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

Acceptance test wizard

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

9. Make a selection in the bottom right of the default view to define whether the test (in this

case: SOS) was successful.

Figure 3-15

Example - Safety acceptance test: SOS, evaluate result

The test name is marked with a green checkmark if the test was evaluated to be positive.

In this case, you can either perform another test by pressing the softkey "Start new test" or

you can switch to the next test type using the softkey "Next test".

If the test was evaluated to be negative, then the test name is assigned a red cross and if

necessary, you can repeat the test.

Define which of the listed alarms should be subsequently documented in the acceptance

report.

Remove the check mark (left) for all alarms that should not be documented in the report.

10.Change the pre-assigned test names as required.

11.Press softkey "Start new test" if you wish to test another axis.

The setting area for an additional axis for this test type is shown in the detailed view.

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12.Press the "Next test" softkey if you wish to perform a test for the next test type. A list of the

necessary activities for this particular test type is shown in the detailed display.

13.Follow the instructions on the screen (generally these involve steps 3 to 13).

After all tests of the individual setting areas have been performed, at the end, the "Finish"

setting area is displayed. In this setting area, you can generate the acceptance report from

the acceptance test and save it (Page 41).

Figure 3-16

Example - Finish

Supplementary functions

• Full screen

Hides the list of the setting areas and displays the detail settings of the currently selected

setting area over the complete screen width.

• Load template (Page 75)

Loads a template (*.xml).

The template must be located in directory .../user/sinumerik/hmi/data/safety/atw/

templates.

• Export template (Page 75)

Exports the current acceptance test as template (in XML format). The template contains a list

of all of the implemented tests that must be carried out for the acceptance test. Further, all

of the texts of the complete acceptance test are included; e.g. details about the machine on

the overview page.

• Save results (Page 78)

Saves the result file (*.atw) to directory .../user/sinumerik/hmi/data/safety/atw/results.

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• Load results (Page 78)

Loads the saved results from a directory. This function is useful if the test is exited before

completion and you wish to continue at the position where you left off.

• Start new test

Starts an additional test in the currently displayed setting area.

• Repeat test

Repeats a selected test in the currently displayed setting area.

• Delete test

Deletes the currently marked test.

• Go to overview

Jumps from the current setting area into the "Overview" setting area.

• Finish

Skips the following setting area and jumps directly to the "Finish" setting area.

• View trace

Displays the trace that was recorded when carrying out the test.

• Advanced settings

Display of the suggested trace recording duration (default). If necessary, you can define the

recording duration (in seconds).

• End SI acceptance

Exits the acceptance test for the Safety Integrated functions.

See also

Tips and tricks (Page 105)

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Procedure

1. Press the "Generate certificate" softkey to generate a certificate from the acceptance report.

The standard file archive is displayed.

Figure 3-18

Example - Safety acceptance, save certificate

2. Select a directory or create a new one. Then press the "OK" softkey to confirm your selection.

You are prompted to assign a name for the future certificate.

3. Enter the certificate name here. Then press the "OK" softkey to confirm your entry.

The certificate is then saved in the selected archive folder as RTF file. As a result of the RTF

format, the certificate can be subsequently supplemented, e.g. to include a machine

diagram.

3.2.5

Acceptance test mode

SINAMICS Safety Integrated has a parameter-supported acceptance test mode for the following

safety functions: SS2, SOS, SDI, SLS, SLP.

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The SINAMICS acceptance test mode is integrated in the SINUMERIK Operate acceptance test

wizard, where you parameterize the time and activate the mode in the associated SINUMERIK

Operate input screens, rather than directly via parameters.

WARNING

Unexpected axis motion at speed setpoint ≠ 0

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.

The limit value violations required and intended for the acceptance test are possible while the

acceptance test mode remains active. For instance, the setpoint speed limits are no longer active

in the acceptance test mode. To ensure that this state is not inadvertently retained, the

acceptance test mode is automatically exited after the parameterized time (p9558).

Normally, SOS can be selected directly or via SS2. To be able to trigger violation of the SOS

standstill limits with the acceptance test mode active (also in the "SS2 active" state) the setpoint

is enabled again by the acceptance test mode after deceleration and transition to SOS to allow

the motor to move. When an SOS violation is acknowledged in the active acceptance test mode,

the actual position is adopted as the new standstill position so that an SOS violation is not

immediately identified again.

Effects of the acceptance test mode in the NC

The following status bits and/or values from the SIC/SCC, relevant for the acceptance test of the

monitoring and stop functions, are linked to the NCs:

• Safety Info Channel status word 3: S_ZSW3B

- Bit 15 ACCEPTANCE_TEST_SELECTED (acceptance test mode selected)

When traversing the axes via the JOG traversing keys, this SIC signal means that in the NC

the set velocity limits, for example MD 32020 $MA_JOG_VELO, as well as the actual

override value are ignored, and the G0 value (maximum axis velocity) is activated as

setpoint.

- Bit 14 ACCEPTANCE_SLP_ACTIVE (acceptance test SLP(SE) selected)

If the acceptance test SLP(SE) is selected, then the software limit switches active in the NC

are deactivated so that SLP limits can be passed over (component of this acceptance test).

In order that users can see the selection and/or the deactivated software limit switch, for

a positive edge of this SIC signal, alarm 27008 "Axis %1 SW limit switch deactivated" is

initiated for the appropriate axis. For a negative edge, the software limit switch is

reactivated and the corresponding alarm is cleared.

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3.2.6

Safety summary (TIA Portal)

You use the safety summary to document the safety-relevant properties of the components

configured in the TIA Portal.

Note

The safety summary is only relevant for SINUMERIK ONE, SINUMERIK MC, and SINUMERIK 840D

sl.

Requirement

Note

Error-free hardware and software compilation

Error-free HW and SW compilation is the prerequisite for the creation of the safety summary for

acceptance purposes. Only then is it assured that all consistency checks have been performed

and that the safety summary was created for a consistent project.

Procedure

To create a safety summary, proceed as follows:

1. In the project navigator, select the Safety Administration Editor of the F-CPU for which you

would like to create the safety summary, e.g. under "CNC_1 > PLC_1 > Safety Administration

Editor".

2. Right-click on the Safety Administration Editor and select the "Print" command.

3. Perform the following settings in the "Print" dialog:

Setting

Procedure

Printer

Select either a printer installed in Windows or a PDF application installed as a

Windows printer.

Document layout

Select one of the ISO formats, e.g. "DocuInfo_ISO_A4_Portrait"

Properties

Activate the "All" option in order to display the F-blocks and F-conformant PLC

data types in the printout. This is necessary to document the program code for

acceptance.

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4. Click "Print" to confirm the settings.

5. Check the safety summary for the following criteria after printing:

- Ensure that all pages have been printed out in their entirety.

Incomplete printouts (as a result of toner deficiency, for example) may not be used for

acceptance of a change.

- Compare the PROFIsafe addresses of the individual drive objects with the value of the

drive parameter p9610 in SINUMERIK Operate.

PROFIsafe addresses of SINAMICS Safety Integrated are listed in the safety summary in

column "F-target address".

Figure 3-19

PROFIsafe addresses of drive objects in the safety summary - example of a NCU 730.3 PN

with SINAMICS Safety Integrated standard configuration

- Compare the PROFIsafe addresses with the values of all other nodes and ensure

uniqueness.

WARNING

Incorrect assignment of the safety functions of an axis

An incorrect assignment of a (valid) F-address results in an incorrect assignment of the

safety functions to the corresponding axis. The system does not identify this incorrect

assignment (in the CPU and in the network). As a consequence, the safety functions can

act in a way that was not intended, which in turn can result in death and serious injury.

• Uniquely address the F-destination address of the fail-safe I/O of PROFIsafe address

type 1.

• Ensure that the F-destination address of the fail-safe I/O (the drive units in this case)

is unique for the entire failsafe I/O throughout the network and the CPU (system-

wide). When doing this, also take into account the fail-safe I/O of PROFIsafe address

type 2, e.g. modules of the ET 200SP type.

• Note also the corresponding documentation in the TIA Portal online help in the

section "SIMATIC Safety - Configuring and programming".

Additional information

• Additional information on the uniqueness of PROFIsafe addresses and the safety summary is

provided in the Programming and Operating Manual SIMATIC Safety - Configuring and

Programming (https://support.industry.siemens.com/cs/ww/en/view/54110126 ) or in the

section with the same name in the TIA Portal online help.

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3.2.6.1

Comparing Safety Programs

Comparing safety programs as in the standard

You can use the comparison editor in STEP 7 for offline-online or offline-offline comparison of

safety programs. This procedure conforms to the that for standard user programs. A comparison

of the content of F-blocks is also undertaken when comparing safety programs. This means that

an offline-offline comparison can also be made when accepting a change. You enable this

comparison by selecting the "Safety" comparison criterion and disabling all other comparison

criteria.

Result of the comparison for safety programs

Display of the comparison result corresponds with the display of STEP 7.

If you click the "Program blocks" folder on the left of the comparison editor, you can see the

collective F-signature of the safety program displayed under "Comparison result". You will also

receive information as to whether the safety program is consistent.

Figure 3-20

Comparison editor

If you click on an F-block, the relevant signatures and interface signatures are displayed to you

in addition to the standard information.

Note

If you interrupt the connection to the F-CPU during the online/offline comparison, the

comparison result will be incorrect.

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Filter options for the comparison

Filters in the Comparison editor allow you to restrict the comparison result to the following block

groups:

• Only compare F-blocks

• Only compare F-blocks relevant for the acceptance

• Only compare standard blocks

You also have the STEP 7 filter options "Show only objects with differences" and "Show identical

and different objects".

F-blocks in the "System blocks" folder are also relevant for the comparison of safety programs.

Comparison criteria

Make sure that under

only the "Safety" comparison criterion is activated.

Classification of displayed changes

Regardless of whether you carried out an offline/online or offline/offline-comparison, the

following changes could account for the indicated changes to the automatically generated F-

blocks:

• Change in the maximum cycle time of F-runtime group and warn cycle time of F-runtime

group

• Change in F-parameters of the F-CPU

• Changed Safety system version or change in the hardware configuration (S7-1200/1500:

This is displayed as a change of the "F_SystemInfo_DB" block).

• (S7-300/400) Change of the F-runtime group communication, e.g. changing the number of

a DB for F-runtime group communication

• Change of the main safety block, F-FB, F-FC, F-DB

• Change of hardware configuration for the fail-safe I/O addressed in the safety program

It may be possible that a block is indicated as having been changed, however, no changes are

indicated in the detailed comparison of the block content. This does not signify a problem in the

display, but rather that changes, e.g. to addresses in the variable table, affect this block. If in

doubt, test this block.

Printing out the result of the comparison

You can print-out the comparison result via "Project > Print" in the menu bar, or using the "Print"

icon in the toolbar. Select "Print objects/area" "All" and "Properties" "All".

Ensure after printing that all pages have been printed out in their entirety. Incomplete printouts

(as a result of toner deficiency, for example) may not be used for acceptance of a change.

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3.2.7

Manufacturer-specific configurations (slatw.ini)

General user-specific and test-specific settings can be made in file slatw.ini.

For SINUMERIK Operate, the file is located under the following directory:

• .../siemens/sinumerik/hmi/cfg

To activate user-specific settings, a file must be created under the same name in the user

directory:

• .../user/sinumerik/hmi/cfg

The subsequently described changes can be entered into this file.

NC/PLC interface signals (only SINUMERIK 840D sl)

The following NC/PLC interface signals can be defined in section [General]:

• Interface signal PLC → NC: "PLC commissioning completed"

Entry: PLCCommCompleteBit=<DBxy.DBXy.z>

Program code

[General]

PLCCommCompleteBit=DBxy.DBXy.z

• Interface signal NC → PLC: "Acceptance test was started"

Entry: WizardRunningPLCBit=<DBxy.DBXy.z>

Program code

[General]

WizardRunningPLCBit=DBxy.DBXy.z

Note

The interface signal is not reset in the following situations

• When the user interface software crashes, e.g. SINUMERIK Operate.

• When the operating system crashes, under which the user interface software is running,

e.g. SINUMERIK Operate.

• If the user interface, e.g. SINUMERIK Operate, is connected with several NCs - using the

1:N function - then the interface signal is only reset for the NC with which the user

interface is currently connected.

• The "WizardRunningPLCBit" is reset if the acceptance test is explicitly exited using softkey

"Exit acceptance test".

Test type-specific settings

In the section available for each test type (see Table below "Test-type-specific sections"), a user-

specific string can be specified, which when executing a test of this type, is displayed in the

acceptance test or is entered in the certificate and the customized template.

Entry: TestName=

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Parameter %<x>, e.g. %1 for the name of the axis selected for the test case, can be included in

the string. The possible parameters are specified in the relevant section.

When displaying the string in the acceptance test, the parameter is replaced by the actual value

at the instant that the test is being performed.

The string must be specified without quotation marks.

Example

The following data are entered in the test case:

• Name of the test case: "Open the door"

• The selected axis

• The number of the test case

Table 3-2

File: .../user/sinumerik/hmi/cfg/slatw.ini

Program code

[TESTFR]

TestName=open door, axis = %1, number = %4

Two test cases are performed in the acceptance test for test type "Function relations":

• Test case 1: Axis X1

• Test case 2: Axis Y1

The following are displayed or entered for the test cases at the user interface of the acceptance

test, in the certificate and in the customized template:

• Test case 1: Open door, axis = X1, number = 1

• Test case 2: Open door, axis = Y1, number = 2

Test type-specific sections

Section

Test type

[TESTPD]

Switch-off signal path

[TESTXS]

External stops

[TESTSPL]

SPL inputs/outputs

[TESTES]

Emergency Stop

[TESTFR]

Functional relationships

[TESTPOS]

Position alignment

[TESTSTO]

STO - Safe Torque Off

[TESTSS1]

SS1 - Safe Stop 1

[TESTSS2]

SS2 - Safe Stop 2

[TESTSS2E]

SS2E - Safe Stop 2 External

[TESTSS2ESR]

SS2ESR - Safe Stop 2 Extended Stop and Retract

[TESTSBH]

SBH - Safe Operating Stop

[TESTSOS]

SOS - Safe Operating Stop

[TESTSG]

SG - Safely Limited Speed

[TESTSLS]

SLS - Safe Limited Speed

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Section

Test type

[TESTSSM]

SSM - Safe Speed Monitoring

[TESTSE]

SE - safe software limit switches

[TESTSLS]

SLP - Safely Limited Position

[TESTSBH]

SBT (SINUMERIK) - Safe Brake Test

[TESTSBH]

SBT (SINAMICS) - Safe Brake Test

[TESTSDI]

SDI - Safe Direction

[TESTFLOGIC]

Safety Activation Test

[TESTSAFECAM]

SCA - Safe Cam

File information

File name:

slatw.ini

Siemens path (source):

.../siemens/sinumerik/hmi/cfg

User path (target):

.../user/sinumerik/hmi/cfg

Editor:

Any editor, saved in the ASCII format

Note

User-specific changes

For user-specific adaptation, use the "slatw.ini" file provided by SIEMENS. This is located in

directory .../siemens/sinumerik/hmi/cfg/. Create a copy and save this to directory .../user/

sinumerik/hmi/cfg/.

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3.3

SINUMERIK 840D sl - system-integrated Safety Functions

3.3.1

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:

• If necessary, the standard NC monitoring functions, such as zero speed monitoring, software

limit switches, etc. must be de-activated (monitoring limits must be made less sensitive)

before the acceptance test is carried out.

The function sequences can be captured and listed using the servo trace function or using the

D/A converter output.

• After the SPL has been commissioned the access authorization for the NCK-SPL (SAFE.SPF) via

the user interface must be reduced to the manufacturer or service level.

• Observe the information in Chapter "Procedure for initial commissioning" in the SINUMERIK

840D sl Safety Integrated Function Manual.

• For SINUMERIK 840D sl, to document a forced checking procedure that has been carried out,

it is sufficient to just log the forced checking procedure alarms of the NCK (27002); it is not

absolutely necessary to log the forced checking procedure alarms of the SINAMICS S120

(C01798).

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

software limit switches) are deactivated, if necessary. 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.

3.3.2

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.

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.

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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.

Calling the acceptance test wizard

MENU SELECT > Commissioning > Safety > Acceptance test

Figure 3-21

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). The test results for both versions are included in the certificate that is finally

generated.

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Available test types/setting ranges

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

STO, SBH, 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.

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.

Modulo rotary axes

Observe the following special issues when recording traces for modulo rotary axes.

Recording errors in the trace can occur when passing the modulo limit <= half of the trace

sampling time. The actual axis position displayed deviates from the real actual position.

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3.3.3

Test types

3.3.3.1

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:

Figure 3-22

Test type/setting area overview

Series commissioning

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

overview values, then this has no effect from a functional perspective. This entry is for

information purposes only.

Test as a result of an SI change

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

the overview values, this has no effect in terms of function.

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Figure 3-23

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

3.3.3.2

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.

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3.3.3.3

Switch-off signal path

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

Figure 3-25

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

3.3.3.4

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" (SBH) must be

selected for all axes of mode group 1 (BAG 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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A trace can be parameterized for the "Functional relations" test type. The XML file must be stored

in the directory ...\safety\atw\trace in order to be able to select the trace for this test case.

Table 3-3

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

If axis-specific variables are contained in the trace, a safety-related axis can be selected before

recording the trace data. The data associated with this axis are marked in the trace, even if a

different axis was parameterized in the trace file.

Only signals in the "/Nck/MachineAxis/..." and "/Nck/ServoData/..." areas are replaced by 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.

3.3.4

Application example

3.3.4.1

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

3.3 SINUMERIK 840D sl - system-integrated Safety Functions

8. Then evaluate the test result. Then check the list as to whether all of the expected alarms have

occurred, and whether the results in the trace recording are correct.

- To display the trace recording, press the "View trace" softkey.

The trace for this test is displayed in the input screen. You can change the display as

needed.

Figure 3-33

Example - Safety acceptance test: SBH, trace

Note

In the event of problems with the trace recording, you will find information on clearing the

problem under "Tips and tricks (Page 105)".

- The "Back" softkey will take you back to the default view of the input screen.

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Acceptance test wizard

3.3 SINUMERIK 840D sl - system-integrated Safety Functions

9. Make a selection in the bottom right of the default view to define whether the test (in this

case: SBH) was successful.

Figure 3-34

Example - Safety acceptance test: SBH, evaluate result

The test name is marked with a green checkmark if the test was evaluated to be positive. In

this case, you can either perform another test in the active setting area by pressing softkey

"Start new test" - or you can initiate the next test in the following setting area by pressing

softkey "Next test".

If the test was evaluated to be negative, then the test name is assigned a red cross and if

necessary, you can repeat the test.

Define which of the listed alarms should be subsequently documented in the acceptance

report.

Remove the check mark (left) for all alarms that should not be documented in the report.

10.Change the pre-assigned test names as required.

11.Press softkey "Start new test" if you wish to test another axis.

The setting area for an additional axis for this test type is now shown in the detailed display.

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Acceptance test wizard

3.3 SINUMERIK 840D sl - system-integrated Safety Functions

12.Press the "Next test" softkey if you wish to perform a test for the next test type. A list of the

necessary activities for this particular test type is shown in the detailed display.

13.Follow the instructions on the screen (generally these involve steps 3 to 13).

After all tests of the individual setting areas have been performed, at the end, the "Finish"

setting area is displayed. In this setting area, you can generate the acceptance report from

the acceptance test and save it (Page 69).

Figure 3-35

Example - Finish

Supplementary functions

• Full screen

Hides the list of the setting areas and displays the detail settings of the currently selected

setting area over the complete screen width.

• Load template (Page 75)

Loads a template (*.xml), which can also be externally created.

The template must be located in directory .../user/sinumerik/hmi/data/safety/atw/

templates.

• Export template (Page 75)

Exports the current acceptance test as template (in XML format). The template contains a list

of all of the implemented tests that must be carried out for the acceptance test. Further, all

of the texts of the complete acceptance test are included; e.g. details about the machine on

the overview page.

• Save results (Page 78)

Saves the result file (*.atw) to directory .../user/sinumerik/hmi/data/safety/atw/results.

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3.3 SINUMERIK 840D sl - system-integrated Safety Functions

• Load results (Page 78)

Loads the saved results from a directory. This function is useful if the test is exited before

completion and you wish to continue at the position where you left off.

• Start new test

Starts an additional test in the currently displayed setting area.

• Repeat test

Repeats a selected test in the currently displayed setting area.

• Delete test

Deletes the currently marked test.

• Go to overview

Jumps from the current setting area into the "Overview" setting area.

• Finish

Skips the following setting area and jumps directly to the "Finish" setting area.

• View trace

Displays the trace that was recorded when carrying out the test.

• End SI acceptance

Exits the acceptance test for the Safety Integrated functions.

3.3.4.2

Generating and saving an acceptance report/certificate

After completing all of the acceptance tests, in the "Finish" setting area, you can generate a

certificate for the acceptance report and save it.

Figure 3-36

Example - Safety acceptance, finish

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Acceptance test wizard

3.3 SINUMERIK 840D sl - system-integrated Safety Functions

A typical procedure for generating an acceptance report/certificate is shown based on the

following example.

Procedure

1. Press the "Generate certificate" softkey to generate a certificate from the acceptance report.

The standard file archive is displayed.

Figure 3-37

Example - Safety acceptance, save certificate

2. Select a directory or create a new one. Then press the "OK" softkey to confirm your selection.

You are prompted to assign a name for the future certificate.

3. Enter the certificate name here. Then press the "OK" softkey to confirm your entry.

The certificate is then saved in the selected archive folder as RTF file. As a result of the RTF

format, the certificate can be subsequently supplemented, e.g. to include a machine

diagram.

3.3.5

Acceptance test mode

For specific test types, the acceptance test mode is activated for the axis and/or the drive involved

while the test is being performed.

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Acceptance test wizard

3.3 SINUMERIK 840D sl - system-integrated Safety Functions

Activating the acceptance test mode has the following effects:

Acceptance test

Effects

Axis: Safely reduced speed (SG)

• Safety Integrated-specific power on

Axis: Safe Operating Stop (SBH)

alarms can be acknowledged using a chan-

nel reset.

Drive: Safely reduced speed (SG)

• The setpoint speed limit is deactivated.

Drive: Safe Operating Stop (SBH)

• It is run with $MA_MAX_AX_VELO.

Axis: Safe software limit switches (SE)

The software limit switches of the axis are de-

activated.

WARNING

Unexpected axis motion at speed setpoint ≠ 0

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.

Time limit

The acceptance test mode may only be active for a limited time - and only during a test. After the

parameterized time has elapsed, the acceptance test mode of NCK and drive is reset

automatically. Even if the test has not yet been completed. As a consequence, the test is

canceled.

If it crystallizes out that the default value is too short, then the time limit can be increased using

the following parameters:

• Safety Integrated

- MD36958 $MA_SAFE_ACCEPTANCE_TST_TIMEOUT (time limit for acceptance test

duration)

- p9558 SI Motion acceptance test mode time limit (Control Unit)

3.3.6

Manufacturer-specific configurations (slatw.ini)

General user-specific and test-specific settings can be made in file slatw.ini.

For SINUMERIK Operate, the file is located under the following directory:

• .../siemens/sinumerik/hmi/cfg

To activate user-specific settings, a file must be created under the same name in the user

directory:

• .../user/sinumerik/hmi/cfg

The subsequently described changes can be entered into this file.

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Acceptance test wizard

3.3 SINUMERIK 840D sl - system-integrated Safety Functions

NC/PLC interface signals (only SINUMERIK 840D sl)

The following NC/PLC interface signals can be defined in section [General]:

• Interface signal PLC → NC: "PLC commissioning completed"

Entry: PLCCommCompleteBit=<DBxy.DBXy.z>

Program code

[General]

PLCCommCompleteBit=DBxy.DBXy.z

• Interface signal NC → PLC: "Acceptance test was started"

Entry: WizardRunningPLCBit=<DBxy.DBXy.z>

Program code

[General]

WizardRunningPLCBit=DBxy.DBXy.z

Note

The interface signal is not reset in the following situations

• When the user interface software crashes, e.g. SINUMERIK Operate.

• When the operating system crashes, under which the user interface software is running,

e.g. SINUMERIK Operate.

• If the user interface, e.g. SINUMERIK Operate, is connected with several NCs - using the

1:N function - then the interface signal is only reset for the NC with which the user

interface is currently connected.

• The "WizardRunningPLCBit" is reset if the acceptance test is explicitly exited using softkey

"Exit acceptance test".

Test type-specific settings

In the section available for each test type (see Table below "Test-type-specific sections"), a user-

specific string can be specified, which when executing a test of this type, is displayed in the

acceptance test or is entered in the certificate and the customized template.

Entry: TestName=

Parameter %<x>, e.g. %1 for the name of the axis selected for the test case, can be included in

the string. The possible parameters are specified in the relevant section.

When displaying the string in the acceptance test, the parameter is replaced by the actual value

at the instant that the test is being performed.

The string must be specified without quotation marks.

Example

The following data are entered in the test case:

• Name of the test case: "Open the door"

• The selected axis

• The number of the test case

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3.3 SINUMERIK 840D sl - system-integrated Safety Functions

Table 3-4

File: .../user/sinumerik/hmi/cfg/slatw.ini

Program code

[TESTFR]

TestName=open door, axis = %1, number = %4

Two test cases are performed in the acceptance test for test type "Function relations":

• Test case 1: Axis X1

• Test case 2: Axis Y1

The following are displayed or entered for the test cases at the user interface of the acceptance

test, in the certificate and in the customized template:

• Test case 1: Open door, axis = X1, number = 1

• Test case 2: Open door, axis = Y1, number = 2

Test type-specific sections

Section

Test type

[TESTPD]

Switch-off signal path

[TESTXS]

External stops

[TESTSPL]

SPL inputs/outputs

[TESTES]

Emergency Stop

[TESTFR]

Functional relationships

[TESTPOS]

Position alignment

[TESTSTO]

STO - Safe Torque Off

[TESTSS1]

SS1 - Safe Stop 1

[TESTSS2]

SS2 - Safe Stop 2

[TESTSS2E]

SS2E - Safe Stop 2 External

[TESTSS2ESR]

SS2ESR - Safe Stop 2 Extended Stop and Retract

[TESTSBH]

SBH - Safe Operating Stop

[TESTSOS]

SOS - Safe Operating Stop

[TESTSG]

SG - Safely Limited Speed

[TESTSLS]

SLS - Safe Limited Speed

[TESTSSM]

SSM - Safe Speed Monitoring

[TESTSE]

SE - safe software limit switches

[TESTSLS]

SLP - Safely Limited Position

[TESTSBH]

SBT (SINUMERIK) - Safe Brake Test

[TESTSBH]

SBT (SINAMICS) - Safe Brake Test

[TESTSDI]

SDI - Safe Direction

[TESTFLOGIC]

Safety Activation Test

[TESTSAFECAM]

SCA - Safe Cam

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Managing templates and results

4.1 Customizing templates

4.1

Customizing templates

4.1.1

Template editor

With the template editor (Page 85) in SINUMERIK Operate, you can create or edit customizing

templates for an acceptance test.

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

You can continue to use templates created using the CT Editor (Customizing Template Editor).

4.1.2

Customizing templates

A customizing template is a user-specific XML file for an acceptance test, in which all of the

required test types and instances - together with the corresponding parameters, limit values,

alarms and handling instructions - are completely specified. As a consequence, using a

customizing template, an acceptance test can be precisely coordinated for a specific machine

and/or machine types.

From the tests specified in a customizing template, during an acceptance test, a deviation can

only be made to the extent that it is possible that individual tests are not performed. Additional

test types or instances cannot be added.

Specifications in a template

The following inputs can be defined in a customer-specific template:

• Test types

• Test instances

• Test parameters

• Limit values

• Problem alarms, i.e. alarms that must occur - or alarms that must not occur

• Filtered alarms, i.e. alarms that are neither displayed nor logged

• User-specific tasks to describe a test with instructions for the operator

Note

Changes

The content of a customer-specific template can only be changed using the template editor. A

change within the acceptance test is not possible.

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Managing templates and results

4.1 Customizing templates

Creating templates

Note

Only create a template from a complete test.

Proceed as follows, to create a customer-specific template from the currently configured test:

1. In the acceptance test, select the setting range "Overview" or "Finish".

2. Press the softkey >>.

3. Press the "Export template" softkey.

Then a file explorer appears with the default storage path "...\user\sinumerik\hmi\data\safety

\atw\templates".

4. Select a different target directory as needed.

5. Create a subdirectory for the template as needed.

6. Assign a name for the template. Confirm your entries with "OK".

Load templates

To load a customer-specific template into the acceptance test (including templates created using

SinuComNC), proceed as follows:

1. In the acceptance test, select the setting range "Overview".

2. Press the softkey >>.

3. Press the "Load template" softkey.

File information

File name:

<name>.xml

Path:

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

Editor:

Template editor (Page 76)

4.1.3

Customizing template (SinuComNC)

An existing customizing template, created using SinuComNC or the CT Editor, can be loaded into

the acceptance test and an acceptance test performed. It is not possible to edit the template.

File information

File name:

<name>.xml

Path:

Source:

Any

Destination:

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

Editor:

Template editor (Page 76)

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Managing templates and results

4.2 Result file

4.2

Result file

Function

The result file (* .atw) is an archive, and is used to backup tests that have been performed. The

result file consists of the following information:

• Session file

• Customer-specific template (if available)

• Trace files (if existing)

The archive can be loaded by SINUMERIK Operate independently of the control system (even

offline).

A certificate can be generated in the acceptance test from a result file at any time after the file

has been loaded.

Customizing templates

If the result file is obtained from a session file with customizing template, then the result file

contains all of the information of the customizing template. This especially includes the

specification of problem alarms and filtered alarms, as the customizing template is also saved in

the result file when it is saved. Without the customizing template, these alarms are not included

in the result file.

Unexpected alarms (it is not permissible that these occur) and missing alarms (must occur) are

summarized as problem alarms. Using a softkey, they can be displayed in the result screen form

instead of the acquired alarms. Initially, the unexpected alarms are displayed in the list of

problem alarms corresponding to the sequence in which they occurred. The missing alarms are

then displayed in the customizing template in the sequence they occurred. For missing alarms,

only the alarm number and the axis/drive designation are displayed.

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Managing templates and results

4.2 Result file

Tests

The tests performed by the acceptance test are classified according to test types and test

instances:

• Test types are responsible for testing different machine mechanisms. This can require various

steps for tests and different machine data/parameters. Examples of different test types

include: Safe operating stop (SBH) and safely reduced speed (SG). If a test type is selected in

the tree-type view, then its start screen form is displayed.

• Each test type can have no, one or several test instances depending on whether a test is to

be applied to a certain machine - and how many tests the user has created and/or has

performed. A test instance can refer to a specific axis and/or motion direction. A specific test

type is defined by specific test steps and the associated machine data/parameters. The same

test steps are executed for all test instances of a test type.

• A customizing template prepopulates the test instances, selected by the user, for the test

being executed. The customizing template already contains certain selections for the test to

be executed (e.g. axes and directions). It also contains other information for the test, e.g.

limits. This means that the customizing template already includes a lot of information that

can also be found in the session and result file (with the exception of data that has been

acquired).

Test instances are either created with the acceptance test using the associated softkeys - or a

customizing template. A customizing template populates the tree-type review with the

previously configured tests for a specific machine. A customizing template can be created using

the template editor integrated in SINUMERIK Operate (see Template editor (Page 85)).

No new test instances can be created if a customizing template was loaded. The start screen

form is displayed if you select a test type or a test defined by a customizing template that has still

not been run in the tree-type view. Before starting the test, press the "Start Test" softkey to access

the screen form for the test that is being performed.

After the test has been performed, the test instance selection is displayed in the overview of the

result screen form. To do this, beforehand the test type must be selected in the tree-type view,

which expands this view. Depending on the particular test type, the result screen form includes

access to alarms and/or traces for the selected test instance. For customizing templates, there is

a dedicated list for "Problem alarms" and "Collected alarms". Only "Collected alarms" is available

if there are no customizing templates. A customizing template can also specify alarms as

"Filtered alarms". These are ignored, which means they neither appear in the user interface nor

in the certificate.

Working offline

If the results of an acceptance test are to be reviewed at a later point in time, or used as basis to

generate a test certificate, then before exiting the acceptance test - or for an external computer,

before disconnecting the connection to the NCU or MCU - the test results must be saved to a

result file (see paragraph below "Saving results").

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Managing templates and results

4.2 Result file

Save results

In order to save the test results in a file, proceed as follows:

1. Press the softkey >>.

2. Press the "Save results" softkey.

Then a file explorer appears with the default storage path "...\user\sinumerik\hmi\data\atw

\results".

3. Select a different target directory as needed.

4. Create a subdirectory for the result file as needed.

5. Assign a name for the result file.

6. Confirm your entries with "OK".

The result file is saved in the selected target directory and is automatically provided with the

extension "atw".

Load results

To reload a result file, proceed as follows:

1. Press the softkey >>.

2. Press the "Load results" softkey.

Then a message appears. It points out that all of the results of the current session will be

automatically deleted when the result file is loaded.

3. If you really want to load the result file, press the "Yes" softkey.

The result file is loaded.

File information

File name:

<Name>.atw

Path:

.../user/sinumerik/hmi/data/safety/atw/results

Editor:

---

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Managing templates and results

4.3 Certificate template

4.3

Certificate template

A certificate template is a language-dependent file in the RTF format. In addition to general texts,

it includes text marks for all information that is required to document the details of the

acceptance test carried out for a specific system.

All of the information that was obtained as part of an acceptance test - and relevant for the

certificate - was saved to a session file. When generating the certificate, this information is

written from the session file into the text marks of the certificate template, thus creating the

certificate.

User-specific adaptations

Using a suitable editor, e.g. Microsoft Word, additional user-specific texts and graphics can be

imported into a certificate template - or standard texts and graphics modified or removed. Is

important that existing text marks are neither changed nor deleted. Otherwise, the

corresponding information will not be entered into the certificate.

The SIEMENS certificate template is located in directory ...\siemens\sinumerik\hmi\lng. Save the

user-specific certificate templates to directory ...\user\sinumerik\hmi\lng, ...\oem\sinumerik\hmi

\lng or ...\addon\sinumerik\hmi\lng.

Text marks

Normally, a text mark comprises invisible square brackets [ ... ] and the name of the text mark in

angle brackets <...>. As example, the text mark included in the certificate template is shown for

the manufacturer's name in the following.

Manufacturer¹⁾

[<MachineManufacturer>]²⁾

Standard, fixed text

Text mark

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Managing templates and results

4.3 Certificate template

When generating the certificate, the text mark is replaced by the content displayed in the

acceptance test menu "Overview" for "Machine manufacturer".

Note

Text marks (Microsoft Word 2010)

• Display text marks in body text

In order that the text marks are displayed in the body text, the "Display text marks" option

must be set:

Menu "File" > "Options" > "Extended" > Group "Display document content"> Option "Display

text marks"

• Display all text marks in the certificate template

Menu "Insert" > Group "Hyperlinks" > "Text mark"

• Update the table of contents

The table of contents is not automatically adapted to the configuration. Proceed as follows

to update the table of contents:

- Place the cursor in the table of contents.

- Open the shortcut menu using the right mouse button.

- Select "Update fields".

- In dialog "Update table of contents", select "Update entire table".

- Confirm with "OK".

File information

File name:

atcerttpl_<language code>.rtf ¹⁾

Path:

.../siemens/sinumerik/hmi/lng

Editor:

RTF-capable editor, e.g. Microsoft Word

See NC Programming Programming Manual, Chapter "Fundamentals" > "Tables" > "Current languages

in the HMI"

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Managing templates and results

4.4 Certificate

4.4

Certificate

The acceptance test provides, with the finally generated certificate (acceptance report), a

confirmation for the machine manufacturer or the acceptance test engineer about the state of

the SI functions of the system when supplied. Based on the SI checksums listed in the

certificate, it is ensured that any subsequent changes to SI-relevant system data can be tracked

and verified.

Generating

The certificate can be subsequently generated as part of the acceptance test after any arbitrary

test has been completed.

1. In the acceptance test, select the setting range "Finish".

2. Press the "Generate certificate" softkey.

See also Generating and saving an acceptance report/certificate (Page 41).

The certificate of the completed acceptance test is then created from the following data:

• Text and graphics of the certificate template (Page 81)

• Test-specific texts

• Graphics and data from the session file

• Static parameterization data of the controller

Languages

The language of the texts in the certificate depend on the following settings:

• Text from the certificate template

The language of the certificate template texts and/or the corresponding language-

dependent file, which is used to generate the certificate, depends on the language set in

SINUMERIK Operate at the time that the certificate is generated.

• Variable control texts

Variable texts generated by the control system during the test, for example, alarm and

message texts, are entered in the certificate in the language that was set in SINUMERIK

Operate at the time of the actual test.

• User-specific text

Text that the user enters in the input fields provided during the course of the acceptance test

are included in the certificate without any changes being made to them.

Update table of contents

If, in the certificate, not all of the sections of the certificate template are included, in the table of

contents, then "Text mark not reference" is displayed for each text mark that is not referenced.

This means that when opening the certificate for the first time, the table of contents must be

updated using a suitable editor.

Example: Microsoft Word:

1. Press the key combination <CTRL> + <A> (select entire content).

2. Then press the key <F9> (update table of contents).

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Template editor

5.2 Working with the template editor

Figure 5-2

Overview

Menu structure

Setting areas

Softkey

Description

• Information about the

Full screen

Switches over the setting area to full screen view.

template

Template >

New

Creates a new template.

• Overview

Open

Opens an existing template (*.xml).

• Safety functions

Save

Saves the template.

Menu >

Options

Here, you define the test scope for the template that you

wish to configure.

• Safety functions

Add test

Using this softkey, you add a new test for the selected

safety function.

Copy test

You create a copy of the selected test, e.g. for an addi-

tional axis.

Delete test

You delete the selected test using this softkey.

You scroll within the setting area of the test using this

softkey.

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Template editor

5.3 Example of SOS - Safe Operating Stop

5.3

Example of SOS - Safe Operating Stop

Setting area at the example "SOS - Safe Operating Stop"

In the following example you can see the setting areas for the "SOS-Safe Operating Stop" safety

function.

1. First, enter the test name. Optionally, you can enter additional information in field

"Description". For text-based adaptations, e.g. the test sequence, click in text field

"Sequence". When editing, the text color changes to "black".

Figure 5-3

Example of the setting area - SOS-Safe Operating Stop (1)

2. Select the axis and define the traversing direction.

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Actions for hardware replacement and

modifications

6.1

Necessity of a new acceptance test

A complete acceptance test is required for the first commissioning of the Safety Integrated

functionality on a machine.

If you carry out certain measures after the acceptance test, it may be necessary to carry out a

new (complete or partial) acceptance test.

These measures include the following for example:

• Safety-related functional expansions

• Transferring the commissioning data to additional series machines

• Hardware changes

• Software upgrades

• Changes within the scope of modular machine concepts

In order to define a partial acceptance test with lower test depth, it is first necessary to describe

the individual parts of the acceptance test and then define logical groups, which represent the

components of the acceptance test. The assignment of the safety-related machine data and

parameters to difference CRCs support this grouping (e.g. to support modular machine

concepts).

Messages during component replacement after Safety commissioning

WARNING

Non-safe states possible after a component has been replaced

Non-safe states are possible after a component has been replaced. If persons are in the danger

zone, accidents causing death or severe injury can occur.

• Before re-entering the danger area and before resuming operation, a simplified function

test must be carried out for all the drives affected by the component replacement (see

Section "Acceptance test wizard (Page 15)").

Safety-related components are assigned a CRC checksum, which can be used to identify if the

hardware has been changed after Safety commissioning:

• Replacing certain drive components after Safety Integrated has been commissioned.

• Different checksums as a result of series commissioning with Safety Integrated functionality

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Actions for hardware replacement and modifications

6.1 Necessity of a new acceptance test

The appropriate messages are displayed depending on the components involved (and the

control type). Example:

Warning

Example

F01650 SI P1 (CU): Acceptance test

Fault value 2005

required

Indicates that the Control Unit has been replaced.

A01695 SI Motion: Sensor Module

Indicates that the Sensor Module has been replaced.

has been replaced

C30711 SI Motion P2: Defect in a

Fault value 1031

monitoring channel

Stop response STOP F

As a consequence of A01695, a defect is signaled in a monitoring channel.

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

Actions for hardware replacement and modifications

6.2 Effect of the acceptance test for specific measures

6.2

Effect of the acceptance test for specific measures

6.2.1

Effects with SINUMERIK 828D Safety Integrated

The effects of the acceptance test with certain measures are described in the following table.

Function test parts 1 and 2, as well as the supplementary measures relate to Chapter Example

contents of the acceptance test (Page 109).

Measure

Documentation

Function test

Supplementary

Completion of the

Part 1

Part 2

measures

report

Replacement of

Inclusion of hard-

Point 4.1

Supplement

the encoder sys-

ware data

(Page 109)

possibly new

tem

checksums and

countersignature

Replacing an SMC,

Inclusion of hard-

Point 4.1

Inclusion of the

SME module

ware data/ soft-

(Page 109)

new checksums

ware version data

and countersigna-

ture

Replacing a motor

Inclusion of hard-

Point 4.1

Inclusion of the

equipped with

ware data/ soft-

(Page 109)

new checksums

DRIVE-CLiQ

ware version data

and countersigna-

ture

Replacing a Motor

Inclusion of hard-

Yes, only Point 2.1

Point 4.1

Countersignature

Module

ware data/ soft-

(Page 109)

ware version data

Replacing the PPU

Inclusion of hard-

Yes

Point 4.1

Countersignature

hardware

ware data/ soft-

(Page 109)

ware version data

Replacing the NX

Inclusion of hard-

Yes, only Point 2.1

Point 4.1

Countersignature

hardware

ware data/ soft-

(Page 109)

(Page 109), only

ware version data

for axes controlled

by the NX

Replacing TM54F

Possibly supple-

Point 4.2

Countersignature

hardware

ment hardware da-

(Page 109)

Changing the mon-

Supplement con-

Yes

Inclusion of the

itoring clock cycle

figuration data

new checksum and

of the drive

countersignature

Changes to the

Supplement con-

Yes

Inclusion of the

TM54F monitoring

figuration data

new checksum and

clock cycle

countersignature

Changes to the

Adapt configura-

Yes, only Point 2.6

Point 4.1

Inclusion of the

drive assignment

tion diagram

(Page 109)

new checksum and

countersignature

SW update ²

Supplement soft-

No ¹

Point 4.3

ware version

(Page 109)

(NCU/drive/PLC)

SW upgrade ³

Supplement soft-

No ¹

Yes, for axes with

Points 4.3 and 4.4

ware version

modified drive

(Page 109)

(NCU/drive/PLC)

checksum ^1,4

SINUMERIK Operate acceptance test

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

Actions for hardware replacement and modifications

6.2 Effect of the acceptance test for specific measures

Measure

Documentation

Function test

Supplementary

Completion of the

Part 1

Part 2

measures

report

Change to an indi-

Inclusion of SI func-

Yes, only test the

Inclusion of the

vidual limit value

tion per axis

corresponding

new checksum and

(e.g. SG limit)

function

countersignature

Expanded function

Inclusion of the SI

Yes, only for the

Inclusion of the

(e.g. additional ac-

function per axis,

tests influenced by

new checksum and

tuator, additional

function table

the function ex-

countersignature

SG stage)

pansion

Data transferred to

Possible supple-

Yes

Points 4.1, 4.3 and

Inclusion of the

additional ma-

ment to the ma-

4.5 (Page 109)

new checksum and

chines with series

chine description

countersignature

commissioning

(check the soft-

ware version)

Regarding the acceptance test, the notes in the documentation of the SW upgrade must be carefully observed.

An update involves an update to a new Service Pack (SP) or a new Hotfix (HF) within a software line, e.g. 02.05.01.03 (01 =

Service Pack; 03 = Hotfix) to 02.05.02.03 (does not take into account any change of the Safety functionality).

An upgrade involves an upgrade to a new software release, e.g. 02.05.xx.xx to 02.06.xx.xx or 02.xx.xx.xx. to 03.xx.xx.xx

(does not take into account any change of the Safety functionality).

If no checksums have changed, then a complete function test, Part 2 does not have to be performed. However, a test should

be performed with reduced test scope.

Note

Test with reduced test scope

Test of Safety Integrated Functions at any axis (each PPU and each NX) and a comparison with

the test results before the upgrade.

Note

If the results of function test, part 2, are taken from another identical machine, then this is the

sole responsibility of the machine manufacturer and must be appropriately commented in the

acceptance report.

6.2.2

Effects with SINUMERIK 840D sl Safety Integrated plus

The effects of the acceptance test with certain measures are described in the following table.

Function test parts 1 and 2, as well as the supplementary measures relate to Chapter Example

contents of the acceptance test (Page 111).

Measure

Documentation

Function test

Supplemen-

Completion of

Part 1

Part 2

tary meas-

the report

ures

Replacement of the encoder

Inclusion of hardware da-

Point 4.1

Document

system

(Page 111)

changed check-

sum

Replacing an SMC, SME mod-

Supplement hardware

Point 4.1

Document

ule

data/software version da-

(Page 111)

changed check-

sum

SINUMERIK Operate acceptance test

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

Actions for hardware replacement and modifications

6.2 Effect of the acceptance test for specific measures

Measure

Documentation

Function test

Supplemen-

Completion of

Part 1

Part 2

tary meas-

the report

ures

Replacing a motor equipped

Supplement hardware

Point 4.1

Document

with DRIVE-CLiQ

data/software version da-

(Page 111)

changed check-

sum

Replacing the Motor Module

Supplement hardware

Yes, only

Point 4.1

data/software version da-

(Page 111)

Point 2.1

(Page 111)

(3.2.1)

Replacing the NCU hardware

Supplement hardware

Yes, only

Point 4.1

data/software version da-

(Page 111)

Point 2.1

(Page 111)

(3.2.1)

Replacing the NX hardware

Supplement hardware

Yes, only

Point 4.1

data/software version da-

(Page 111),

Point 2.1

only for axes

(Page 111)

controlled by

(3.2.1)

the NX

Hardware replacement, PROFI-

Point 4.2

safe I/O

(Page 111)

Change to the SI clock cycle

Supplement configura-

Yes

Document

tion data

changed check-

sum

Changes to the drive assign-

Adapt configuration dia-

Yes,

Point 4.1

Document

ment

gram

only Point 2.6

(Page 111)

changed check-

(Page 111) for

sum

the changed

axes

Reconfigure PROFIsafe I/O (in

Safety summary

Only test the

Document

STEP 7)

modified con-

changed check-

figuration

sum

SW update ²

Supplement software

No ¹

version

(NCU/drive/PLC)

Changed jerk and/or accelera-

No ¹

Yes,

tion

only Point 4.3

(Page 111)

SW upgrade³

Supplement software

No ¹

No ^{1, 4}

No ¹

version

(NCU/drive/PLC)

Software upgrade (HMI)

Supplement software

version

Changing an individual limit

Inclusion of SI function

Yes, only test

Document

value (e.g. SLS limit)

per axis

changed check-

of the corre-

sum

sponding

function at

the axes in-

volved

SINUMERIK Operate acceptance test

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

Actions for hardware replacement and modifications

6.2 Effect of the acceptance test for specific measures

Measure

Documentation

Function test

Supplemen-

Completion of

Part 1

Part 2

tary meas-

the report

ures

Function expansion or new

Inclusion of the SI func-

Yes, only for

Yes, only

Document

functions (e.g. additional ac-

tion per axis, function ta-

the tests influ-

changed check-

tests influ-

tuator, additional SLS level)

ble

enced by the

sum

enced by the

function ex-

pansion

Change the safety program

Inclusion of SI function

Yes,

Document

per axis, function table,

only Points

changed check-

safety summary

2.4, 2.5 and

sum

2.6 (Page 111)

Data transferred to additional

Include machine descrip-

Yes

Points 4.1

Document

machines via series commis-

tion (check the SW ver-

and 4.5

changed check-

sioning

sion)

(Page 111)

sum

¹⁾ Regarding the acceptance test, the notes in the documentation of the SW upgrade must be

carefully observed.

²⁾ An update involves an update to a new Service Pack (SP) or a new Hotfix (HF) within a software

line, e.g.:

04.07.02.00 (02=Service Pack; 00=Hotfix) auf 04.07.03.00 (does not take into account any

change of the Safety functionality).

³⁾ An upgrade involves an upgrade to a new software release, e.g.:

04.07.xx.xx to 04.08.xx.xx (does not take into account any change to the safety functionality).

⁴⁾ If no drive checksums have changed, then a complete function test Part 2 does not have to be

performed. However, a test should be performed with reduced test scope.

Note

Test with reduced test scope

Test of Safety Integrated Functions at any axis (each NCU and each NX) and a comparison with

the test results before the upgrade.

Note

If the results of function test, Part 2 are taken from another identical machine, then this is the

sole responsibility of the machine manufacturer and should be appropriately commented in the

acceptance report.

SINUMERIK Operate acceptance test

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

Actions for hardware replacement and modifications

6.2 Effect of the acceptance test for specific measures

6.2.3

Effects for SINUMERIK ONE Safety Integrated

The effects of the acceptance test with certain measures are described in the following table.

Function test parts 1 and 2, as well as the supplementary measures relate to Chapter Example

contents of the acceptance test (Page 113).

Measure

Documentation

Function test

Supplemen-

Completion of

Part 1

Part 2

tary meas-

the report

ures

Replacement of the encoder

Inclusion of hardware da-

Point 4.1

Document

system

(Page 113)

changed check-

sum

Replacing an SMC, SME mod-

Supplement hardware

Point 4.1

Document

ule

data/software version da-

(Page 113)

changed check-

sum

Replacing a motor equipped

Supplement hardware

Point 4.1

Document

with DRIVE-CLiQ

data/software version da-

(Page 113)

changed check-

sum

Replacing the Motor Module

Supplement hardware

Yes, only

Point 4.1

data/software version da-

(Page 113)

Point 2.1

(Page 113)

Replacing the NCU/PPU hard-

Supplement hardware

Yes, only

Point 4.1

ware

data/software version da-

(Page 113)

Point 2.1

(Page 113)

Replacing the NX hardware

Supplement hardware

Yes, only

Point 4.1

data/software version da-

(Page 113),

Point 2.1

only for axes

(Page 113)

controlled by

the NX

Hardware replacement, PROFI-

Point 4.2

safe I/O

(Page 113)

Change to the SI clock cycle

Supplement configura-

Yes

Document

tion data

changed check-

sum

Changes to the drive assign-

Adapt configuration dia-

Yes,

Point 4.1

Document

ment

gram

only Point 2.6

(Page 113)

changed check-

(Page 113) for

sum

the changed

axes

Reconfigure PROFIsafe I/O (in

Safety summary

Only test the

Document

STEP 7)

modified con-

changed check-

figuration

sum

SW upgrade update ² (NCU/

Supplement software

No ¹

drive/PLC)

version

Changed jerk and/or accelera-

No ¹

Yes,

tion

only Point 4.3

(Page 113)

SW upgrade, upgrade³ (NCU/

Supplement software

No ¹

No ^{1, 4}

No ¹

drive/PLC)

version

Software upgrade (HMI)

Supplement software

version

SINUMERIK Operate acceptance test

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

Actions for hardware replacement and modifications

6.2 Effect of the acceptance test for specific measures

Measure

Documentation

Function test

Supplemen-

Completion of

Part 1

Part 2

tary meas-

the report

ures

Changing an individual limit

Inclusion of SI function

Yes, only test

Document

value (e.g. SLS limit)

per axis

changed check-

of the corre-

sum

sponding

function at

the axes in-

volved

Function expansion or new

Inclusion of the SI func-

Yes, only for

Yes, only

Document

functions (e.g. additional ac-

tion per axis, function ta-

the tests influ-

changed check-

tests influ-

tuator, additional SLS level)

ble

enced by the

sum

enced by the

function ex-

pansion

Change the safety program

Inclusion of SI function

Yes,

Document

per axis, function table,

only Points

changed check-

safety summary

2.4, 2.5 and

sum

2.6 (Page 113)

Data transferred to additional

Include machine descrip-

Yes

Points 4.1

Document

machines via series commis-

tion (check the SW ver-

and 4.5

changed check-

sioning

sion)

(Page 113)

sum

¹⁾ Regarding the acceptance test, the notes in the documentation of the SW upgrade must be

carefully observed.

²⁾ An update involves an update to a new Service Pack (SP) or a new Hotfix (HF) within a software

line, e.g.:

04.07.02.00 (02=Service Pack; 00=Hotfix) auf 04.07.03.00 (does not take into account any

change of the Safety functionality).

³⁾ An upgrade involves an upgrade to a new software release, e.g.:

04.07.xx.xx to 04.08.xx.xx (does not take into account any change to the safety functionality).

⁴⁾ If no drive checksums have changed, then a complete function test Part 2 does not have to be

performed. However, a test should be performed with reduced test scope.

Note

Test with reduced test scope

Test of Safety Integrated Functions at any axis (each NCU and each NX) and a comparison with

the test results before the upgrade.

Note

If the results of function test, Part 2 are taken from another identical machine, then this is the

sole responsibility of the machine manufacturer and should be appropriately commented in the

acceptance report.

SINUMERIK Operate acceptance test

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

Actions for hardware replacement and modifications

6.2 Effect of the acceptance test for specific measures

6.2.4

Effects for SINUMERIK MC Safety Integrated

The effects of the acceptance test with certain measures are described in the following table.

Function test parts 1 and 2, as well as the supplementary measures relate to Chapter Example

contents of the acceptance test (Page 115).

Measure

Documentation

Function test

Supplemen-

Completion of

Part 1

Part 2

tary meas-

the report

ures

Replacement of the encoder

Inclusion of hardware da-

Point 4.1

Document

system

(Page 115)

changed check-

sum

Replacing an SMC, SME mod-

Supplement hardware

Point 4.1

Document

ule

data/software version da-

(Page 115)

changed check-

sum

Replacing a motor equipped

Supplement hardware

Point 4.1

Document

with DRIVE-CLiQ

data/software version da-

(Page 115)

changed check-

sum

Replacing the Motor Module

Supplement hardware

Yes, only

Point 4.1

data/software version da-

(Page 115)

Point 2.1

(Page 115)

Replacing the MCU hardware

Supplement hardware

Yes, only

Point 4.1

data/software version da-

(Page 115)

Point 2.1

(Page 115)

Hardware replacement, PROFI-

Point 4.2

safe I/O

(Page 115)

Change to the SI clock cycle

Supplement configura-

Yes

Document

tion data

changed check-

sum

Changes to the drive assign-

Adapt configuration dia-

Yes,

Point 4.1

Document

ment

gram

only Point 2.6

(Page 115)

changed check-

(Page 115) for

sum

the changed

axes

Reconfigure PROFIsafe I/O (in

Safety summary

Only test the

Document

STEP 7)

modified con-

changed check-

figuration

sum

SW upgrade, update²

Supplement software

No ¹

(MCU/drive/PLC)

version

Changed jerk and/or accelera-

No ¹

Yes,

tion

only Point 4.3

(Page 115)

SW upgrade³

Supplement software

No ¹

No ^{1, 4}

No ¹

(MCU/drive/PLC)

version

Software upgrade (HMI)

Supplement software

version

SINUMERIK Operate acceptance test

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

SINUMERIK 840D sl. Service - Safety Integrated. Manual (2020) - page 18