SINUMERIK 840D sl. Service - Safety Integrated. Manual (2020)

Data descriptions

11.6 Process data

11.6

Process data

11.6.1

Overview: Process data in telegrams

Table 11-18 Process data from PROFIsafe telegrams

901

902

903

Process data

Safety control word 1

PZD1

S_STW1

Safety status word 1

PZD1

S_ZSW1

Safety control word 2

PZD1…2

S_STW2

Safety status word 2

PZD1…2

S_ZSW2

SLS limit value input

PZD3

S_SLS_LIMIT_A

Active SLS limit value

PZD3

PZD5

S_SLS_LIMIT_A_ACTIVE

Counter for the safety cycle

PZD4

S_CYCLE_COUNT

Actual position value (16 bits)

PZD5

S_XIST16

Actual position value (32 bits)

PZD5…6

S_XIST32

Safe Cam status word

PZD3…4

S_ZSW_CAM1

Detailed information about the process data of these telegrams is provided in Chapter

"PROFIsafe process data (Page 354)".

Table 11-19 Process data from SIEMENS telegram 701 (SIC/SCC)

701

Process data

Safety Control Channel control word 1

PZD1

S_STW1B

SI Motion Safety Info Channel status word

PZD1

S_ZSW1B

Safety Info Channel status word 2

PZD2

S_ZSW2B

Safety Control Channel control word 3

PZD2

S_STW3B

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Data descriptions

11.6 Process data

701

Process data

SLS setpoint speed limiting (32 bit)

PZD3…4

S_V_LIMIT_B

Safety Info Channel status word 3

PZD5

S_ZSW3B

Detailed information about the process data of telegram 701 is provided in Chapter "SIC/SCC

(PROFIdrive) process data (Page 369)".

11.6.2

PROFIsafe process data

Note

Additional information in the function block diagrams

Generally, for the subsequent descriptions, reference is made to a function block diagram. You

can find the function block diagram mentioned in the SINAMICS S120/S150 List Manual.

Note

Reserved control/status bits

A series of control and/or status bits are listed as reserved in the following tables. The reason for

this is that various Safety Integrated Functions will only be implemented at a later point in time.

The bits are reserved for future functions.

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Data descriptions

11.6 Process data

11.6.2.1

S_STW1: Safety control word 1

S_STW1 (Basic Functions)

Safety control word 1 (S_STW1)

S_STW1, output signals

see function chart [2806].

Table 11-20 Description of safety-control word1 (S_STW1)

Byte

Bit

Meaning

Remarks

STO

Deselect STO

Select STO

SS1

Deselect SS1

Select SS1

SS2

-¹⁾

SOS

-¹⁾

SLS

-¹⁾

Reserved

SLP

-¹⁾

Internal Event ACK

1/0

Acknowledgment

No acknowledgment

SLA

-¹⁾

Select SLS bit 0

-¹⁾

Select SLS bit 1

Reserved

SDI positive

-¹⁾

SDI negative

6, 7

Reserved

Signals not relevant for Basic Functions: Should be set to "0".

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Data descriptions

11.6 Process data

S_STW1 (Extended Functions)

Safety control word 1 (S_STW1)

S_STW1, output signals

see function chart [2842].

Table 11-21 Description of safety-control word1 (S_STW1)

Byte

Bit

Meaning

Remarks

STO

Deselect STO

Select STO

SS1

Deselect SS1

Select SS1

SS2

Deselect SS2

Select SS2

SOS

Deselect SOS

Select SOS

SLS

Deselect SLS

Select SLS

Reserved

SLP¹⁾

Deselect SLP

Select SLP

Internal Event ACK

1/0

Acknowledgment

No acknowledgment

SLA

Deselect SLA

Select SLA

Select SLS bit 0

Selection of the speed limit for SLS (2 bits)

Select SLS bit 1

Reserved

SDI positive

Deselect SDI positive

Select SDI positive

SDI negative

Deselect SDI negative

Select SDI negative

6, 7

Reserved

Signals not relevant for Extended Functions: Must not be evaluated.

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Data descriptions

11.6 Process data

11.6.2.2

S_ZSW1: Safety status word 1

S_ZSW1 (Basic Functions)

Safety status word 1 (S_ZSW1)

S_ZSW1, input signals

see function diagram [2806].

Table 11-22 Description of safety status word 1 (S_ZSW1)

Byte

Bit

Meaning

Remarks

STO active

STO not active

SS1 active

SS1 not active

SS2 active

-¹⁾

SOS active

-¹⁾

SLS active

-¹⁾

Reserved

SLP active

-¹⁾

Internal Event

Internal event

No internal event

SLA active

-¹⁾

Active SLS level bit 0

-¹⁾

Active SLS level bit 1

SOS selected

-¹⁾

SDI positive active

-¹⁾

SDI negative active

-¹⁾

Reserved

SSM (speed below limit value)

-¹⁾

Signals not relevant for Basic Functions: Must not be evaluated.

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Data descriptions

11.6 Process data

S_ZSW1 (Extended Functions)

Safety status word 1 (S_ZSW1)

S_ZSW1, input signals

see function diagram [2842].

Table 11-23 Description of safety status word 1 (S_ZSW1)

Byte

Bit

Meaning

Remarks

STO active

STO not active

SS1 active

SS1 not active

SS2 active

SS2 not active

SOS active

SOS not active

SLS active

SLS not active

Reserved

SLP active¹⁾

SLP active

SLP not active

–

The status signal "SLP active" is not the same as

the diagnostic signal "SLP active" (r9722.6), but is

the AND logic operation of "SLP active" (r9722.6)

and "safely referenced" (r9722.23).

Internal Event

Internal event

No internal event

SLA active

SLA not active

Active SLS level bit 0

Display of the speed limit for SLS (2 bits)

Active SLS level bit 1

SOS selected

SOS deselected

SDI positive active

SDI positive not active

SDI negative active

SDI negative not active

Reserved

SSM (speed)

SSM (speed below limit value)

SSM (speed higher than/equal to limit)

Signals not relevant for Extended Functions: Must not be evaluated.

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Data descriptions

11.6 Process data

11.6.2.3

S_STW2: Safety control word 2

S_STW2 (Basic Functions)

Safety control word 2 (S_STW2)

S_STW2, output signals

see function diagram [2806].

Table 11-24 Description of safety-control word 2 (S_STW2)

Byte

Bit

Meaning

Remarks

STO

Deselect STO

Select STO

SS1

Deselect SS1

Select SS1

SS2

-¹⁾

SOS

-¹⁾

SLS

-¹⁾

Reserved

SLP

-¹⁾

Internal Event ACK

1/0

Acknowledgment

No acknowledgment

SLA active

-¹⁾

Select SLS bit 0

-¹⁾

Select SLS bit 1

Reserved

SDI positive

-¹⁾

SDI negative

-¹⁾

6, 7

Reserved

0 ... 2

Reserved

Select SLP position range

-¹⁾

4 ... 6

Reserved

SCA

-¹⁾

Select gearbox stage, bit 0

-¹⁾

Select gearbox stage, bit 1

-¹⁾

Select gearbox stage, bit 2

-¹⁾

Gearbox stage switchover

-¹⁾

SS2E

-¹⁾

SS2ESR

-¹⁾

6, 7

Reserved

Signals not relevant to Basic Functions should be set to "0".

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Data descriptions

11.6 Process data

S_STW2 (Extended Functions)

Safety control word 2 (S_STW2)

S_STW2, output signals

see function diagram [2843].

Table 11-25 Description of safety-control word 2 (S_STW2)

Byte

Bit

Meaning

Remarks

STO

Deselect STO

Select STO

SS1

Deselect SS1

Select SS1

SS2

Deselect SS2

Select SS2

SOS

Deselect SOS

Select SOS

SLS

Deselect SLS

Select SLS

Reserved

SLP

Deselect SLP

Select SLP

Internal Event ACK

1/0

Acknowledgment

No acknowledgment

SLA

Deselect SLA

Select SLA

Select SLS bit 0

Selection of the speed limit for SLS (2 bits)

Select SLS bit 1

Reserved

SDI positive

Deselect SDI positive

Select SDI positive

SDI negative

Deselect SDI negative

Select SDI negative

6, 7

Reserved

0 ... 2

Reserved

Select SLP position range¹⁾

Select SLP area 2 (SLP2)

Select SLP area 1 (SLP1)

4 ... 6

Reserved

SCA

Deselect SCA

Select SCA

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Data descriptions

11.6 Process data

Byte

Bit

Meaning

Remarks

Select gearbox stage, bit 0

Select gearbox stage (3 bits)

Select gearbox stage, bit 1

Select gearbox stage, bit 2

Gearbox stage switchover

With increased position tolerance

Without increased position tolerance

SS2E

Deselect SS2E

Select SS2E

SS2ESR

Deselect SS2ESR

Select SS2ESR

6, 7

Reserved

Signals not relevant for Extended Functions: Must not be evaluated.

11.6.2.4

S_ZSW2: Safety status word 2

S_ZSW2 (Basic Functions)

Safety status word 2 (S_ZSW2)

S_ZSW2, input signals

see function diagram [2806].

Table 11-26 Description of safety status word 2 (S_ZSW2)

Byte

Bit

Meaning

Remarks

STO active

STO not active

SS1 active

SS1 not active

SS2 active

-¹⁾

SOS active

-¹⁾

SLS active

-¹⁾

Reserved

SLP active

-¹⁾

Internal Event

Internal event

No internal event

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Data descriptions

11.6 Process data

Byte

Bit

Meaning

Remarks

SLA active

-¹⁾

Active SLS level, bit 0

-¹⁾

Active SLS level, bit 1

Reserved

SDI positive active

-¹⁾

SDI negative active

-¹⁾

Reserved

SSM (speed)

-¹⁾

0 ... 2

Reserved

SLP active position range

-¹⁾

4, 5

Reserved

Safe position valid

-¹⁾

Safely referenced

-¹⁾

0 ... 2

F-DI 0 ... 2²⁾

-¹⁾

SS2ESR active

-¹⁾

SS2E active

-¹⁾

SOS selected

-¹⁾

SLP upper limit maintained

-¹⁾

SLP lower limit maintained

-¹⁾

Signals not relevant for Basic Functions: Must not be evaluated.

Only valid for CU310-2.

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Data descriptions

11.6 Process data

S_ZSW2 (Extended Functions)

Safety status word 2 (S_ZSW2)

S_ZSW2, input signals

see function diagram [2843].

Table 11-27 Description of safety status word 2 (S_ZSW2)

Byte

Bit

Meaning

Remarks

STO active

STO not active

SS1 active

SS1 not active

SS2 active

SS2 not active

SOS active

SOS not active

SLS active

SLS not active

Reserved

SLP active¹

SLP active

SLP not active

–

The status signal "SLP active" is not the same as

the diagnostic signal "SLP active" (r9722.6), but is

the AND logic operation of "SLP active" (r9722.6)

and "safely referenced" (r9722.23).

Internal Event

Internal event

No internal event

SLA active

SLA not active

Active SLS level bit 0

Display of the speed limit for SLS (2 bits)

Active SLS level bit 1

Reserved

SDI positive active

SDI positive not active

SDI negative active

SDI negative not active

Reserved

SSM (speed)

SSM (speed below limit value)

SSM (speed higher than/equal to limit)

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Data descriptions

11.6 Process data

Byte

Bit

Meaning

Remarks

0 ... 2

Reserved

SLP active position range¹⁾

SLP area 2 (SLP2) active

SLP area 1 (SLP1) active

The status signal "SLP active position range" al-

ways corresponds to the diagnostic signal "SLP

active position range" (r9722.19).

4, 5

Reserved

Safe position valid

Safe position invalid

Safely referenced

Safe position is applicable as "safely referenced"

Safe position is not applicable as "safely refer-

enced"

Signals not relevant for Extended Functions: Must not be evaluated.

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Data descriptions

11.6 Process data

Byte

Bit

Meaning

Remarks

F-DI 0²⁾

F-DI 0 inactive

F-DI 0 active

F-DI 1²⁾

F-DI 1 inactive

F-DI 1 active

F-DI 2²⁾

F-DI 2 inactive

F-DI 2 active

SS2ESR active

SS2ESR not active

SS2E active

SS2E not active

SOS selected

SOS deselected

SLP upper limit maintained

SLP: Upper limit maintained

SLP: Upper limit not maintained

–

The status signal "upper SLP limit maintained" al-

ways corresponds to the diagnostic signal "upper

SLP limit maintained" (r9722.30).

SLP lower limit maintained

SLP: Lower limit maintained

SLP: Lower limit not maintained

The status signal "lower SLP limit maintained" al-

ways corresponds to the diagnostic signal "lower

SLP limit maintained" (r9722.31).

Signals not relevant for Extended Functions: Must not be evaluated.

Only valid for CU310-2.

11.6.2.5

S_SLS_LIMIT_A: SLS limit value input

S_SLS_LIMIT_A

• PZD3 in telegram 901, 902, 903, output signals

• SLS limit value input

• Value range 1 ... 32767; 32767 ≙ 100% of the 1st SLS level

11.6.2.6

S_SLS_LIMIT_A_ACTIVE: Active SLS limit value

S_SLS_LIMIT_A_ACTIVE

• PZD3 in telegram 901, 902, 903, input signals

• Active SLS limit value

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Data descriptions

11.6 Process data

• Value range 1 ... 32767; 32767 ≙ 100%

• Must only be evaluated if SLS 1 active and p9501.24 = 1.

11.6.2.7

S_CYCLE_COUNT: Counter for the safety cycle

S_CYCLE_COUNT

• PZD4 in telegrams 901 and 902, input signals

• Counter for the safety cycle

• Value range -32768 ... +32767

• May only be evaluated if the transfer of safe position values is active (p9501.25 = 1) and the

position value is valid (r9722.22 = r9722.23 = 1).

11.6.2.8

S_XIST16: Current actual position value (16 bits)

S_XIST16

• PZD5 in telegram 901, input signals

• Current actual position value (16 bits)

• Value range ±32767

• Scaling using p9574

Note

Scaling

It is not permissible that the position value transferred in S_XIST16 exceeds the value range

that can be represented. This is the reason that the safe position value of the drive (r9713[0])

can be allocated a scaling factor. The position value is divided by this factor before transfer.

As a consequence, a wider value range can be transferred with a reduced accuracy.

Example: For a position of -29.999 mm signaled in r9708[0] and r9708[1] and a scaling

factor of p9x74 = 1000, a numerical value of -29 is signaled to the controller.

• May only be evaluated if the transfer of safe position values is active (p9501.25 = 1) and the

position value is valid (r9722.22 = r9722.23 = 1).

11.6.2.9

S_XIST32: Current actual position value (32 bits)

S_XIST32

• PZD5 and PZD6 in telegram 902, input signals

• Current actual position value (32 bits)

• Value range ±737280000

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Data descriptions

11.6 Process data

• Unit: 1 μm (linear axis), 0.001 ° (rotary axis)

• May only be evaluated if the transfer of safe position values is active (p9501.25 = 1) and the

position value is valid (r9722.22 = r9722.23 = 1).

11.6.2.10

S_ZSW_CAM1

S_ZSW_CAM1, Safe Cam

see function diagram [2844].

Table 11-28 Description of Safety status word Safe Cam (S_ZSW_CAM1)

Byte

Bit

Meaning

Remarks

Position at cam 1

Position is at cam 1

Position is not at cam 1

Position at cam 2

Position is at cam 2

Position is not at cam 2

Position at cam 3

Position is at cam 3

Position is not at cam 3

Position at cam 4

Position is at cam 4

Position is not at cam 4

Position at cam 5

Position is at cam 5

Position is not at cam 5

Position at cam 6

Position is at cam 6

Position is not at cam 6

Position at cam 7

Position is at cam 7

Position is not at cam 7

Position at cam 8

Position is at cam 8

Position is not at cam 8

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Data descriptions

11.6 Process data

Byte

Bit

Meaning

Remarks

Position at cam 9

Position is at cam 9

Position is not at cam 9

Position at cam 10

Position is at cam 10

Position is not at cam 10

Position at cam 11

Position is at cam 11

Position is not at cam 11

Position at cam 12

Position is at cam 12

Position is not at cam 12

Position at cam 13

Position is at cam 13

Position is not at cam 13

Position at cam 14

Position is at cam 14

Position is not at cam 14

Position at cam 15

Position is at cam 15

Position is not at cam 15

Position at cam 16

Position is at cam 16

Position is not at cam 16

Position at cam 17

Position is at cam 17

Position is not at cam 17

Position at cam 18

Position is at cam 18

Position is not at cam 18

Position at cam 19

Position is at cam 19

Position is not at cam 19

Position at cam 20

Position is at cam 20

Position is not at cam 20

Position at cam 21

Position is at cam 21

Position is not at cam 21

Position at cam 22

Position is at cam 22

Position is not at cam 22

Position at cam 23

Position is at cam 23

Position is not at cam 23

Position at cam 24

Position is at cam 24

Position is not at cam 24

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Data descriptions

11.6 Process data

Byte

Bit

Meaning

Remarks

Position at cam 25

Position is at cam 25

Position is not at cam 25

Position at cam 26

Position is at cam 26

Position is not at cam 26

Position at cam 27

Position is at cam 27

Position is not at cam 27

Position at cam 28

Position is at cam 28

Position is not at cam 28

Position at cam 29

Position is at cam 29

Position is not at cam 29

Position at cam 30

Position is at cam 30

Position is not at cam 30

Safe Cam active

Safe Cam is active

Safe Cam is not active

Validity of the values of Safe Cam

Values of Safe Cam apply

Values of Safe Cam do not apply

11.6.3

SIC/SCC (PROFIdrive) process data

11.6.3.1

S_STW1B: Safety Control Channel control word 1

S_STW1B

Safety Control Channel control word 1

Table 11-29 Description of S_STW1B

Bit

Meaning

Remarks

Parameter

0...7

Reserved

Extended Functions test stop/forced

Extended Functions test stop/forced checking pro-

r10251.8

checking procedure

cedure selected

Extended Functions test stop/forced checking pro-

cedure deselected

9...12

Reserved

Close brake from control

"Close brake from control" selected

r10251.13

"Close brake from control" deselected

14, 15

Reserved

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Data descriptions

11.6 Process data

11.6.3.2

S_ZSW1B: SI Motion / Safety Info Channel status word

S_ZSW1B

SI Motion Safety Info Channel status word

Table 11-30 Description S_ZSW1B

Bit

Meaning

Remarks

Parameter

STO active

r9734.0

STO not active

SS1 active

r9734.1

SS1 not active

SS2 active

r9734.2

SS2 not active

SOS active

r9734.3

SOS not active

SLS active

r9734.4

SLS not active

SOS selected

r9734.5

SOS deselected

SLS selected

r9734.6

SLS deselected

Internal event

r9734.7

No internal event

SLA selected

r9734.8

SLA deselected

Active SLS level bit 0

Display of the velocity limit for SLS (2 bits)

r9734.9

Active SLS level bit 1

r9734.10

Reserved

SDI positive selected

r9734.12

SDI positive deselected

SDI negative selected

r9734.13

SDI negative deselected

ESR retract requested

r9734.14

ESR retract not requested

Safety message effective

r9734.15

No Safety message effective

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Data descriptions

11.6 Process data

11.6.3.3

S_ZSW2B: Safety Info Channel status word 2

S_ZSW2B

Safety Info Channel status word 2

Table 11-31 Description of S_ZSW2B

Bit

Meaning

Remarks

Parameter

0...3

Reserved

SLP selected position range

SLP area 2 selected

r9743.4

SLP area 1 selected

5, 6

Reserved

SLP selected and user agreement

SLP selected and user agreement set

r9743.7

SLP selected or user agreement not set

SDI positive

SDI positive selected

r9743.8

SDI positive deselected

SDI negative

SDI negative selected

r9743.9

SDI negative deselected

10, 11

Reserved

Test stop active

r9743.12

Test stop not active

Test stop required

r0743.13

Test stop not required

14, 15

Reserved

11.6.3.4

S_STW3B: Safety Control Channel control word 3

S_STW3B

Safety Control Channel control word 3

Table 11-32 Description of S_STW3B

Bit

Meaning

Remarks

Parameter

Select brake test

Brake test selected

r10231.0

Brake test deselected

Start brake test

Start brake test requested

r10231.1

Start brake test not requested

Brake selection

Test brake 2 selected

r10231.2

Test brake 1 selected

Select direction of rotation

Negative direction selected

r10231.3

Positive direction selected

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Data descriptions

11.6 Process data

Bit

Meaning

Remarks

Parameter

Select test sequence

Test sequence 2 selected

r10231.4

Test sequence 1 selected

Status of external brake

External brake closed

r10231.5

External brake open

6...15

Reserved

11.6.3.5

S_ZSW3B: Safety Info Channel status word 3

S_ZSW3B

Safety Info Channel status word 3

Table 11-33 Description of S_ZSW3B

Bit

Meaning

Remarks

Parameter

Brake test

Brake test selected

r10234.0

Brake test deselected

Setpoint input, drive/external¹⁾

Setpoint specification for the drive

r10234.1

Setpoint specification, external (controller)

Active brake

Test brake 2 active

r10234.2

Test brake 1 active

Brake test active

Test active

r10234.3

Test inactive

Brake test result

Test successful

r10234.4

Test error

Brake test completed

Test run

r10234.5

Test incomplete

External brake request

Close brake

r10234.6

Open brake

Current load sign

Negative sign

r10234.7

Positive sign

8...10

Reserved

SS2E active

r10234.11

SS2E inactive

SS2ESR active

r10234.12

SS2ESR inactive

Reserved

Acceptance test SLP (SE) selected

r10234.14

Acceptance test SLP (SE) deselected

Acceptance test mode selected

r10234.15

Acceptance test mode deselected

Setpoint input for the drive: The speed setpoint is entered by the function SBT.

External setpoint input (open-loop control): The "normal" speed setpoint is effective.

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System features

12.1

Latest information

Important note for maintaining the operational safety of your system:

Note

Requirements for operational safety

Systems with safety-related characteristics are subject to special operational safety

requirements on the part of the operating company. The supplier is also obliged to comply with

special product monitoring measures. For this reason, we publish a special newsletter

containing information on product developments and features that are (or could be) relevant

when operating safety-related systems.

• You should subscribe to the corresponding newsletter in order to obtain the latest

information and to allow you to modify your equipment accordingly.

Subscribing to the Safety Integrated Newsletter

1. Go to the following Internet address in your browser:

Safety Integrated Newsletter (https://new.siemens.com/global/de/produkte/

automatisierung/themenfelder/safety-integrated/fertigungsautomatisierung/

newsletter.html)

2. Select the desired language for the Web page.

3. Enter your address data on the Newsletter page.

4. Select your areas of interest in the Safety Integrated domain.

5. Activate the consent.

6. Click on "Send".

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System features

12.2 Response times

12.2

Response times

The Basic Functions are executed in the monitoring cycle (p9780). PROFIsafe telegrams are

evaluated in the PROFIsafe scan cycle, which corresponds to twice the monitoring clock cycle

(PROFIsafe scan cycle = 2 · r9780).

Note for understanding the tables

The drive system is the component that provides the safety functions. The designation "fault-

free drive system" means that the component that provides the safety functions does not have

a defect itself:

• Worst case for a fault-free drive system

For faults outside the drive system, such as e.g. faulty setpoint input from a control system,

limit value violations as a result of the behavior of the motor, closed-loop control, load, etc.,

the "Worst case for a fault-free drive system" response time is guaranteed.

• Worst case when a fault exists

For a single fault within the drive system, such as a defect in a switch-off signal path of the

power unit, a defect in an encoder actual value measurement, a defect in a microprocessor

(Control Unit or Motor Module) etc., the "Worst case when a fault exists" response time is

guaranteed.

12.2.1

Controlling Basic Functions via terminals on the Control Unit and Motor

Module

The following table lists the response times from the control via terminals until the response

actually occurs.

Table 12-1

Response times for control via terminals on the Control Unit and the Motor Module.

Function

Worst case for

Drive system has no fault

A fault is present

STO

2 · r9780 + t_E¹⁾

3 · r9780 + t_E¹⁾

SBC

4 · r9780 + t_E¹⁾

8 · r9780 + t_E¹⁾

SS1/SS1E (time-controlled)

Selection until STO is initiated

2 · r9780 + p9652 + t_E¹⁾

3 · r9780 + p9652 + t_E¹⁾

SS1/SS1E (time-controlled)

Selection until SBC is initiated

4 · r9780 + p9652 + t_E¹⁾

8 · r9780 + p9652 + t_E¹⁾

SS1 (time-controlled)

Selection until braking is initiated

3 · r9780 + 2 ms + t_E¹⁾

4 · r9780 + 2 ms + t_E¹⁾

The following applies for t_E (debounce time of the digital input being used):

p9651 = 0

t_E = 2 · p0799 (default = 4 ms)

p9651 ≠ 0

t_E = p9651 + p0799 + 1 ms

The minimum time for t_E is t_E_min = 2 ms.

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System features

12.2 Response times

12.2.2

Controlling the Basic Functions via PROFIsafe

The following table lists the response times¹⁾ from receiving the PROFIsafe Telegram in the drive

up to initiating the particular response.

Table 12-2

Response times when controlling via PROFIsafe

Function

Worst case for

Drive system has no fault

A fault is present

STO

5 · r9780 + t_E²⁾

SBC

6 · r9780 + t_E²⁾

10 · r9780 + t_E²⁾

SS1/SS1E (time-controlled)

Selection until STO is initiated

5 · r9780 + p9652 + t_K²⁾

SS1/SS1E (time-controlled)

Selection until SBC is initiated

6 · r9780 + p9652 + t_K²⁾

10 · r9780 + p9652 + t_K²⁾

SS1 (time-controlled)

Selection until braking is initiated

5 · r9780 + 2 ms + t_K²⁾

The specified response times involve internal SINAMICS response times. Program run times in the F-host and the transmission

time via PROFIBUS or PROFINET are not taken into account. When calculating the response times between the F-CPU and the

converter, you must take into account that faults in the communication can result in a safety function only being selected after

the PROFIsafe monitoring time (F_WD_Time) has expired. The PROFIsafe monitoring time (F_WD_Time) must also be

included in the calculation when an error occurs.

t_K is the time for internal communication within the SINAMICS module; t_K can be determined as follows:

t_K = To (for To, see parameter r2064[4])

12.2.3

Controlling the Extended Functions via PROFIsafe

The following table lists the response times^{1) 2)} from receiving the PROFIsafe Telegram in the

drive up to initiating the particular response.

Table 12-3

Response times when controlling via PROFIsafe

Function

Worst case for

Drive system has no fault

A fault is present

STO

5 · p9500⁸⁾ + r9780 + t_K⁶⁾

5 · p9500⁸⁾ + 2 · r9780 + t_K⁶⁾

SBC

5 · p9500⁸⁾ + 2 · r9780 + t_K⁶⁾

5 · p9500⁸⁾ + 6 · r9780 + t_K⁶⁾

SS1 (time controlled), SS1E, SS2E: Time from selecting

up to starting the safe timer

SS1 (acceleration controlled), SS2: Time from selecting

up to initiating braking

5 · p9500⁸⁾ + 2 ms + t_K⁶⁾

SOS: Time from selecting up to starting standstill mon-

itoring

SBR or SAM (limit value violation until STO active)

2 · p9500 + r9780

2.5 · p9500 + r9780 + t_ACT⁵⁾

SOS standstill tolerance window violated

1.5 · p9500 + 2 ms

3 · p9500 + 2 ms + t_ACT⁵⁾

SLS speed limit violated ³⁾

2 · p9500 + 2 ms

3.5 · p9500 + 2 ms + t_ACT⁵⁾

SSM⁴⁾

4 · p9500

4.5 · p9500 + t_ACT⁵⁾

SDI (limit value violation until braking is initiated)

1.5 · p9500 + 2 ms

3 · p9500 + 2 ms + t_ACT⁵⁾

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System features

12.2 Response times

Function

Worst case for

Drive system has no fault

A fault is present

SLA ⁹⁾: Selection or deselection

5 · p9500⁸⁾ + t_K

3 · p9500 + 2 ms

4 · p9500 + 2 ms + t_act

SLA: Limit value violation

SLP (limit value violation until a response is initiated)

1.5 · p9500 + 2 ms

3 · p9500+ 2 ms + t_ACT⁵⁾

SCA: Time between violation of a cam start or end po-

sition and output of the feedback message in

3.5 · p9500

4 · p9500 + t_ACT⁵⁾

S_ZSW_CAM1

SP⁷⁾ with isochronous PROFIsafe telegram

3 · p9500

3 · p9500 + t_ACT⁵⁾

The specified response times are valid for Extended Functions with and without selection.

The specified response times involve internal SINAMICS response times. Program run times in the F-host and the transmission

time via PROFIBUS or PROFINET are not taken into account. When calculating the response times between the F-CPU and the

converter, you must take into account that faults in the communication can result in a safety function only being selected after

the PROFIsafe monitoring time (F_WD_Time) has expired. The PROFIsafe monitoring time (F_WD_Time) must also be

included in the calculation when an error occurs.

SLS: Specification of the response time required to initiate a braking response in the drive - or for the output of the "SOS

selected" message to the motion control system.

SSM: The data corresponds to the times between the limit value being undershot up to sending the information via PROFIsafe.

t_ACT:

For p9511 ≠ 0

t_ACT = p9511

For p9511 = 0

t_ACT = PROFIBUS cycle

t_K is the time for internal communication within the SINAMICS module; t_K can be determined as follows:

t_K = To (for To, see parameter r2064[4])

SP: The data corresponds to the times between acquisition of the safe position and transfer of the safe position via PROFIsafe.

For the best possible execution (relating to time) on the F-CPU this component is reduced from 5 · p9500 to 3 · p9500.

In SINUMERIK Operate, the settings for SLA can only be made via the parameter list.

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13.2 Comparison of the safety functions

13.2

Comparison of the safety functions

13.2.1

Overview

In some instances, the "SINUMERIK Safety Integrated" safety functions use their own function

names. The designations of "SINUMERIK Safety Integrated plus" safety functions correspond to

SINAMICS Safety Functions, and are therefore based on DIN EN 60204-1.

These names are compared in this chapter.

For "SINUMERIK Safety Integrated plus", the safety functions (STO, SBC, SS1) available with

"SINUMERIK Safety Integrated" and integrated in the drive, belong to the Basic Functions, and are

available under the same function names. These are not listed here.

Table 13-1

Comparison of the "SINUMERIK Safety Integrated" safety functions and the "SINUMERIK Safety Integrated plus"

Extended Functions.

SINUMERIK Safety Integrated

SINUMERIK Safety Integrated plus

More information

External STOP A

Stop A/SH

Safe Torque Off

STO

(Safe Torque Off)

Safe Stop 1

SS1

(Safe stop in accordance with

stop Category 1)

Ext. STOP C

STOP C

Safe Stop 2

SS2

(Safe stop in accordance with

stop Category 2)

Ext. STOP D

STOP D

Safe Stop 2 with external stop

SS2E

(Safe Stop 2 with external stop)

Ext. STOP E

STOP E

Safe Stop 2 Extended Stop and

SS2ES

Retract

(Safe Stop 2 Extended Stop and

Retract)

Safe Operating Stop

SBH

Safe Operating Stop

SOS

(Safe Operating Stop)

Safely-Limited Speed

SLS

(Safely-Limited Speed)

SG override

Override

SLS Override

Enters the correction factor in the

for SG

safety program via PROFIsafe

(32 SG levels can be selected via

(Page 382)

SPL)

Safe Acceleration Monitoring

SBR

Safe Acceleration Monitor

SAM

(Safe Acceleration Monitoring)

Safe Brake Ramp

SBR

(Safe brake ramp monitoring)

Safety-related output signal

n<nx

Safe Speed Monitor

SSM

n<nx

(Safe Speed Monitor)

Safe Direction

SDI

(Safe motion direction)

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13.2 Comparison of the safety functions

SINUMERIK Safety Integrated

SINUMERIK Safety Integrated plus

More information

Safe Limit Positions

Safely-Limited Position

SLP

(Safely-Limited Position)

Safe Brake Test

SBT

(SI_BrakeTest [FB11])

Safe Brake Test

SBT

Safe Brake Test

SBT

(SIC/SCC)

(Safe Brake Test)

Safe Cams/cam track

Safe Position

Safe Cams (Page 383)

(Safe position)

Safe Cam

SCA

(Safe Cams)

Internal SOS deselection

Dyn. Stop D

Additional operations for the

See also: General information about

displaying and evaluating diagnos-

tic information (Page 317)

13.3.2

Commissioning the F-I/O

SINUMERIK Safety Integrated

Initially, you configure and parameterize the F-I/O in STEP 7. You then load the configuration to

the NCU, and also enter some settings in the machine data:

• F-source addresses (PROFIsafe addresses of the F-master)

• F-destination addresses (PROFIsafe addresses of the F-DI-/F-DO modules)

• Allocate symbolic names for F-modules (optional)

• Distribution of the computational load on the NC side

• Select F-user data signals to be transferred in the SPL (F-user data filter)

• Assign F-user data signals to be transferred to the SPL-SGE/SGA

SINUMERIK Safety Integrated plus

You configure and parameterize the F-I/O completely in STEP 7 (TIA Portal).

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13.3 Additional differences when commissioning

13.3.3

Parameterizing the safety functions

SINUMERIK Safety Integrated

SINUMERIK Operate has function-specific (generally tabular) screen forms to enter some general

safety-related settings - as well as for the safety functions SBR, SBH/SG, SBC, safety-related end

positions and safety-related cams.

Figure 13-4

Parameterizing a safety function (SBH/SG)

Additional settings and safety functions should be configured in SINUMERIK Operate using

machine data and drive parameters that can be filtered.

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Switching over from SINUMERIK Safety Integrated

13.3 Additional differences when commissioning

Figure 13-6

Parameterizing a safety function (SBR)

The "Recommended values" softkey is available as supplementary function; this allows

recommended values to be automatically calculated and entered. The basis for the calculated

recommended values is the corresponding equations to be taken into account for manual

parameterization.

Alternatively, all safety-related settings can be made in tabular expert lists ("Parameter list"

softkey), in which all parameters are listed which involve the corresponding safety function

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Switching over from SINUMERIK Safety Integrated

13.3 Additional differences when commissioning

13.3.4

Fault response and acknowledgment for F-I/O faults

SINUMERIK Safety Integrated

In the context of "SINUMERIK Safety Integrated", F-I/O faults are identified by evaluating the

PROFIsafe status of F-I/O devices. A system response is initiated if such a fault occurs:

Error detected by

System response

Drive/NC-CDC

STOP F

SPL-CDC

STOP D/E

(Redundant configuration of the stop response to be initiated in the machine

data and in data block SPL [DB18].)

Communication CDC

The SGE/SGA involved are brought into a failsafe state (substitute values are

provided). Substitute values can be specified.

Additional system-specific responses can be configured by reading out

DB18.DBX119.5.

Generally, the system response can involve passivation of all of the F-I/O modules - or only those

of the channel involved. The cause of the fault must be removed and acknowledged in order to

remove the fault and to reset the system response.

SINUMERIK Safety Integrated plus

"SINUMERIK Safety Integrated plus" responds to F-I/O faults by providing substitute values, i.e.

passivation is realized.

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13.3 Additional differences when commissioning

The following options exist to adapt and supplement the response:

• Passivate all of the F-I/O modules - or only those of the channel involved.

• Reintegration (depassivation) of the F-I/O automatically, depending on the configuration,

with a user acknowledgment.

• In addition, each F-I/O has its own F-I/O DB. This means that you can access status

information and program user-specific system responses.

Figure 13-7

Example of an F-I/O DB

Additional information

• Implementing user acknowledgment for global reintegration (Page 228)

• System alarms and diagnostic screens for F-PLC and F-I/O. (Page 302)

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13.3 Additional differences when commissioning

13.3.5

Accessing status/control information

As the safety functions of the two safety operating modes are implemented using different

subcomponents, there are some fundamental differences regarding the control options:

Access from → to

SINUMERIK Safety Integrated

plus

PLC program → F-I/O

SPL [DB18]

Process image

PLC program → drive

PLC program → safety function

Axis-specific signals for the sys-

Process data in telegrams (PROFI-

tem-integrated safety functions

safe, SIC/SCC)

PLC program → safety-related set-

in <axis DB>.DB22 … <axis

ting

DB>.DB125.

Axis-specific signals for drive-integrated safety functions in <axis

DB>.DB140 … <axis DB>.DB187 (mapped from SIC).

Control via terminals for drive-integrated safety functions (Basic

Functions)

∼ 20 NC variables

5 NC variables (mapped from SIC)

NC part program → safety func-

∼ 50 system variables

2 system variables (mapped from

tion

SIC)

NC part program → safety-rela-

ted setting

SINUMERIK Safety Integrated

For Safety Integrated, the basic PLC program automatically connects the I/O (F-user data) of an

F-module to the SPL interface in data block SPL [DB18]. It is not possible to connect them in a PLC

user program.

The safety functions are accessed on an axis-for-axis basis.

SINUMERIK Safety Integrated plus

For Safety Integrated plus, F-I/O and safety-related drive telegrams are accessed via the process

image, as is the case for the standard I/O. The PLC user program can access this status/control

information, therefore allowing functional expansions to be made.

Safety functions are accessed on an axis-for-axis basis.

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13.4 Procedure when switching over between systems

13.4

Procedure when switching over between systems

The transition from "SINUMERIK Safety Integrated" to "SINUMERIK Safety Integrated plus" cannot

be carried out within the scope of an automatic migration of the existing safety functions.

• The safety-related program code used in the two safety modes differs significantly. This

relates to the programming language and operations - as well as the positions and/or blocks

from where the safety program can be called.

• Instead of the safety functions of "SINUMERIK Safety Integrated" integrated in the system, for

"SINUMERIK Safety Integrated plus", the drive-based safety functions of SINAMICS Safety

Integrated are used; although they are functionally comparable, they use different

parameters and values however.

However, the existing risk analysis and the safety concept can be used to create a new safety

program on this basis - and to configure the drive-integrated safety functions.

Fundamental approach when switching over

The procedure can be roughly split-up into the following steps:

1. Migrating a STEP 7 V5.x project to the TIA Portal

"SINUMERIK Safety Integrated plus" is supported from SINUMERIK STEP 7 toolbox V14 (TIA

Portal) and higher.

Information about migrating the standard components of a STEP 7 5.x project into the

TIA Portal is provided in the TIA Portal online help, search terms "Migrating SINUMERIK PLC

projects" and "Migrating PLC project".

2. Deleting components of the Safety Integrated (SPL) program from the TIA Portal project:

- Remove the access operations to SPL function blocks or functions - and to SPL data blocks

signals from your PLC user program.

(you can use the following commands to find these locations: "Cross-references" in the

shortcut menu of an SPL block, "Browse project" in the shortcut menu of the program

block folder)

- Delete the Safety Integrated (SPL) blocks used in the project:

SI_relay [FB10]

SI_BrakeTest [FB11]

SPL [DB18]

Additional blocks (e.g. test stop blocks "SI Pulse Teststop SL [FC264]", "SI External Stop SL

[FC265]")

3. Adapting the configuration (Page 214)

4. Setting the safety program (Page 223)

5. Commissioning safety functions integrated in the drive

- Comparison of the functions (Page 380)

- Configuring NC and drive-specific safety settings (Page 237)

- Safety functions integrated in the drive (Page 79)

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Table of contents

Preface

Fundamental safety instructions

1.1

General safety instructions

1.2

Warranty and liability for application examples

1.3

Security information

Introduction

2.1

Purpose and requirements

2.2

Preconditions for the acceptance test

2.3

Documentation, data archiving and authorized persons

Acceptance test wizard

3.1

Introduction

3.2

SINUMERIK 828D/840D sl/ONE/MC - drive-based safety functions

3.2.1

Criteria for conducting an acceptance test

3.2.2

Acceptance test Wizard

3.2.3

Test types

3.2.3.1

Overview

3.2.3.2

Test type not required

3.2.3.3

Switch-off signal path

3.2.3.4

Function relations

3.2.4

Application example

3.2.4.1

Configuring and performing an acceptance test

3.2.4.2

Generating and saving an acceptance report/certificate

3.2.5

Acceptance test mode

3.2.6

Safety summary (TIA Portal)

3.2.6.1

Comparing Safety Programs

3.2.7

Manufacturer-specific configurations (slatw.ini)

3.3

SINUMERIK 840D sl - system-integrated Safety Functions

3.3.1

Criteria for conducting an acceptance test

3.3.2

Acceptance test Wizard

3.3.3

Test types

3.3.3.1

Overview

3.3.3.2

Test type not required

3.3.3.3

Switch-off signal path

3.3.3.4

Function relations

3.3.4

Application example

3.3.4.1

Configuring and performing an acceptance test

3.3.4.2

Generating and saving an acceptance report/certificate

3.3.5

Acceptance test mode

3.3.6

Manufacturer-specific configurations (slatw.ini)

SINUMERIK Operate acceptance test

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Table of contents

Managing templates and results

4.1

Customizing templates

4.1.1

Template editor

4.1.2

Customizing templates

4.1.3

Customizing template (SinuComNC)

4.2

Result file

4.3

Certificate template

4.4

Certificate

Template editor

5.1

Introduction

5.2

Working with the template editor

5.3

Example of SOS - Safe Operating Stop

Actions for hardware replacement and modifications

6.1

Necessity of a new acceptance test

6.2

Effect of the acceptance test for specific measures

6.2.1

Effects with SINUMERIK 828D Safety Integrated

6.2.2

Effects with SINUMERIK 840D sl Safety Integrated plus

6.2.3

Effects for SINUMERIK ONE Safety Integrated

6.2.4

Effects for SINUMERIK MC Safety Integrated

6.2.5

Effects with SINUMERIK 840D sl Safety Integrated (system-integrated)

101

Tips and tricks

105

Appendix

109

A.1

Example contents of the acceptance test

109

A.1.1

Overview

109

A.1.2

SINUMERIK 828D/840D sl/ONE/MC - drive-based safety functions

109

A.1.2.1

SINUMERIK 828D with Safety Integrated

109

A.1.2.2

SINUMERIK 840D sl with Safety Integrated plus

111

A.1.2.3

SINUMERIK ONE with Safety Integrated

113

A.1.2.4

SINUMERIK MC with Safety Integrated

115

A.1.3

SINUMERIK 840D sl - system-integrated safety functions

117

A.1.3.1

SINUMERIK 840D sl with Safety Integrated (system-integrated)

117

A.2

Documentation overview

119

A.3

Abbreviations

120

Index

125

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Fundamental safety instructions

1.1

General safety instructions

WARNING

Danger to life if the safety instructions and residual risks are not observed

If the safety instructions and residual risks in the associated hardware documentation are not

observed, accidents involving severe injuries or death can occur.

• Observe the safety instructions given in the hardware documentation.

• Consider the residual risks for the risk evaluation.

WARNING

Malfunctions of the machine as a result of incorrect or changed parameter settings

As a result of incorrect or changed parameterization, machines can malfunction, which in turn

can lead to injuries or death.

• Protect the parameterization against unauthorized access.

• Handle possible malfunctions by taking suitable measures, e.g. emergency stop or

emergency off.

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Fundamental safety instructions

1.2 Warranty and liability for application examples

1.2

Warranty and liability for application examples

Application examples are not binding and do not claim to be complete regarding configuration,

equipment or any eventuality which may arise. Application examples do not represent specific

customer solutions, but are only intended to provide support for typical tasks.

As the user you yourself are responsible for ensuring that the products described are operated

correctly. Application examples do not relieve you of your responsibility for safe handling when

using, installing, operating and maintaining the equipment.

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Fundamental safety instructions

1.3 Security information

1.3

Security information

Siemens provides products and solutions with industrial security functions that support the

secure operation of plants, systems, machines and networks.

In order to protect plants, systems, machines and networks against cyber threats, it is necessary

to implement - and continuously maintain - a holistic, state-of-the-art industrial security

concept. Siemens’ products and solutions constitute one element of such a concept.

Customers are responsible for preventing unauthorized access to their plants, systems,

machines and networks. Such systems, machines and components should only be connected to

an enterprise network or the internet if and to the extent such a connection is necessary and only

when appropriate security measures (e.g. firewalls and/or network segmentation) are in place.

For additional information on industrial security measures that may be implemented, please

visit

https://www.siemens.com/industrialsecurity https://www.siemens.com/industrialsecurity ).

Siemens’ products and solutions undergo continuous development to make them more secure.

Siemens strongly recommends that product updates are applied as soon as they are available

and that the latest product versions are used. Use of product versions that are no longer

supported, and failure to apply the latest updates may increase customer’s exposure to cyber

threats.

To stay informed about product updates, subscribe to the Siemens Industrial Security RSS Feed

under

https://www.siemens.com/industrialsecurity https://new.siemens.com/global/en/products/

services/cert.html#Subscriptions).

Further information is provided on the Internet:

Industrial Security Configuration Manual (https://support.industry.siemens.com/cs/ww/en/

view/108862708)

WARNING

Unsafe operating states resulting from software manipulation

Software manipulations, e.g. viruses, Trojans, or worms, can cause unsafe operating states in

your system that may lead to death, serious injury, and property damage.

• Keep the software up to date.

• Incorporate the automation and drive components into a holistic, state-of-the-art industrial

security concept for the installation or machine.

• Make sure that you include all installed products into the holistic industrial security concept.

• Protect files stored on exchangeable storage media from malicious software by with suitable

protection measures, e.g. virus scanners.

• On completion of commissioning, check all security-related settings.

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Introduction

2.1

Purpose and requirements

The goal of the acceptance test is to check the correct parameterization and mode of operation

of the safety functions and to detect potential configuration errors or to document the

correctness of the configuration.

During the acceptance test, the limit values entered for all of the activated safety functions must

be violated so that the proper execution of the function can be checked and verified.

WARNING

Unwanted motion due to incorrect parameter changes

Changes to accepted safety functions may lead to faults or to unwanted motion and thus to

serious injuries or death.

• Perform a new acceptance test as soon as changes have been made to any of the safety

functions.

• Also create an appropriate acceptance report.

See also: Measures for hardware replacement & modifications (Page 91)

Responsibility for the acceptance test

The machine manufacturer is responsible for carrying out and documenting an acceptance test.

Examples of complete acceptance tests are provided in the Appendix (Example contents of the

acceptance test (Page 109)).

Use of the results of the acceptance tests for any other purpose is not permitted!

The values (e.g. distance, time) measured and the system behavior (e.g. initiation of a specific

stop) determined during the acceptance test are used for a plausibility check of the configured

safety functions. The recorded measured values are typical and are not worst-case values. They

represent the behavior of the machine at the time of measurement. These measurements

cannot be used to derive real values (e.g. maximum paths for over-travel).

Requirements laid down in the EC Machinery Directive and DIN EN ISO 13849-1

The requirements laid down in the EC Machinery Directive and DIN EN ISO 13849-1 mean that

machine builders (OEMs) are responsible in carrying out the following measures:

• Performing an acceptance test to check the safety-relevant functions and machine parts

• Documenting the acceptance test using an acceptance report, which lists the test results

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Function Manual, 10/2020, 6FC5397-3HP40-0BA1

Introduction

2.2 Preconditions for the acceptance test

2.2

Preconditions for the acceptance test

Before you can perform an acceptance test, the following requirements must be met:

•

The commissioning and configuration have been completed.

Commissioning of the open-loop and closed-loop control must be completed, as e.g. the

over-travel distance may otherwise change as a result of a changed dynamic response of the

drive control.

Observe all of the warnings in the SIMATIC Safety Programming and Operating Manual

(https://support.industry.siemens.com/cs/ww/en/view/54110126 ).

Note

Configuring and programming

The configuration and programming must be carried out as described in the associated

documentation.

• SINUMERIK 828D Safety Integrated, SINUMERIK 840D sl Safety Integrated plus,

SINUMERIK ONE Safety Integrated, SINUMERIK MC (only with SINAMICS S120) Safety

Integrated:

The F-PLC (for SINUMERIK 840D sl, SINUMERIK ONE, SINUMERIK MC only) or fail-safe I/O

must be configured in the hardware and network editor of the TIA Portal. F-blocks must

be created with the program editor of the TIA Portal.

For the system acceptance test, you must use the safety summary that was created as per

the documentation.

• SINUMERIK 840D sl Safety Integrated (system-integrated):

The fail-safe I/O and creation of the F-blocks must be configured in STEP 7 or in TIA Portal.

There is no safety summary.

No other procedures are permitted.

Note

Commissioning via SINUMERIK Operate required

The commissioning and parameterization of all of the drive-integrated safety functions and

associated settings to be used must be done via SINUMERIK Operate. Each SI function must

be tested and the results documented and signed in the acceptance report by an authorized

person.

No other procedures are permitted.

Note

System of units of NC

The acceptance test with SINUMERIK Operate can only be performed with the metric system

of units. Set the machine data MD10240 for the metric system of units of the NC to 1 (metric).

•

The machine is properly wired

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Function Manual, 10/2020, 6FC5397-3HP40-0BA1

Introduction

2.2 Preconditions for the acceptance test

• All of the safety equipment (e.g. protective door monitoring devices, light barriers and

emergency limit switches or similar) are connected and ready for operation

• No one is lingering in the danger zone.

WARNING

Unexpected axis motion during the acceptance test

If a speed setpoint ≠ 0 is present, the active stop function SS2 is set, and the motor is at a

standstill (active SOS), the axis starts to move as soon as the acceptance test is activated. If

persons are in the danger zone, accidents causing death or severe injury can occur.

• Take suitable measures to ensure that nobody is in the danger zone during the

acceptance test.

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Introduction

2.3 Documentation, data archiving and authorized persons

2.3

Documentation, data archiving and authorized persons

Documentation

The results of the acceptance test as well as all hardware and software changes must be

documented in a suitable form (as an acceptance report).

Within the scope of the acceptance report, the alarm displays must be checked or the alarm logs

must be incorporated into the acceptance report.

The following changes are acquired using the "Safety logbook" function of SINAMICS S120 with

Safety Integrated. SINUMERIK Operate outputs the corresponding parameters in the acceptance

report.

• Functional changes are recorded in the checksum r9781[0]:

- Functional CRC of the motion monitoring functions (p9729[0..1]), axis-specific

- Functional cyclic redundancy checks of the basic safety functions integrated in the drive

(p9799, SI setpoint checksum SI parameters CU), axis-specific

- Functional CRC of the TM54F (p10005[0]), global (only relevant for SINUMERIK 828D)

- Enable drive-integrated functions (p9601), for each axis

• Hardware-dependent changes are recorded in the checksum r9781[1]:

- Hardware-dependent CRC of the motion monitoring functions (p9729[2]), for each axis

- Hardware-dependent CRC of the TM54F (p10005[1]), global (only relevant for

SINUMERIK 828D)

Archiving

In addition to the acceptance report, the following safety-related data must be archived:

• NC machine data (only for SINUMERIK 840D sl with Safety Integrated (integrated in the

system))

• Drive parameters

• Complete safety summary (for SINUMERIK 840D sl with Safety Integrated plus, for

SINUMERIK ONE with Safety Integrated, and for SINUMERIK MC with Safety Integrated)

Note: You create the safety summary in the TIA Portal.

• PLC project

The access right to SI parameters must be protected by a password. This procedure must be

documented in the acceptance report; the password itself must not appear there.

The acceptance report and all of the associated safety-related data must be kept in a safe place.

Authorized persons

Personnel from the machine manufacturer who, on account of their technical qualifications and

knowledge of the safety functions, are in a position to perform the acceptance test in the correct

manner, are authorized to carry out an acceptance.

The person that carries out the acceptance test must also sign the acceptance report.

SINUMERIK Operate acceptance test

Function Manual, 10/2020, 6FC5397-3HP40-0BA1

Acceptance test wizard

3.1

Introduction

Note

SINUMERIK MC with SINAMICS S120

SINUMERIK MC with SINAMICS S120 is configured with the SINUMERIK ONE Commissioning

Tool. The description of the acceptance test wizard applies analogously to the SINUMERIK ONE

Commissioning Tool.

This chapter describes the acceptance test wizard of SINUMERIK Operate. A distinction is made

here between the drive-based safety for SINUMERIK 828D, SINUMERIK 840D sl, SINUMERIK ONE,

and SINUMERIK MC and the system-integrated safety for SINUMERIK 840D sl.

The following table provides you an overview of the available test types, depending on the

respective SINUMERIK control systems.

Overview of the test types for drive-based safety

SINUMERIK control system

SINUMERIK

SINUMERIK ONE

SINUMERIK

840D sl

and

828D

SINUMERIK MC

Option package/Functions

Safety Integrated

plus

Basic functions

Safe Torque Off (STO)

Testing of the Safe Torque Off (STO) verifies the following

points for an axis/drive:

• Principle of operation of the hardware

• Wiring of the switch-off signal paths

• Assignment of the terminals for STO on the Control Unit

• STO grouping (if available)

• Parameterizing the STO function

In addition, the following points are verified if Safe Brake

Control (SBC) is configured for the axis/drive:

• Connecting the brake

• Principle of operation of the hardware

• Parameterizing the SBC function

• Forced checking procedure for the brake control

SINUMERIK Operate acceptance test

Function Manual, 10/2020, 6FC5397-3HP40-0BA1

Acceptance test wizard

3.1 Introduction

SINUMERIK control system

SINUMERIK

SINUMERIK ONE

SINUMERIK

840D sl

and

828D

SINUMERIK MC

Safe Stop 1 (SS1)

Testing of the SS1 - Safe Stop 1 (SS1) verifies the following

points for an axis/drive:

• Principle of operation of the hardware

• Wiring of the switch-off signal paths

• Assignment of the terminals for SS1 on the Control Unit

• SS1 grouping (if available)

• Parameterizing the SS1 function

In addition, the following points are verified if Safe Brake

Control (SBC) is configured for the axis/drive:

• Connecting the brake

• Principle of operation of the hardware

• Parameterizing the SBC function

• Forced checking procedure for the brake control

Extended Functions

Switch-off signal path

This test checks the switch-off signal paths for the drives with

Safety Integrated by way of a forced checking procedure

(forced dormant error detection).

Functional relationships

Functional relationships of the safety applications are

checked and documented with this test.

Position alignment

This test verifies the following points:

• Encoder evaluations of the SI monitoring channels corre-

spond with the positions of the higher-level control sys-

tem

• The motion direction of the machine (MCS) corresponds

to the motion direction of the monitoring channels (safe

actual positions)

SINUMERIK Operate acceptance test

Function Manual, 10/2020, 6FC5397-3HP40-0BA1

Acceptance test wizard

3.1 Introduction

SINUMERIK control system

SINUMERIK

SINUMERIK ONE

SINUMERIK

840D sl

and

828D

SINUMERIK MC

Safe Torque Off (STO)

Testing of the Safe Torque Off (STO) verifies the following

points for an axis/drive:

• Principle of operation of the hardware

• STO grouping (if available)

• Parameterizing the STO function

In addition, the following points are verified if Safe Brake

Control (SBC) is configured for the axis/drive:

• Connecting the brake

• Principle of operation of the hardware

• Parameterizing the SBC function

• Forced checking procedure for the brake control

Safe Stop 1 (SS1)

Testing of the SS1 - Safe Stop 1 (SS1) verifies the following

points for an axis/drive:

• Principle of operation of the hardware

• SS1 grouping (if available)

• Parameterizing the SS1 function

In addition, the following points are verified if Safe Brake

Control (SBC) is configured for the axis/drive:

• Connecting the brake

• Principle of operation of the hardware

• Parameterizing the SBC function

• Forced checking procedure for the brake control

Safe Stop 2 (SS2)

This test verifies the following points:

• Initiating Safe Stop 2 (SS2) is detected

• The associated axis/drive brakes

• Monitoring for Safe Operating Stop (SOS) for this axis/

drive is activated when the parameterized transition time

elapses

Safe Stop 2 External (SS2E)

Testing of the Safe Stop 2 External (SS2E) verifies the follow-

ing points for an axis/drive:

• Triggering of Safe Stop 2 External (SS2E) is detected

• The associated axis/drive brakes

• Monitoring for Safe Operating Stop (SOS) for this axis/

drive is activated, or a safe stop (STO) is initiated by the

application once the parameterized transition time has

elapsed

SINUMERIK Operate acceptance test

Function Manual, 10/2020, 6FC5397-3HP40-0BA1

Acceptance test wizard

3.1 Introduction

SINUMERIK control system

SINUMERIK

SINUMERIK ONE

SINUMERIK

840D sl

and

828D

SINUMERIK MC

Safe Stop 2 Extended Stop and Retract (SS2ESR)

Testing of the Safe Stop 2 Extended Stop and Retract

(SS2ESR) verifies the following points for an axis/drive:

• Triggering of Safe Stop 2 Extended Stop and Retract

(SS2ESR) is detected

• The associated axis/drive brakes

• Monitoring for Safe Operating Stop (SOS) for this axis/

drive is activated, or a safe stop (STO) is initiated by the

application once the parameterized transition time has

elapsed

Safe Operating Stop (SOS)

When the standstill tolerance for Safe Operating Stop (SOS)

is violated, the test verifies whether the following points oc-

cur:

• The drive is stopped

• Stop responses and alarms of both monitoring channels

are initiated

• Response times and over-travel comply with the require-

ments

Safely-Limited Speed (SLS)

This test checks whether an overshoot of the Safely Limited

Speed (SLS) is detected.

For SLS limit val-

If a configured SLS limit value is exceeded, the configured

ue 1, an override

stop responses and alarms should be triggered for both mon-

can additionally be

itoring channels. The response times and over-travel should

specified via the

comply with the requirements.

fail-safe PLC.

Safe Speed Monitor (SSM)

Testing the Safe Speed Monitor (SSM) verifies the following

points for an axis/drive:

• It is detected if the limit value of the Safe Speed Monitor

is exceeded

• A message is output

Safety Activation Test

This test checks and documents the functions of the safety

application. It checks how the active monitoring function of

the axis/drive relates to the relevant operating mode/sensor

technology.

All relevant signals must be described in an input and reac-

tion table. The required start and end signal states must be

specified when the signals are included in the table.

SINUMERIK Operate acceptance test

Function Manual, 10/2020, 6FC5397-3HP40-0BA1

Acceptance test wizard

3.1 Introduction

SINUMERIK control system

SINUMERIK

SINUMERIK ONE

SINUMERIK

840D sl

and

828D

SINUMERIK MC

Safely-Limited Position (SLP)

This test verifies the following points:

• It is detected if the upper or lower limit value of the Safely-

Limited Position (SLP) is exceeded

• The monitoring limit values for SLP correspond with the

required machine positions

• The configured stop responses and alarms of both moni-

toring channels are initiated when an SLP limit value is

violated (exceeded or fallen below)

Safe Brake Test (SBT)

The Safe Brake Test (SBT) diagnostic function verifies wheth-

er the brake is functioning correctly and that the required

holding torque is observed.

SCA Safe Cam

The SCA acceptance test must be performed separately for

each axis/drive. Plus and minus cams must be checked inde-

pendently of each other.

Safe Direction (SDI)

Testing the Safe Direction (SDI) verifies for an axis/drive

whether the following points occur when the configured SDI

tolerance is exceeded in the blocked direction:

• The drive is stopped

• Configured stop responses and alarms of both monitor-

ing channels are initiated

• Response times and over-travel comply with the require-

ments

Overview of the test types for system-integrated safety

SINUMERIK control system

SINUMERIK 840D sl

Option package/Functions

Safety Integrated (system-inte-

grated)

Switch-off signal path

This test checks the switch-off signal paths for the drives with Safety Integrated by way

of a forced checking procedure (forced dormant error detection).

Functional relationships

Functional relationships of the safety applications are checked and documented with

this test.

External stops

This test checks whether all applied external stops are tested separately in the drive and

NCK is tested by way of a forced checking procedure (forced dormant error detection).

SINUMERIK Operate acceptance test

Function Manual, 10/2020, 6FC5397-3HP40-0BA1

Acceptance test wizard

3.1 Introduction

SINUMERIK control system

SINUMERIK 840D sl

SPL inputs/outputs

This test checks whether the I/O actuated by the SPL inputs/outputs are tested by way of

a forced checking procedure, an error is detected and the alarms and reactions desig-

nated for an error are triggered.

Emergency Stop

This test checks the response of the EMERGENCY STOP function for axes if the EMER-

GENCY STOP response was implemented via the external stops of the safe programma-

ble logic (SPL).

Safe Brake Test (SBT)

The Safe Brake Test (SBT) function verifies whether the brake is functioning correctly and

that the required holding torque is observed.

Safe Operating Stop (SBH)

When the standstill tolerance is exceeded for the Safe Operating Stop (SBH), this test

verifies whether the following points occur:

• The drive is stopped

• Stop responses and alarms of both monitoring channels are initiated

• Response times and over-travel comply with the requirements

Safely reduced speed (SG)

This test verifies that the system detects when "Safely reduced speed" (SG) is exceeded.

Safe software limit switches (SE)

This test verifies the following points:

• It is detected if the upper or lower limit value of the safe software limit switch (SE) is

exceeded

• The monitoring limit values for SE correspond to the required machine positions

• The configured stop responses and alarms of both monitoring channels are initiated

when an SE limit value is violated (exceeded or fallen below)

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Acceptance test wizard

3.2 SINUMERIK 828D/840D sl/ONE/MC - drive-based safety functions

3.2

SINUMERIK 828D/840D sl/ONE/MC - drive-based safety functions

3.2.1

Criteria for conducting an acceptance test

The criteria for performing an acceptance test are obtained from the requirements laid down in

the specified directives and standards. The acceptance test is used to specifically check that all

safety, monitoring and stop functions - which are used in the NCK, PLC and drive - have been

correctly configured:

• Check the hardware configuration for completeness, correctness, and mode of operation

• Testing of safety program (not for 828D)

- Agreement of the elements of the system library used in the safety program with the TÜV

certificate

- Correct functioning of the safety functions

- Consistency of the online safety program

• Test the safety functions integrated in the drive

- Testing of the implemented test mechanisms (forced checking procedure measures)

- Provoking of the individual monitoring functions to respond by specifically violating

tolerance limits

• Test the communication

- Correctness of the communication configuration

- Correct functioning of the communication relationships

• Test other properties

- Software versions

- NC machine data

- Drive parameters

- ...

During the acceptance test, standard NC monitoring functions (e.g. standstill monitoring or

software limit switches) are in some instances deactivated. The function sequences can be

captured and listed using the servo trace function or using the D/A converter output.

For acceptance of the plant, all relevant user-specific standards must be complied with. This also

applies to systems that do not legally require acceptance.

Additional information

• Details related to possible test/check criteria are provided in Chapter Example contents of the

acceptance test (Page 109).

• PFH values of the individual SINAMICS S120 safety components can be found in the SIOS

entry 76254308 (https://support.industry.siemens.com/cs/document/76254308/ ).

SINUMERIK Operate acceptance test

Function Manual, 10/2020, 6FC5397-3HP40-0BA1

Acceptance test wizard

3.2 SINUMERIK 828D/840D sl/ONE/MC - drive-based safety functions

• PFH and PFD

avg

values from F-CPUs, fail-safe I/O and SIMATIC components can be found in the

SIOS entry 109481784 (https://support.industry.siemens.com/cs/document/109481784 ).

The values of SIMATIC CPU 317F-2 PN/DP apply for the integrated F-PLC 317F-3 PN/DP.

• Specific information regarding how you can identify and document the correctness of the

properties or components involved is provided in the SIMATIC Safety manual.

Programming and Operating Manual - SIMATIC Safety - Configuring and Programming

(https://support.industry.siemens.com/cs/ww/en/view/54110126 )

• When conducting the acceptance test, you must carefully observe the regulations in the

report associated with the certificate:

Annex 1 of the Report to the Certificate for SIMATIC Safety System (https://

support.industry.siemens.com/cs/ww/en/view/57141289)

3.2.2

Acceptance test Wizard

SINUMERIK Operate has an acceptance test wizard, which uses specific input screens to guide

the person authorized by the machine manufacturer through the acceptance test. After all of the

relevant data has been entered and the test cases are concluded, a log template is generated,

which must be completely filled in, checked, and signed. You can find examples of a complete

acceptance test in the annex Example contents of the acceptance test (Page 109).

The acceptance test integrated in SINUMERIK Operate, is used to support the user (test

engineer) for the following tasks as part of an acceptance test:

• Coordination and execution of SI function tests

• Generation of a certificate (Page 83) (acceptance report) to document the state of all SI-

relevant functions when the equipment is shipped.

Note

Automation

In compliance with the relevant directives, the result status of a test (successful/not successful)

must be determined by the user. As a consequence, the acceptance test cannot be completely

automated.

The acceptance test can be modified in the template editor of the acceptance test wizard. For

instance, you can define test cases and default settings for a certain machine type.

SINUMERIK Operate acceptance test

Function Manual, 10/2020, 6FC5397-3HP40-0BA1

Acceptance test wizard

3.2 SINUMERIK 828D/840D sl/ONE/MC - drive-based safety functions

Calling the acceptance test wizard

MENU SELECT > Commissioning > Safety > Acceptance test

Figure 3-1

SINUMERIK Operate - Acceptance test wizard (example)

Descriptions of the individual test cases and information to be entered in the acceptance test

wizard can be found directly in the respective input screens.

Working with the acceptance test wizard

With the acceptance test, tests can be carried out with safety functions integrated in the system

(SINUMERIK Safety Integrated) as well as for axes with safety functions integrated in the drives

(SINAMICS Basic and Extended Functions). The test results for both versions are included in the

certificate that is finally generated.

Available test types/setting ranges

In the left-hand section of the acceptance test basic screen, the test types (switch-off signal path,

function relationships, STO, SS1, SOS, etc.) of the SI functions, currently configured in the

system, are displayed in a selection list. Test instances can only be created for these - or tests

carried out for these.

Access rights

In order that the acceptance test can be started, for all of the components within the scope of

the SI functions to be tested (NC, drive) access rights that permit changes to be made to machine

data and parameters must be active.

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Acceptance test wizard

3.2 SINUMERIK 828D/840D sl/ONE/MC - drive-based safety functions

Special cases

Gantry axes

As part of an acceptance test, when compared to "standard" SI axes, gantry axes are not handled

in a special way, and are also not specifically designated in the acceptance test user interface.

The following supplementary conditions must be observed:

• Every SI axis of a gantry group is individually tested.

• If it is necessary for a following axis to be traversed for a test, then the leading axis must also

be traversed.

• If the acceptance test mode has to be active when testing an axis of a gantry group, then the

acceptance test mode is active for all SI axes of the gantry group.

Leading/following axes

In the acceptance test, leading/following axes are not handled in a special way that is different

from "standard" SI axes, and are also not specifically identified in the acceptance test user

interface.

The following supplementary conditions must be observed:

• Every SI axis of a leading/following axis group is individually tested.

• If a following axis has to be traversed for a test, the leading axis must also be traversed.

• If the acceptance test mode has to be active when an axis of a leading/following group is

tested, the acceptance test mode is active for all SI axes of the leading/following group.

3.2.3

Test types

3.2.3.1

Overview

The "Overview" setting area is automatically activated after the acceptance test function is

called. In this setting area, you can either manually enter the required overview values, or load

the content of a template ("Load template" softkey) to the setting area.

The following overview values can be entered:

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Acceptance test wizard

3.2 SINUMERIK 828D/840D sl/ONE/MC - drive-based safety functions

Figure 3-2

Test type/setting area overview

Series commissioning

If you set the check mark in the "Overview" setting area for "Series commissioning" under the

overview values, this has no effect in terms of function. This entry is for information purposes

only.

Test as a result of an SI change

If you set the checkmark in the setting area "Overview" for "Test as a result of an SI change" under

the overview values, then this has no effect from a functional perspective.

SINUMERIK Operate acceptance test

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Acceptance test wizard

3.2 SINUMERIK 828D/840D sl/ONE/MC - drive-based safety functions

Figure 3-3

Test as a result of an SI change - change values

Here, you document the changes:

• Description of the change

• Reason for the change

• Verification tests required

• Manufacturer-specific regulations taken into account

• Responsibility

3.2.3.2

Test type not required

An acceptance test can be carried out for every safety function used on the machine. Not all of

the Safety functions listed in the dialog are used on the machine. Therefore, in the acceptance

test wizard, you can set the acceptance test (test type) for individual Safety Functions to not

required.

A test can be predefined using a customizing template. You can also hide test types from the

customized template as required.

SINUMERIK Operate acceptance test

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Acceptance test wizard

3.2 SINUMERIK 828D/840D sl/ONE/MC - drive-based safety functions

3.2.3.3

Switch-off signal path

To test the switch-off signal paths, carefully follow the instructions in the detailed display.

Figure 3-5

Test type/setting range switch-off signal path

You can make the following settings here, for example:

• Enter conditions to initiate the test

• Select acquired alarms that should appear in the report

• Confirm a test result

3.2.3.4

Function relations

User-specific test cases for safety-related functions can be saved in test type "Function relations".

After the test case has started, the user executes the steps required at the system itself. He

observes the response/behavior, and documents the test result that has been monitored.

Example of a function to be tested

When the machining area door is opened, safety function "Safe Operating Stop" (SOS) must be

selected for all axes of mode group 1.

Trace

When creating a test instance, a user-defined trace can be activated, which documents the

signal characteristic of the signals that are relevant for the particular test case.

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Acceptance test wizard

3.2 SINUMERIK 828D/840D sl/ONE/MC - drive-based safety functions

The trace is parameterized using the standard SINUMERIK Operate function and saved as trace

template (XML file).

The trace template must be available in directory ...\safety\atw\trace so that the trace template

can be selected for a particular test case.

Table 3-1

File information

File name:

<name>.xml

Path:

...\user\sinumerik\hmi\data\safety\atw\trace

Note

Default path for the trace template: ...\user\sinumerik\hmi\data\trace

Axis-specific trace variables

The trace file is parameterized for a specific axis. Before you start recording, you can however

select another safety-related axis. The data associated with this axis are then marked in the trace.

Only the servo signals are replaced by signals of the selected axis.

If an axis is not selected for the test case, then the data of the axis parameterized in the trace

template are recorded.

Note

If you select a drive trace file together with an axis in order to test the functional

interrelationships, note the following peculiarity.

During the test, the axis-specific signals contained in the drive trace file are adapted to the axis

selected for the test. The trace sampling interval is also adapted to the safety monitoring cycle

of the axis selected for the test. With this automatic adaptation, the trace sampling interval can

be modified by a factor > 10.

If you have selected the "If memory full" option in the trace settings, the recording duration of

the trace is also modified by adaptation of the trace sampling interval.

3.2.4

Application example

3.2.4.1

Configuring and performing an acceptance test

The following example shows the typical procedure for configuring and performing an

acceptance test.

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Acceptance test wizard

3.2 SINUMERIK 828D/840D sl/ONE/MC - drive-based safety functions

Procedure:

1. Enter the information required for the machine in the "Overview" setting area.

Figure 3-6

Example - Safety acceptance test: Overview

2. Press the "First test" softkey.

The "Switch-off signal path" setting area/test type becomes active.

If you do not wish to use this test, in this setting area, activate option "This test type is not

required for this machine". Also in other setting areas you can deactivate the particular test

in the same way.

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Function Manual, 10/2020, 6FC5397-3HP40-0BA1

SINUMERIK 840D sl. Service - Safety Integrated. Manual (2020) - page 17