supporter since 2004

Functional Safety Engineer (TV) since 2008
Manager of safety industry solutions & customer support since 2014

Required measures for machine safety

Product Safety Law
Machinery Directive
2006/42/EG

Harmonised Standards
EN ISO 13849

EN 62061

Safety Lifecycle for Machines

Structured procedure
For the implementation of all required measures for achieving machine
safety, Phoenix Contact works according to the phases of the safety
lifecycle*
Our work is:
Systematic
Binding
Traceable
Reproducible
Consistent
Sustainable
Reliable

* The phases of the safety lifecycle in accordance with

EN ISO 13849-1 and EN 62061

Services for safety lifecycle

Support for all required measures for
achieving machine safety
Consultation
Moderation incl. documentation templates
Engineering
Training
Development and support of industrial solutions
Safety support
Technology and product hotline during office hours
Product hotline 24 hours a day, 365 days a year
On-site service

What is PROFIsafe?
PROFIsafe
is the first communication standard according
to IEC 61508 to support standard and failsafe
communication on one and the same cable
has been standardized through cooperation between
numerous manufacturers and end users in the
PROFIBUS User Organization (PNO)
is listed as an international standard in IEC 61784-3-3
enables failsafe communication for PROFIBUS and
PROFINET based on standard network components

PROFIsafe topology

Safety-integrity up to
SIL3 / Kat. 4 / PL e

Compressed air

Standardized interfaces

400V AC
24V DC
PROFINET

Valvestation
&
PROFIsafe-application

Black channel principle

Source: PROFIsafe Profile V2.6 (2013)

PROFIsafe-protocol
PROFINET-IO-data

standard safe standard standard safe standard standard

Safe IO-data

Status-/
Controlbyte

Checksum

max. 12 bytes or
max. 123 bytes

1 byte
1 byte

3 bytes or
4 bytes

PROFIsafe-telegram

PROFIsafe-failure detection
Consecutive
number

TimeOut ID sender/
receiver

CRCchecksum

Corruption of data

Permanent repetition

Incorrect sequence

Loss

Delay > WD-Time

Insertion

Masquerade

Addressing

Out-of-sequence

PROFIsafe Devices

ABB
Euchner
FANUC
FESTO
KUKA
LENZE
LEUZE
Phoenix Contact
Phoenix Contact
SEW
SICK
Siemens
TR-Electronic
TWK

PLC+IO-Controller
MGB Muntifunctional gate box
Robot controller
Valve station
Robot controller
Failsafe frequency inverter
Light curtain
IO-system IB IL 24 PSD
PLC+IO-Controller, PROFIsafe-Gateway
Failsafe frequency inverter
Laserscanner, Licht curtain
PLC+IO-Controller, IOs, etc.
Encoder
Encoder

Evolution from safety-relays to PROFIsafe

-1SN1

-1SN1

-1SN2

-1SN3

EstopButton
-1SN2
EstopButton
-1SN3
EstopButton
-K4

S22 S11

S12 A2

Safety-relay

Safetyrelay

S33 S34

SafetyProg
Quit

1SN1 1SN2 1SN3

Quit

Function-block

SF_Emergency
Stop_V1_00

Estop
OK

Reference high current test laboratory

Test laboratory for overvoltage protection
producs and components of Phoenix Contact
High voltages, high current, magnetic fields
Galvanic insulation of operator panel and
actuators and by optical cables
IO-station is supplied by a transformator and on
high voltage potential for a short moment
IO-controller with PROFIsafe to protect the
operator and the equipment
(Short circuit power 240MW)

Application elektrostatic paintshop

Paint particles find their target by electrostatic
load with low loss
IO-controller is located on ground potential 0V
Some IO-stations are located on high voltage
potential ~ 80.000-90.000Volt
Failsafe connunication by PROFIsafe-protocol
Galvanic insulation by optical cables
Supply-voltages insulated by transformators

Reference Volkswagen Amarok

Volkswagen factory in Hannover, Germany

Bodyshop-application
IO-controller: Siemens CPU 3xx-F
IO-system: Phoenix Contact INLINE-System

Reference Audi A3 / A4
Automotive bodyshop application in the Audi
factories Ingolstadt, Germany and Gyr, Hungary
PROFIsafe control technology of
Phoenix Contact
PROFIsafe-applications with safe-IO-devices
of more then 10 different manufacturers
Up to 100 PROFIsafe-devices at one controller
Application conform to the VASS-Standard
(VW, Audi, Seat, Skoda)

Reference metro Barcelona

Controlling firebreak doors in metro tunnels
Trains are allowed to pass the tunnels, when
doors are opened and locked by bolts
Network redundancy by an optical ethernet ring
Very robust to electromagnetical fields by optical
cables
The PROFIsafe-application saves a lot of
copper/money because parallel wireing is not
required any more

Main cabinet

Optical
cable

Distance 2.500m from door cabinet to door cabinet.

Failsafe data-transmission by PROFINET and optical
cables.
Good network-availebility by redundant rings.

Door cabinet

Crane clutch at a
nuclear power plant in Germany
Removeable crane clutch for containers with
nuclear contents
Supply voltage by accumulators
No cables between crane and clutch
PROFIsafe data transmission by Bluetooth
Crane-function and clutch-function are locked
to each other by the PROFIsafe plc system

Crane system of the nuclear

power plant in Germany
PROFIsafe-communication

S7-CPU-F

PROFINET

PROFINET

Bluetooth

FL BT EPA

FL BT EPA

S7-IOs

PN BK
PSDI
PSDO

Crane-Box

Bluetooth

Clutch-Box

Thank You very much!!!