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ProfiSafe Technical Guide for e-Series

Use this guide to help you connect your UR robot to other devices using PROFIsafe 

Last modified on Sep 30, 2024

Examples are valid for: 

  • e-Series Software version: 5.12 and up 
  • TIA Portal v16 
  • PROFIsafe GSDML version: v2.42 

NOTE: Newer software versions can behave differently. 

For information on configuring and using PROFINET see the following article on the Support Site.

 

Specifications 

Here is an overview of some important information to get started.  

PLC (used in example) 

  • Siemens S7-1500F 
    • 1516F-3 PN/DP 
    • TIA Portal v16  

Robot 

  • Valid for all eSeries robots running Polyscope v.5.12+ only with PROFISafe license 

Sample Programs: 

The files listed are available for download at the bottom of this page and are used in the example (.zal16 project library files are compatible with TIA Portal v16: 

GSDML File 

Features 

Safety Stops Types 

Trigger 

Reaction

Function 

Emergency Stop 

Stop Category 1 

Stop by commanding motion and then removal of power  
(controlled stop) 

Safeguard Stop 

Stop Category 2 

Stop by commanding motion power remains on  
(controlled stop) 

Limit Violation 

Stop Category 0 

Stop by immediate removal of power 
(uncontrolled stop) 

Fault Detection 

Stop Category 0 

Stop by immediate removal of power  
(uncontrolled stop) 

 

Safety Signals  

A control message received from the safety PLC contains the information in the table below. 

Robot Inputs, PLC Outputs 

SignaL

Description 

E-Stop by system 

Asserts the system e-stop. 

Safeguard stop 

Asserts the safeguard stop. 

Reset safeguard stop 

Resets safeguard stop state (on low-to-high transition in automatic mode) if safeguard stop inputs are cleared beforehand. 

Safeguard stop auto 

Asserts safeguard stop if the robot is operating in Automatic mode. 

Reset safeguard stop auto 

Resets safeguard stop auto state (on low-to-high transition when in automatic mode) if no safeguard stop auto inputs are cleared beforehand. 

Reduced mode 

Activates the Reduced mode safety limits. 

Operational mode 

Activates either manual or automatic operational mode. If the safety configuration "Operational mode selection via PROFIsafe" is disabled, this field shall be omitted from the PROFIsafe control message. 

 

A status message sent to the safety PLC contains the information in the table below. 
Robot Outputs, PLC Inputs 

Signal 

Description 

Stop, cat. 0 

Robot is performing, or it has completed, a safety stop of category 0; A hard stop by immediate removal of power to the arm and the motors. 

Stop, cat. 1 

Robot is performing, or it has completed, a safety stop of category 1; A controlled stop after which the motors are left in a power off state with brakes engaged. 

Stop, cat. 2 

Robot is performing, or it has completed, a safety stop of category 2; A controlled stop after which the motors are left in a power on state. 

Violation 

Robot is stopped because the safety system failed to comply with the safety limits currently defined. 

Fault 

Robot is stopped because of an unexpected exceptional error in the safety system. 

E-stop by system 

Robot is stopped because of one of the following conditions: 

• a safety PLC connected via PROFIsafe has asserted system level e-stop. 

• an IMMI module connected to the control box has asserted a system level e-stop. 

• a unit connected to the system e-stop configurable safety input of the control box has asserted system level e-stop. 

E-stop by robot 

The robot is stopped because of one of the following conditions:

• The e-stop button of the teach pendant is pressed.

• An e-stop button connected to the robot e-stop nonconfigurable safety input of the control box is pressed.

Safeguard stop 

The robot is stopped due to one of the following conditions: 

• A safety PLC connected via PROFIsafe has asserted the safeguard stop. 

• A unit connected to the safeguard stop non-configurable input of the control box has asserted the safeguard stop. 

• A unit connected to the safeguard stop configurable safety input of the control box has asserted the safeguard stop. 

The signal follows the safeguard reset semantics. A configured safeguard stop reset functionality shall be used to reset this signal. 

PROFIsafe implies use of the safeguard reset functionality. 

Safeguard stop auto 

The robot is stopped because it is operating in Automatic mode and because of one of the following conditions: 

• A safety PLC connected via PROFIsafe has asserted safeguard stop auto. 

• A unit connected to a safeguard stop auto configurable safety input of the control box has asserted safeguard stop auto. 

The signal follows the safeguard reset semantics. A configured safeguard stop reset functionality shall be used to reset this signal PROFIsafe implies use of the safeguard reset functionality 

3PE stop 

Robot is stopped because it is operating in Manual mode and because of one of the following conditions: 

• You are using a 3PE TP and none of the buttons are in the middle position. 

• A 3-position enabling device connected to a configurable safety input of the control box has asserted the 3PE stop. 

Operational mode 

Indication of the current operational mode of the robot. This mode can be: Disabled, Automatic, or Manual. 

Reduced mode 

Reduced mode safety limits are currently active. 

Active limit set 

The active set of safety limits. This can be: Normal, Reduced, or Recovery. 

Robot moving 

Robot is moving. If any joint moves at a velocity of 0.02 rad/s or higher the robot is considered in motion. 

Safe home position 

Robot is at rest (robot not moving), and in the position defined as the Safe Home Position. 

 

PLC Safety Output Signals

FOutputs(PLC) 

Description 

Address  

(Telegram1) 

Address  

(Telegram2) 

ESTOP_OK 

Set Robot E-Stop 

%Q480.0 

%Q980.0 

SAFEGUARD_STOP_OK 

Set Robot Safeguard Stop 

 %Q480.1 

 %Q980.1 

RESET_SAFEGUARD 

Reset Robot Safeguard Stop 

 %Q480.2 

 %Q980.2 

SAFEGUARD_STOP_AUTO_OK 

Set Robot Safeguard Automatic Stop 

 %Q480.3 

 %Q980.3 

RESET_AUTO_SAFEGUARD_STOP 

Reset Robot Safeguard Automatic Stop 

 %Q480.4 

 %Q980.4 

SAFE_REDUCED_MODE_DEACTAVE 

Deactivate Robot Reduced Mode 

 %Q480.5 

 %Q980.5 

SPARE1 

NOT USED 

 %Q480.6 

 %Q980.6 

SPARE2 

NOT USED 

 %Q480.7 

 %Q980.7 

MODE_SELECTOR 

Only Telegram1, 

0=MANUAL, 1=AUTO 

 %Q481.0 

 %Q981.0 

 

PLC Safety Input Signals 

Finputs (PLC) 

Description 

Address  

(Telegram1) 

Address  

(Telegram2) 

SS0_ACTIVE 

Robot in StopCat0 

%I480.0 

%I980.0 

SS1_ACTIVE 

Robot in StopCat1 

 %I480.1 

 %I980.1 

SS2_ACTIVE 

Robot in StopCat2 

 %I480.2 

 %I980.2 

VIOLATION_ACTIVE 

Robot has a collision 

 %I480.3 

 %I980.3 

FAULT_ACTIVE 

Robot controller fault 

 %I480.4 

 %I980.4 

SYSTEM_ESTOP_ACTIVE 

Robot gets external E-Stop 

 %I480.5 

 %I980.5 

ROBOT_ESTOP_ACTIVE 

Robot has internal E-Stop 

 %I480.6 

 %I980.6 

SAFEGUARD_STOP_ACTIVE 

Robot in Safeguard Stop 

 %I480.7 

 %I980.7 

SAFEGUARD_STOP_AUTO_ACTIVE 

Robot in Safeguard Automatic Mode Stop 

 %I481.0 

 %I981.0 

3PE_ACTIVE 

Dead man switch pressed 

 %I481.1 

 %I981.1 

SPARE1 

NOT_USED 

 %I481.2 

 %I981.2 

SPARE2 

NOT_USED 

 %I481.3 

 %I981.3 

SPARE3 

NOT_USED 

 %I481.4 

 %I981.4 

SPARE4 

NOT_USED 

 %I481.5 

 %I981.5 

SPARE5 

NOT_USED 

 %I481.6 

 %I981.6 

SPARE6 

NOT_USED 

 %I481.7 

 %I981.7 

AUTOMATIK_MODE_ACTIVE 

Robot is in Automatic mode 

 %I482.0 

 %I982.0 

MANUAL_MODE_ACTIVE 

Automatic is not in use =>Robot in Manual Mode 

 %I482.1 

 %I982.1 

REDUCED_MODE_ACTIVE 

Robot in reduced mode 

 %I482.2 

 %I982.2 

LIMITS_REDUCED_MODE_ACTIVE 

Robot in reduced mode 

 %I482.3 

 %I982.3 

LIMITS_RECOVERY_MODE_ACTIVE 

Robot in recovery mode 

 %I482.4 

 %I982.4 

ROBOT_MOVING 

Robot is moving 

 %I482.5 

 %I982.5 

SAFE_HOME 

Robot is in Safe home 

 %I482.6 

 %I982.6 

SPARE7 

NOT_USED 

%I482.7 

%I982.7 

 

Telegrams 

The available telegrams are :

  • Telegram 1– Allows for access to mode selector signals. Automatic & Manual modes 
  • Telegram 2 – Same as telegram 1 without access to mode selector signals 
  • Each telegram is available with a 3- or 4-byte CRC depending on which PLC is used 

Example Library Contents 

Included in the example library, Universal Robots_FailSafe_Library.zal16, is the following:

  • UR_Standard_FBs -  
  • Function blocks for Universal robots 
  • Hardware Configuration 
  • A preconfigured robot with all IO modules. 
  • PLC Tags 
  • Tag table for a robot. 
  • Tag table with test signals. 
  • UDTs 
  • UDTs for IO structure and the function blocks. 
  • URExample Project 
  • A sample project to test the possibilities 

Setup and Walkthrough 

 Global Library 

The Global Library contains the required elements for PROFINET and PROFIsafe to communicate with a UR robot.  

  • Function Blocks
  • Hardware Configurations
  • PLC Tags
  • UDTs
  • Example project

Import the Global library into TIA portal to add the robot with PROFIsafe device.   

To import the Global Library:

  1. Install and open TIA Portal 
  2. Navigate to Global libraries 
  3. Click Open Global library 
  4. Browse to the Universal Robots_FailSafe_Library.zal16 file downloaded from the support site 
  5. Select a folder to save the Library file 

 

Setting up the Example project in TIA Portal 

  1. Install and Open TIA Portal 
  2. Open Universal Robots_FailSafe_Example.zap16 project file downloaded from the support site 
  3. Choose destination folder to save project 
  4. Once the project is open, open the Devices & networks to assign IP Addresses  
    1. To set IP address for PLC  
      1. Double click on the PLC and enter the Device View 
      2. In the Properties window select the ProfiNet interface used (X1 or X2) 
      3. Select Ethernet addresses 
      4. Enter the desired IP address and Subnet mask 
    2. To set IP address for Robot 
      1. Double click on the UR_Rob device and enter the Device View 
      2. In the Properties window select the ProfiNet interface [X1] 
      3. Select Ethernet addresses 
      4. Enter the desired IP address and Subnet mask 
  5. The PROFIsafe parameters for the Robot need to be set 
    1. Double click on the UR_Rob device and enter the Device View 
    2. In the Device overview tab select the Safety telegram used 
    3. In the Properties window, select PROFIsafe in the General Tab

 These are the available PROFIsafe parameters that can be modified 

F_Source_Add 

The Safety address(F-Address) of F-Host (PLC) 
Allowed values are 1..65534 

F_Dest_Add 

The Safety address(F-Address) of F-Device (Robot) 
Allowed values are 1..65534 

F_WD_Time 

With selectable checkbox 
“Manual assignment of F-monitoring time” 
F-Watchdog timer in milliseconds 
Allowed values 100…2000 
Default value = 200  

F_iPar_CRC 

CRC used for iParameters (Dynamic Parameters) 
This is the safety checksum generated by the robot. That is displayed in the 8-character code displayed in the header of the Teach Pendant  

 

Ex:  = “A7E570CA” value 

Setting to “0” ignores the CRC value 

F-I/O DB-number 

With selectable checkbox  
“F-I/O DB manual number assignment”  
 

 

The following table lists the PROFIsafe  read only parameters.

F_SIL 

Failsafe Safety Integrity Level 
Value = "SIL3" 

F_CRC_Length 

Byte length of CRC used in the configuration 
Value = “3-Byte-CRC” or “4-Byte-CRC” 
depending on which telegram is used 

F_Block_ID 

The block ID label of the robot failsafe device 
Value = ”1” 

F_Par_Version 

Version of the failsafe parameters 
Value = “1” 

F_Par_CRC_WithoutAddress 

Value = “0” 

F_Par_CRC 

The calculated CRC value for the F-Device 

F-I/O DB-name: 

Name of the F-I/O DB dependent on the telegram used. 

 

Setting up the Example project in Polyscope 

  1. Set up IP address on robot controller 
    1. Enable PROFINET Installation Tab-> FieldBus-> PROFINET 
    2. Enable 
    3. Configure the behavior if the PROFINET communication is lost for the  
      1. Robot IO Module 
      2. Registers module 1 
      3. Registers module 2 
  2. Enable ProfiSafe functionality on robot controller 
    1. Installation Tab-> Safety-> PROFIsafe 
    2. Enable 
    3. Set Source Address (PLC) 
    4. Set Destination Address (Robot) 
    5. Enable Control Operational Node 

 

 

Features and Common Functions 

Features of the example project include the following components, that are intended to provide an example of available safety functions. The Provided examples are selections of code that can be used as apart of the complete safety solution. Additional programming and verification of safety functions is required. 

  • Program Blocks 
    • F-Blocks-> Main_Safety_RTG1 [FB1]  
      • Safety related block and functions 
      • Network Descriptions 
        • 1: Enabling of Fail-Safe IO 
        • 2: Reintegration of Safety functions 
        • 3: Safety Signals 
        • 4: Telegrams 
    • UR_Examples->FBs 
      • Non-safety related block and functions 
      • (Outside of the scope of this article) Included in the ProfiNet support article 
  • PLC Tags 
    • PLC Tags for specific telegram in use 
      • Safe_Telegram1 
      • Safe_Telegram2 

Common functions of the example project include steps that detail how to implement common safety functions, such as: triggering and recovery from a Safety Stop (Emergency & Protective), integration, and reintegration of the safety communication etc. These highlight the necessary steps needed to preform these functions. Additional programming and verification of safety functions is required. 

  • (Re)Integrate the robot safety communications 
    • Enable robot 
      • Network 1: %M30.5 “ENABLE_ROBOT_1” 
      • Toggle bit (CTRL+F2 to enable and CTRL+F3 to disable) 
    • Reintegrate and Acknowledge Safety 
      • Network 2: Reintegrate Ack Safety: %M30.4 “ACK_SAFETY” 
      • Toggle bit (CTRL+F2 to enable and CTRL+F3 to disable) 
    • Test bits 
      • Network 3: set Safety Signals 
      • %M30.0 – “ESTOP” 
      • %M30.1 – “SAFEGUARD_STOP” 
      • %M30.2 – “AUTO_SAFEGUARD_STOP” 
      • %M30.3 – “REDUCED_MODE” 
      • %M30.4 – “AUTO_MODE” 
  • Clearing Safety Stops 
    • Safety Stop needs to be reset (LOW) 
    • Toggle %M30.4 “ACK_SAFETY”  
  • Clearing Emergency Stops – Using UR_Robots[FB3] example 
    • Assuming Robot is in Automatic mode with Remote Control enabled 
    • Reset Emergency Stop bit 
      • Reset %M30.0 – “ESTOP” 
    • Set PowerON Bit 
      • Set UR_Robots[FB3] – Network 3: %M1.1 – “PowerOn” 
    • Acknowledge Safety error 
      • Pulse %M30.4 – “ACK_Safety” 
    • Brake Release 
      • Set UR_Robots[FB3] – Network 3: %M1.2 – “Brake Release” 
    • Close Safety PopUp 
      • UR_Robots[FB3] – Network 3: %M6.4 – “Dashboard13” 
    • Restart/ resume program 

Attached files