AS-i Safety

2 ｜Sinergia_Engineering – [Hardware plan]

Topics
• 1. Definitions
• 2. Overview
• 3. Code Sequences
• 4. Components
• 5. Diagnostics
• 6. Maintenance

AS-i Safety is an extension of the standard AS-i BUS system.

Now safe signals can be transmitted on the same line that is also
used for standard data.
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Definitions
 Standard slave AS-i slave with AS-i address and type code, connected to the AS-i master using
4 bit I/O for switching.
 Safety slave AS-i slave with AS-i address, type code and unique code sequence (8x4 bit) for
safety reasons. This code is continuously transmitted to the safety monitor in a
safe condition. In an unsafe condition "0000" is transferred! This slave signals
have only two conditions: "Safe" or "Not safe"

 Safety monitor The Safety-CPU of the machine controls. It contains the programmed safety
logic! It monitors the condition of all safety slaves and switches the enable
circuits e.g., to stop the machine drives.

 Combined safety device AS-i master/gateway with integrated safety monitor

 Safe output Provokes hardware disconnection depending on the logics stored in the safety
monitor.
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Definitions
 Safe status The slave sends a valid code sequence (8x4 bit) to the monitor, e.g.:
emergency stop not pressed / guard door closed / jog switch pressed.

 Unsafe status The slave transmits a code sequence 0000 to the monitor.
The switch is not in a safe status
 Status ON Safe output closed (safe)
 Status OFF Safe output open (not safe)
 Release code A uniquely generated protection code for transferring the new/modified
"Safety-Project" to the safety monitor and chip card! The "Release Code" and
a protocol are stored at Krones archives! Changes in the Safety logic will
result in a different "Release Code".
 AS-i Mon Software for programming and transferring the "Safety Project" to the AS-i
Safety Monitor.
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Overview
• Necessary components:
Safe slaves/safety monitors

• Safety and standard components can be operated

simultaneously.

• Safe exchange of information via code sequences (monitor

and slave).

• Connection of protective and emergency stop

components via AS-i safety. The combined AS-i device is availalbe in single and double master
version with one integrated safety monitor respectively. Control of
• Information: the logic and time behaviour on
Safe slaves require a complete AS-i address. the AS-i line.
Subdivision in A and B addresses is not possible.
The configuration of the master including the monitor in a safe and
unsafe area is stored on a chip card (SIM).
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Codesequences

• Protection of the data transmission by means of permanent

change of the data content (4 bit working data).

• The safety monitor reads the code tables of all safe slaves
by means of "teach in" function, in order to continuously
monitor their operation.

• During operation, the required (target) and transmitted

(actual) code tables are continuously compared.

• In the event of deviations or faults, the safety monitor

disconnects the safe outputs according to the programmed
shutdown logics.
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Codesequences
Function of safe Inputs:

• Every slave has a unique pattern of 8 times 4 bit values

( code pattern )
• The code will be transmitted from the slave to the master
• Reserved Codes:
• Pattern „0“ ( 0000 ) has the special function ( switch off )
• Pattern „F“ ( 1111 ) has the special function „ error“
• Reserved codes are never part of a normal pattern

• Example for a normal pattern of a slave: 1C BA 75 DE

• 0001 1
• 1100 C
• 1011 B
• 1010 A
• 0111 7
• 0101 5
• 1101 D
• 1110 E
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Codesequences

2nd Example with partly interruption:

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Components
Monitor

Combined safety device as double master with integrated safety monitor

4 enable circuits onBoard
16 enable circuits in total
by using extensions
62 safety slaves max. on two lines

Profinet / Profibus Master

( used in bloc or blow moulder )
6 enable circuits onBoard
16 enable circuits in total
by using extensions
62 safety slaves max. on two lines
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Components
LED´s on the AS-i Master
• power
Sufficient power is provided.
• PROFIBUS / PROFINET
The gateway has detected the profibus / profinet
master.
• config error
A configuration fault has occurred.
• U AS-i
The AS-i circuit is supplied with adequate power.
• AS-i active
Normal operation is active.
• prg enable
The addresses can be programmed automatically.
• prj mode
Configuration mode active
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Components
Contacts and LEDS of Safety Monitor
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Components
• Various AS-i slaves are available
• Slave:
Always use a clear code sequence (8 x 4 bit)! (Comparable with
MAC address.)
In a safe status, the address is transmitted
in 8 cycles in groups of 4 bits to the monitor.

One slave address (no A/B address)

Two basic conditions:

Safe: Transmits a code sequence
Unsafe: Transmits 0000

Examples: Hand-held pendant

Guard door switch
Emergency stop
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Components

Extension-modules

• If more than 6 enable circuits are required, additional circuits can be provided by means of extension modules.
(1 additional enable circuit per module)

• These modules are connected to the AS-i bus and require 2 slave addresses.

1 x safe address:
Programming in switch position "PROG"

1 x A-address:
Programming in switch position "RUN" (to read in the feedback
circuit)

Attention !
If the programmer displays "F2" while reading or programming
the slave address, the corresponding button must be pressed
twice to execute!
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Components
Contact reproduction

• The safe outputs (SO…)can be

reproduced with safety switching
devices. (Here: 9 contacts
per device)

• The monitor evaluates the safe

function of the
switching device by means of feedback
signals.
(Terminals SI1, SI2, SI3, SI4, SI5, SI6)
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Components • Use:
Safe input module For example, connection of a
conventional "emergency stop", provided
to AS-i safety from foreign machines.

Double-channel: addressing as with

standard modules.

Use:
For example, connection of a
conventional safety switch
to AS-i safety.
Assembly position detection (module II)
Double-channel: addressing via direct
connection to the programming unit.
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Components
Control panel

• Emergency stop and

mode of operation selector switch

One AS-i safety OEM slave respectively is

mounted on the rear. Emergency stop
Emergency stop
Mode of operation
selector switch

Addressing: AS-i safety OEM slave

AS-i safety OEM slave

As for standard AS-i key strips. Connect the

assigned address jacks according to the
legend in the hardware diagram (group Address jack
Address jack
0901 LEG).
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Components
E-Stop
AS-i Safety addressing

Mode of operation
selector switch

AS-i Safety Slave addressing jack

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Components
JOG switch on the hand-held pendant

• AS-i safety JOG switch for height adjustment.

Use:
Safe jogging while the guard door is open.
The addresses are set with the same procedure
as for normal AS-i stations. Labelling station height adjustment

• Three pushing positions: Down Up

OFF
JOG
Machine stop
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Components
Hand-held pendant with 2 functions
During replacement, the
plug must be connected
with the new handheld
Emergency stop with JOG switch
pendant!
• Two safety slaves in one device
Plug Lead - Emergency stop
Pin 1 brown - Jog switch
Pin 3 blue Emergency stop
(slave addresses according to hardware
Pin 2 black 2 Functiongroup 1101
diagram
Pin 4 black 1
• Both slaves can work on the same AS-i line or
Guard door on two different AS-i lines.
Functiongroup 1201
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Components
Hand-held pendant with 2 functions

Emergency stop with JOG switch

Because only pin 1 and 3 of these AS-i plugs are used
for AS-i+ and AS-i - (Emergency Stop), and the Jog
switch uses pins 2 + 4, an A/B adapter (Y-
connector) is included in the delivery, to allow for
programming the slave address of the jog switch.

Plug B for jog switch Plug A for emergency stop

or directly at the programming unit (without adapter)
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Components
Hand-held pendant with 2 functions

Emergency stop is connected to one AS-i line (Pin 1 + 3).

The jog button is connected to the second AS-i line (Pin 2 + 4).
Addressing via plug A at the Y-connector
(Addresses are assigned consecutively)
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Components
Jog service door foot switch

Jogfunction
FBG 1201

Unlock E-Stop

3 positions: E-Stop-function
OFF FBG 1101
JOG
E-Stop
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Components

Two-hand jog button E-Stop-function

FBG 1101

Jogfunction
FBG 1201

Contact synchronisation time: 0,3-3 sec

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Components

Jog-button / E-Stop Jog-function Option

E-Stops Function FG 1201 flashlight
FG 1101

Top view Side view

Up/down
FG 0901
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Components
Guard door safety switches

The AS-i safety guard door safety switch is not provided

with a door lock, and is used, for example, on the main
machine of the module 2 labeller.
AS-i safety is not used for modular labelling stations.

The slave addresses are set with the same procedure as

for normal AS-i stations.
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Components
Guard door safety switches with door lock function

The AS-i safety guard door safety switch is

provided with a door lock function, and is used,
for example, on the main machine of the
module 2, labeller, filler, etc.
The slave addresses are set with the same
procedure as for normal AS-i stations

Mounting manual
TD 10015830
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Components
Emergency stop safety switch

The AS-i safety emergency stop safety switch is

used, for example, on the bottle table of the
main machine of the module 2 labeller.
The slave addresses are set with the same
procedure as for normal AS-i stations.
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Components
The AS-i safety proximity-type safety switch
Docking station safety switch is used, for example, on the labelling station
docking station of the main machine of the
module 2 labeller.
Requires a coded counterpart.

The slave addresses are set with the same

procedure as for normal AS-i stations.
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Diagnostics
MMA > Diagnostics > Guard/Emergency Stop Overview

This screen displays a machine-specific overview

of all existing safety doors, acknowledgment
buttons and emergency stop buttons and their
current states.

As an example, the protection / emergency stop

overview of a blow molding machine with
preform feed is shown here.
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Diagnostics
Touchscreen
• The status of each AS-i monitor is displayed on the Krones
touch-screen.

Current operating status:

- Safety mode
- Configuration
- Critical device fault

or of the used enable circuit.

• The legend with additional information can be called with

the information button.

Navigation: (touch-screen)
Diagnostics\AS-i safety\overview
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Diagnostics
Status on the Touchscreen

• Current AS-i safety slaves status.

The status is displayed as safe or not

safe.

• A malfunction has been caused by the

marked slave.
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AS-i Safety component replacement

• Prior to the replacement, the slave must be assigned the slave
address with the handheld programming unit. (Information
from the hardware plan)

• The combined AS-i safety device learns the slave address, but
not the code sequence of a new slave!

• In order to learn the code sequence, the slave must be in a safe

status (e. g. Emergency stop not pressed), otherwise the code
sequence of the new slave will not be learned.
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AS-i Safety component replacement

Procedure for teaching a safety code to the monitor:

In Main Menue choose

• -> Safety
• -> AS-i Safety
• -> Teach Safety
• -> Single Slave
• -> AS-i Circuit 1/2
• -> Slave address
• -> Change address
• -> Confirm with OK

• …wait for a few seconds

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Maintenance
Transmitting the Configuration (Chipcard)

Combined AS-i safety device

The configuration is stored on the chip card.

De-energise the new device and insert the card.

The chip card is subdivided in two sections. (Safe and unsafe data)

If at the start of a new device a "released" configuration is found on the chip

card, the safe data as well as the unsafe data is written into monitor and
master.
The display directly shows the copy menu.
Scroll all the way down and enter the displayed "release code". Then, start the
monitor!
Components can be replaced by identical parts only!
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Maintenance
Transmitting the Configuration (Chipcard)

Info:
• The displayed release code
value must
be confirmed (repeated).
• After confirmation of the
successful process, the data
from the chipcard will be
transferred to the master
(unsafe data) and Monitor
(safe data)
• The default Pin is 0000 or
9401
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Maintenance
Safe Link – safe cross communication

guards

operation Jog/inching
Principl Ifintwo or several safety combination devices are required
order to process safe signals of a machine, they can be
e: linked with each other via cross communication using
Profinet.
E-stop
To do so, a safety combined device must be defined as a
so-called manager of the cross communication and set in
the ASiMon software. In this manager the configuration
of the cross communication is stored.
Safe cross PLC
communication The AS-i BUS will not be impaired by this safe cross
Profinet communication.
ASi-Bus

foreign machine
ASi-Safety combi- ASi-Safety combi- E-stop
monitor
Speed-

device 2 device 1
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Maintenance
Safe Link – safe cross communication
Path: Menu ► Diagnostics ► Safety equipment ► ASi-Safety overview of machine

Detailed view
machine controller

Equipment identifier
safety combined device

Current status
safety combined device

Current status
safe cross communication
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Maintenance
Safe Link – safe cross communication
Relearning of the safe cross communication / Monitor replacement

If the machine has a safe cross communication, it

must be relearned after replacement.

Open menu

confirm warning number of exchanged devices confirm warning

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Maintenance
Safe Link – safe cross communication
Monitor-/Managerexchange

For several AS-i Safety Monitors, one monitor

is always the manager in the Safety system.
The manager can be recognized on the display
in the monitor itself. Namely, if "Node
Address" and "Manager Addr" are the same.
The configuration of the secure cross
communication is stored in the SIM card of
the manager. If the manager needs to be
replaced, the data is automatically copied
from the SIM card when it is inserted into the
new Monitor / Manager.
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Maintenance
Set Profibus-address

• Set the Profibus-address of the Combined AS-i safety

device
Attention!
Always check the Profibus address after copying the
chip card!

When components are replaced, the address is

displayed on the touch-screen, or can be seen on the
hardware diagram.

During setting, the Profibus line must be disconnected.

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Maintenance
Backup Chip-Card

• If possible, always use a new and empty chipcard! Krones part number from
spare part list (different sizes)
• Insert new chipcard into the master while power is off.
• Turn on power and wait!
• New chipcard will be detected as empty.
• Chipcard will be formatted and safe data as well as unsafe data will be copied
automatically from monitor and master onto the chipcard.
• The new created chipcard stays in the device and the original chipcard can be
kept as backup!

Attention!
▪ If there is only a used chipcard available for backup, it can be deleted for the unsafe area in the menu "SETUP / CHIPCARD
/ Clear Chipcard" and deleted completely in the menu "AS-I Safety / Save Chipcard / Clear Save Card"!
▪ A master restart launches the copy process as described above.
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Maintenance
AS-i Mon Software

• AS-i Mon3 software:

- Creation of the safety logics
- Loading the configuration in the
monitor
- Learning code sequences
- Startup

A PC with AS-i Mon software is not required for AS-i

safety components replacement!

• The created safety logics is stored in a configuration file.

Questions?