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

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 115)

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 115)

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 MCU 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

100

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

Actions for hardware replacement and modifications

6.2 Effect of the acceptance test for specific measures

6.2.5

Effects with SINUMERIK 840D sl Safety Integrated (system-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 117).

Measure

Documentation

Function test

Supplementary

Completion of the

Part 1

Part 2

measures

report

Replacement of

Supplement hard-

Point 4.1

Document the

the encoder system

ware data

(Page 117)

modified check-

sum. From soft-

ware release 4.5

SP6, the modified

checksum is docu-

mented in the log

file.

Replacing an SMC,

Supplement hard-

Point 4.1

Document the

SME module

ware data/ soft-

(Page 117)

modified check-

ware version data

sum. From soft-

ware release 4.5

SP6, the modified

checksum is docu-

mented in the log

file.

Replacing a motor

Inclusion of hard-

Point 4.1

Document the

equipped with

ware data/ soft-

(Page 117)

modified check-

DRIVE-CLiQ

ware version data

sum. From soft-

ware release 4.5

SP6, the modified

checksum is docu-

mented in the log

file.

Replacing a Motor

Supplement hard-

Yes, only Points 2.1

Point 4.1

Module

ware data/ soft-

and 2.2 (Page 117)

(Page 117)

ware version data

Replacing the NCU

Inclusion of hard-

Yes, only Points

Point 4.1

hardware

ware data/ soft-

2.1, 2.2, 2.3 and

(Page 117)

ware version data

2.5 (Page 117)

(without trace re-

cording)

Replacing the NX

Inclusion of hard-

Yes, only Points 2.1

Point 4.1

hardware

ware data/ soft-

and 2.2 (Page 117)

(Page 117), only

ware version data

for axes controlled

by the NX

Hardware replace-

Point 4.2

ment, PROFIsafe

(Page 117)

I/O

Change system

Supplement con-

Yes

Document

clock cycle (SI clock

figuration data

changed checksum

cycle changes)

Changed system

Supplement con-

Yes

clock cycle (SI clock

figuration data

cycle, IPO remains

the same)

SINUMERIK Operate acceptance test

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

101

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

Changed IPO clock

Supplement con-

Yes

Document

cycle (checksum

figuration data

changed checksum

NCK 0 changes)

Change to the SI

Supplement con-

Yes

Document

clock cycle

figuration data

changed checksum

Changed PROFI-

Supplement con-

Yes, only Point 2.7

Document

safe clock cycle

figuration data

(Page 117)

changed checksum

Changes to the

Adapt configura-

Yes, only Point 2.6

Point 4.1

Document

drive assignment

tion diagram

(Page 117) for the

(Page 117)

changed checksum

changed axes

Changed

Supplement, SI

Yes, only for the

Document

SAFE_USER_DATA

function per axis,

tests influenced by

changed checksum

function table

the function ex-

pansion

Reconfigured PRO-

Supplement con-

Only test the modi-

Document

FIsafe I/O in S7

figuration data

fied configuration

changed checksum

Changed within

Supplement con-

Yes, only Points 2.6

Document

the scope of "mod-

figuration diagram

and 2.7 (Page 117)

changed checksum

ular PROFIsafe"

and function table

Change within the

Supplement con-

Yes, only Points 2.6

Document

scope of “F_SEND/

figuration diagram

and 2.7 (Page 117)

changed checksum

F_RECEIVE"

and function table

SW upgrade²(NCU/

Supplementary

No¹

No ¹

Document

drive/PLC)

software version

changed checksum

Changed jerk

No¹

Yes, only Point 4.3

and/or acceleration

(Page 117)

SW upgrade ³

Supplementary

No ¹

No ^{1, 4}

Points 4.3 and 4.4

Document

software version

(Page 117)

changed checksum

(NCU/drive/PLC)

Software upgrade

Supplementary

(HMI)

software version

Changing an indi-

Inclusion of SI func-

Yes, only test the

Document

vidual limit value

tion per axis

corresponding

changed checksum

(e.g. SG limit)

functions at the ax-

es involved

Expanded function

Inclusion of the SI

Yes, only for the

Document

(e.g. additional ac-

function per axis,

tests influenced by

changed checksum

tuator, additional

function table

the function ex-

SG stage)

pansion

SPL change

Inclusion of the SI

Yes, only Point 2.6

Document

function per axis,

(Page 117)

changed checksum

function table

Data transferred to

Possibly supple-

Yes

Points 4.1 and 4.5

Document

additional ma-

ment, machine de-

(Page 117)

changed checksum

chines with series

scription (check

commissioning

the SW 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).

SINUMERIK Operate acceptance test

102

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

Actions for hardware replacement and modifications

6.2 Effect of the acceptance test for specific measures

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 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

103

Tips and tricks

Trace does not start n < n_x

System:

SINUMERIK 840D sl with Safety Integrated

Version:

CNC software V4.7 or higher

Description:

If n < n_x,then the trace cannot start.

The most common reason for this is the machine data MD36060 (n<n_min). The machine data is

not Safety machine data, is seldom used, and is therefore overlooked.

The default value is 5 mm/min or 1 rpm. Reduce the size of the data item.

Remedy:

The trace start will commence if the following prerequisite is met:

V > 2 * [MD36060]

Trace does not start, axis oscillating

System:

SINUMERIK 840D sl with Safety Integrated

Version:

CNC software V4.7 or higher

Description:

The trace is stopped at V < [MD36060].

A motor exhibiting intense vibrations (e.g. single encoder system in the motor and rack-and-

pinion drive) can generate a start and immediate stop trigger. This will produce the same result.

Remedy:

Optimize the drive.

Trace does not start (wrong direction of rotation)

System:

SINUMERIK 840D sl with Safety Integrated

SINUMERIK Operate acceptance test

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

105

Tips and tricks

Version:

CNC software V4.7 or higher

Description:

If the safe actual values (NCK/drive) run contrary to the MCS actual value, then the trace cannot

start.

Remedy:

Change the direction of rotation and start the trace again.

Trace does not start (gantry and leading/following axis)

System:

SINUMERIK 840D sl with Safety Integrated

Version:

CNC software V4.7 or higher

Description:

Limit value was exceeded for one axis only as a result of mechanical occurrences or disparate

parameterization for both axes. The limit value in this regard would not necessarily have to be

exceeded for the tested axis.

Remedy:

Check the alarm messages. If the limit value was not exceeded for the axis to be tested, adapt

the parametrization.

Inserting a blank line into the template

Description:

Normal editors use the Enter key to enter a new blank line.

But if you press on the Enter key in the template editor, the next input field becomes active.

Remedy:

1. Move the cursor to the beginning of a line.

2. Press the "Ctrl + Return" key combination.

The new blank line is inserted in front of the line that is highlighted with the cursor.

Performing a trace for the test type "Function relations"

To ensure that a trace can be carried out for the test type "Function relationships (Page 28)", the

following precondition is necessary:

The trace definition for this type of test must be saved in the "Acceptance test/Trace" folder.

SINUMERIK Operate acceptance test

106

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

Appendix

A.1

Example contents of the acceptance test

A.1.1

Overview

Note

This chapter includes exemplary acceptance tests for drive-based safety for the SINUMERIK

828D, SINUMERIK 840D sl, SINUMERIK ONE and SINUMERIK MC, as well as an exemplary

acceptance test for system-integrated Safety for the SINUMERIK 840D sl.

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

A.1.2

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

A.1.2.1

SINUMERIK 828D with Safety Integrated

DOCUMENTATION

Documentation of the machine including the safety functions

1.1 Machine description (with overview diagram)

1.2 Details about the control system

1.3 Configuration diagram

1.4 Function table

Active monitoring functions depending on the operating mode, the protective doors and

other sensors.

It makes sense that this table is part of the documentation of the engineering work that

has been carried out.

1.5 SI functions per axis

1.6 Information and data about safety equipment

FUNCTION TEST PART 1

General function test, including a check of the wiring/configuring

2.1 Testing the switch-off signal paths

Testing the forced checking procedure of the switch-off signal paths

2.2 Testing the forced checking procedure of the inputs and outputs

2.3 Testing the Emergency Stop function and the safety circuits

2.4 Testing the function table

SINUMERIK Operate acceptance test

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

109

Appendix

A.1 Example contents of the acceptance test

2.5

Testing the control signals of the drive groups of TM54F

FUNCTION TEST PART 2

Detailed function test incl. checking the values of the individual SI functions used

3.1

Testing the SI Safe Torque Off function (safe operating stop, SBH) - STO

3.2

Testing the SI function Safe Stop 1 - SS1

3.3

Testing the SI function Safe Stop 2 - SS2

3.4

Testing the SI function Safe Operating Stop - SOS

(with evaluated measurement diagram or measured values)

3.5

Testing the SI function Safely-Limited Speed - SLS

(with evaluated measurement diagram or measured values)

3.6

Testing the SI function Safe Speed Monitor - SSM

(with evaluated measurement diagram or measured values)

3.7

Testing the SI function Safely-Limited Position - SLP

(with evaluated measurement diagram or measured values)

3.8

Testing the SI function Safe Direction - SDI

(with evaluated measurement diagram or measured values)

3.9

Testing the SI function Safe Brake Control/Safe Brake Test - SBC/SBT

(with evaluated measurement diagram or measured values)

Supplementary measures

4.1

Function test, actual value sensing

• General testing of the actual value sensing

After replacing a component, the system is switched on and briefly operated in both

directions.

• Check of the safe actual value acquisition

With the motion monitoring functions activated, the drive is briefly moved in both

directions.

4.2

Checking the SGE/SGA signals of the relevant module

4.3

After changing the acceleration behavior/jerk, axis-specific tests are carried out of Func-

tion Test Part 2

4.4

Testing the new safety functionality

4.5

Checking checksums and software versions, comparing whether checksums and soft-

ware versions are identical with the reference machine.

COMPLETION OF THE REPORT

A report of the commissioning status that was checked is generated with the appropriate

counter-signatures

5.1

Checking SINAMICS Safety Integrated parameters

5.2

Checking SINAMICS software releases

5.3

Logging and documenting SINAMICS Safety Integrated checksums

5.4

Verifying data archiving

5.5

Countersignature

APPENDIX

Reports/measurement plots for FUNCTION TEST PARTS 1/2

• Archiving SI-relevant drive parameters

SINUMERIK Operate acceptance test

110

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

Appendix

A.1 Example contents of the acceptance test

A.1.2.2

SINUMERIK 840D sl with Safety Integrated plus

DOCUMENTATION

Documentation of the machine including the safety functions

1.1

Machine description (with overview diagram)

1.2

Details about the control system

1.3

Configuration diagram

1.4

Function table

Active monitoring functions depending on the operating mode, the protective doors and

other sensors/CPU-CPU communication.

It makes sense that this table is part of the documentation of the engineering work that

has been carried out.

1.5

SI functions per axis

1.6

Information and data about safety equipment

1.7

Safety summary of the F-PLC

FUNCTION TEST PART 1

General function test, including a check of the wiring/configuring

2.1

Test of the SI function "Safe Torque Off" (STO)

• Required when used in Basic and/or Extended Functions.

• You do not need to prepare a trace recording for this test.

2.2

Test of the SI function "Safe Brake Control" (SBC)

• Required when using Basic and/or Extended Functions.

• You do not need to prepare a trace recording for this test.

2.3

Testing the forced checking procedure of the inputs and outputs

2.4

Testing the Emergency Stop function and the safety circuits

2.5

Test of all of the switching states of the safety-related sensors and actuators and associ-

ated input/output signals (test of the function table)

2.6

Test of the PROFIsafe input/output signals

2.7

Check of the monitoring and delay times based on the safety summary

FUNCTION TEST PART 2

Detailed function test incl. checking the values of the individual SI functions used

3.1

Test of the SI function Safe Operating Stop (SOS)

(with the evaluated measurement diagram or measured values in each case)

3.2

Test of the SI function Safely-Limited Speed (SLS)

(with the evaluated measurement diagram or measured values in each case)

3.3

Test of the SI function Safe Speed Monitor (SSM)

(with the evaluated measurement diagram or measured values in each case)

3.4

Test of the SI function Safely-Limited Position (SLP)

(with the evaluated measurement diagram or measured values in each case)

3.5

Test of the SI function Safe Cam (SCA) (check via

diagnostics display or assigned SGA or with the evaluated measurement diagram or

measured values in each case)

SINUMERIK Operate acceptance test

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

111

Appendix

A.1 Example contents of the acceptance test

3.6

Test of the SI function Safe Direction SDI

(with the evaluated measurement diagram or measured values in each case)

3.7

Test of the SI function Safe Stop 1 (SS1)

(with the evaluated measurement diagram or measured values in each case)

3.8

Test of the SI function Safe Stop 2 (SS2)

(with the evaluated measurement diagram or measured values in each case)

3.9

Test of the SI function Safe Stop 2 (SS2E)

(with the evaluated measurement diagram or measured values in each case)

3.10

Test of the SI function Safe Stop 2 Extended Stop and Retract (SS2ESR)

(with evaluated measurement diagram or measured values)

3.11

Testing the SI function Safe Brake Control/Safe Brake Test - SBC/SBT

(with evaluated measurement diagram or measured values)

Supplementary measures

4.1

Function test, actual value sensing

• General testing of the actual value sensing

After replacing a component, the system is switched on and briefly operated in both

directions.

• Check of the safe actual value acquisition

With the motion monitoring functions activated, the drive is briefly moved in both

directions.

4.2

Check of the input/output signals of the relevant module

4.3

After changing the acceleration behavior/jerk, axis-specific tests are carried out of Func-

tion Test Part 2

4.4

Testing the new safety functionality

4.5

Checking checksums and software versions, comparing whether checksums and soft-

ware versions are identical with the reference machine. Hardware checksum p9729[2] is

always different from that of the reference machine.

COMPLETION OF THE REPORT

A report of the commissioning status that was checked is generated with the appropriate

counter-signatures

5.1

Check the SI parameterization

5.2

Check of the hardware configuration of the PROFIsafe peripherals

5.3

Logging of the checksums (SINAMICS parameters, PROFIsafe peripherals, FOverallsigna-

ture, Signature of the F-blocks with F-attribute)

5.4

Verifying data archiving

5.5

Countersignature

APPENDIX

Reports/measurement plots for FUNCTION TEST PARTS 1/2

• Alarm logs/servo trace measurements

• Archiving of the following safety-related data:

- Drive parameters

- Safety program of the F-PLC

- PLC project (if existing)

SINUMERIK Operate acceptance test

112

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

Appendix

A.1 Example contents of the acceptance test

A.1.2.3

SINUMERIK ONE with Safety Integrated

DOCUMENTATION

Documentation of the machine including the safety functions

1.1

Machine description (with overview diagram)

1.2

Details about the control system

1.3

Configuration diagram

1.4

Function table

Active monitoring functions depending on the operating mode, the protective doors and

other sensors/CPU-CPU communication.

It makes sense that this table is part of the documentation of the engineering work that

has been carried out.

1.5

SI functions per axis

1.6

Information and data about safety equipment

1.7

Safety summary of the F-PLC

FUNCTION TEST PART 1

General function test, including a check of the wiring/configuring

2.1

Test of the SI function "Safe Torque Off" (STO)

• Required when used in Basic and/or Extended Functions.

• You do not need to prepare a trace recording for this test.

2.2

Test of the SI function "Safe Brake Control" (SBC)

• Required when using Basic and/or Extended Functions.

• You do not need to prepare a trace recording for this test.

2.3

Testing the forced checking procedure of the inputs and outputs

2.4

Testing the Emergency Stop function and the safety circuits

2.5

Test of all of the switching states of the safety-related sensors and actuators and associ-

ated input/output signals (test of the function table)

2.6

Test of the PROFIsafe input/output signals

2.7

Check of the monitoring and delay times based on the safety summary

FUNCTION TEST PART 2

Detailed function test incl. checking the values of the individual SI functions used

3.1

Test of the SI function Safe Operating Stop (SOS)

(with the evaluated measurement diagram or measured values in each case)

3.2

Test of the SI function Safely-Limited Speed (SLS)

(with the evaluated measurement diagram or measured values in each case)

3.3

Test of the SI function Safe Speed Monitor (SSM)

(with the evaluated measurement diagram or measured values in each case)

3.4

Test of the SI function Safely-Limited Position (SLP)

(with the evaluated measurement diagram or measured values in each case)

3.5

Test of the SI function Safe Cam (SCA) (check via

diagnostics display or assigned SGA or with the evaluated measurement diagram or

measured values in each case)

SINUMERIK Operate acceptance test

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

113

Appendix

A.1 Example contents of the acceptance test

3.6

Test of the SI function Safe Direction SDI

(with the evaluated measurement diagram or measured values in each case)

3.7

Test of the SI function Safe Stop 1 (SS1)

(with the evaluated measurement diagram or measured values in each case)

3.8

Test of the SI function Safe Stop 2 (SS2)

(with the evaluated measurement diagram or measured values in each case)

3.9

Test of the SI function Safe Stop 2 (SS2E)

(with the evaluated measurement diagram or measured values in each case)

3.10

Test of the SI function Safe Stop 2 Extended Stop and Retract (SS2ESR)

(with evaluated measurement diagram or measured values)

3.11

Testing the SI function Safe Brake Control/Safe Brake Test - SBC/SBT

(with evaluated measurement diagram or measured values)

Supplementary measures

4.1

Function test, actual value sensing

• General testing of the actual value sensing

After replacing a component, the system is switched on and briefly operated in both

directions.

• Check of the safe actual value acquisition

With the motion monitoring functions activated, the drive is briefly moved in both

directions.

4.2

Check of the input/output signals of the relevant module

4.3

After changing the acceleration behavior/jerk, axis-specific tests are carried out of Func-

tion Test Part 2

4.4

Testing the new safety functionality

4.5

Checking checksums and software versions, comparing whether checksums and soft-

ware versions are identical with the reference machine. Hardware checksum p9729[2] is

always different from that of the reference machine.

COMPLETION OF THE REPORT

A report of the commissioning status that was checked is generated with the appropriate

counter-signatures

5.1

Check the SI parameterization

5.2

Check of the hardware configuration of the PROFIsafe peripherals

5.3

Logging of the checksums (SINAMICS parameters, PROFIsafe peripherals, FOverallsigna-

ture, Signature of the F-blocks with F-attribute)

5.4

Verifying data archiving

5.5

Countersignature

APPENDIX

Reports/measurement plots for FUNCTION TEST PARTS 1/2

• Alarm logs/servo trace measurements

• Archiving of the following safety-related data:

- Drive parameters

- Safety program of the F-PLC

- PLC project (if existing)

SINUMERIK Operate acceptance test

114

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

Appendix

A.1 Example contents of the acceptance test

A.1.2.4

SINUMERIK MC with Safety Integrated

DOCUMENTATION

Documentation of the machine including the safety functions

1.1

Machine description (with overview diagram)

1.2

Details about the control system

1.3

Configuration diagram

1.4

Function table

Active monitoring functions depending on the operating mode, the protective doors and

other sensors/CPU-CPU communication.

It makes sense that this table is part of the documentation of the engineering work that

has been carried out.

1.5

SI functions per axis

1.6

Information and data about safety equipment

1.7

Safety summary of the F-PLC

FUNCTION TEST PART 1

General function test, including a check of the wiring/configuring

2.1

Test of the SI function "Safe Torque Off" (STO)

• Required when used in Basic and/or Extended Functions.

• You do not need to prepare a trace recording for this test.

2.2

Test of the SI function "Safe Brake Control" (SBC)

• Required when using Basic and/or Extended Functions.

• You do not need to prepare a trace recording for this test.

2.3

Testing the forced checking procedure of the inputs and outputs

2.4

Testing the Emergency Stop function and the safety circuits

2.5

Test of all of the switching states of the safety-related sensors and actuators and associ-

ated input/output signals (test of the function table)

2.6

Test of the PROFIsafe input/output signals

2.7

Check of the monitoring and delay times based on the safety summary

FUNCTION TEST PART 2

Detailed function test incl. checking the values of the individual SI functions used

3.1

Test of the SI function Safe Operating Stop (SOS)

(with the evaluated measurement diagram or measured values in each case)

3.2

Test of the SI function Safely-Limited Speed (SLS)

(with the evaluated measurement diagram or measured values in each case)

3.3

Test of the SI function Safe Speed Monitor (SSM)

(with the evaluated measurement diagram or measured values in each case)

3.4

Test of the SI function Safely-Limited Position (SLP)

(with the evaluated measurement diagram or measured values in each case)

3.5

Test of the SI function Safe Cam (SCA) (check via

diagnostics display or assigned SGA or with the evaluated measurement diagram or

measured values in each case)

SINUMERIK Operate acceptance test

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

115

Appendix

A.1 Example contents of the acceptance test

3.6

Test of the SI function Safe Direction SDI

(with the evaluated measurement diagram or measured values in each case)

3.7

Test of the SI function Safe Stop 1 (SS1)

(with the evaluated measurement diagram or measured values in each case)

3.8

Test of the SI function Safe Stop 2 (SS2)

(with the evaluated measurement diagram or measured values in each case)

3.9

Test of the SI function Safe Stop 2 (SS2E)

(with the evaluated measurement diagram or measured values in each case)

3.10

Test of the SI function Safe Stop 2 Extended Stop and Retract (SS2ESR)

(with evaluated measurement diagram or measured values)

3.11

Testing the SI function Safe Brake Control/Safe Brake Test - SBC/SBT

(with evaluated measurement diagram or measured values)

Supplementary measures

4.1

Function test, actual value sensing

• General testing of the actual value sensing

After replacing a component, the system is switched on and briefly operated in both

directions.

• Check of the safe actual value acquisition

With the motion monitoring functions activated, the drive is briefly moved in both

directions.

4.2

Check of the input/output signals of the relevant module

4.3

After changing the acceleration behavior/jerk, axis-specific tests are carried out of Func-

tion Test Part 2

4.4

Testing the new safety functionality

4.5

Checking checksums and software versions, comparing whether checksums and soft-

ware versions are identical with the reference machine. Hardware checksum p9729[2] is

always different from that of the reference machine.

COMPLETION OF THE REPORT

A report of the commissioning status that was checked is generated with the appropriate

counter-signatures

5.1

Check the SI parameterization

5.2

Check of the hardware configuration of the PROFIsafe peripherals

5.3

Logging of the checksums (SINAMICS parameters, PROFIsafe peripherals, FOverallsigna-

ture, Signature of the F-blocks with F-attribute)

5.4

Verifying data archiving

5.5

Countersignature

APPENDIX

Reports/measurement plots for FUNCTION TEST PARTS 1/2

• Alarm logs/servo trace measurements

• Archiving of the following safety-related data:

- Drive parameters

- Safety program of the F-PLC

- PLC project (if existing)

SINUMERIK Operate acceptance test

116

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

Appendix

A.1 Example contents of the acceptance test

A.1.3

SINUMERIK 840D sl - system-integrated safety functions

A.1.3.1

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

1) DOCUMENTATION

Documentation of the machine including the safety functions

1.1

Machine description (with overview diagram)

1.2

Details about the control system

1.3

Configuration diagram

1.4

Function table

Active monitoring functions depending on the operating mode, the protective doors and

other sensors/CPU-CPU communication

Ideally, this table should be the objective and result of the configuring work.

1.5

SI functions per axis

1.6

Information and data about safety equipment

2) FUNCTION TEST PART 1

General function check incl. checking the wiring/programming/configuring

2.1

Testing the switch-off signal paths

(check the forced checking procedure of the switch-off signal paths)

2.2

Test the external stops

2.3

Test of the holding torque

2.4

Testing the forced checking procedure of the inputs and outputs

2.5

Testing the Emergency Stop function and the safety circuits

2.6

Test all SPL switching states and associated input/output signals

(test of the function table)

2.7

Test of the PROFIsafe input/output signals

Recommendation:

A forced checking procedure should be automatically performed each time that the control

system runs up.

3) FUNCTION TEST PART 2

Detailed function test incl. checking the values of the individual SI functions used

3.1

Test of the SI function Safe Operating Stop - SBH

(with evaluated measurement diagram or measured values)

3.2

Test of the SI function safely reduced speed - SG

(with the evaluated measurement diagram or measured values)

3.3

Test of the SI function safety-related output n < n_x

(with evaluated measurement diagram or measured values)

3.4

Test the SI function safe limit positions - SE

(with evaluated measurement diagram or measured values)

3.5

Test of the SI function Safe Cams - SN

(check using the diagnostics display or assigned SGAs or with the evaluated measuring

diagrams and measured values)

SINUMERIK Operate acceptance test

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

117

Appendix

A.1 Example contents of the acceptance test

3.6

If necessary, test the SI function external stops

(with evaluated measurement diagram or measured values)

3.7

Test the SI function SBC/SBT

(with evaluated measurement diagram or measured values / PROFIsafe I/O)

4) Supplementary measures

4.1

Function test, actual value sensing

After replacing a component, the system is switched on and briefly operated in both

directions.

Warning

During this process, all personnel must keep out of the danger area.

With the motion monitoring functions are activated, check that the SI encoder evaluation

and count direction match the encoder evaluation and count direction of SINUMERIK.

4.2

Checking the SGE/SGA signals of the relevant module

4.3

After changing the acceleration behavior/jerk, axis-specific tests are carried out of Func-

tion Test Part 2

4.4

Test the new safety functionality

4.5

Checking checksums and software versions, comparing whether checksums and soft-

ware versions are identical with the reference machine. Hardware checksum 36998[1] is

always different from that of the reference machine.

5) COMPLETING THE REPORT

Documenting and reporting the tested commissioning state

5.1

Check the SI machine data

5.2

Check the hardware configuration of the PROFIsafe I/O

5.3

Check the NCK and SINAMICS software releases

5.4

Log of the checksums (axis MD / SPL / PROFIsafe I/O)

5.5

Completing the NCK commissioning (protect synchronized actions)

5.6

Complete the PLC commissioning

5.7

Verifying data archiving

APPENDIX

SINUMERIK Operate acceptance test

118

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

Appendix

A.3 Abbreviations

A.3

Abbreviations

The most important abbreviations are listed alphabetically.

Abbreviation

Derivation of the abbreviation

Meaning

1v1

1 von 1 Auswertung

Encoder signal is available through one channel, is read

once

2v2

2 von 2 Auswertung

Encoder signal is available through one channel, is read

twice and compared

A...

Alarm

Warning about a possible or expected error state detected

by the drive.

Ausgangsbyte

Output byte

ACX

Accessdescription Compressed and eXtensible

Binary format to describe data

ASIC

Application Specific Integrated Circuit

Semiconductor module developed for special applica-

tions

ASUP

Asynchrones Unterprogramm

Asynchronous subprogram

AUS3

Antrieb wird an der AUS3-Rampe (p1135) ab-

Control command which a drive uses to brake its motor

gebremst

with the AUS3 return time and to switch it off during

standstills.

BAG

Betriebsartengruppe

Mode group

BAG-STOP

Stop in der entsprechenden Betriebsarten-

Stop in corresponding mode group

gruppe

Susceptibility to common cause failure

Prone to faults due to common cause

Berufsgenossenschaft

Employer's Liability Insurance Association

Bgr.

Baugruppe

Module

BHG

Bedienhandgerät

Handheld unit

BICO

Binector Connector Technology

Binector connector technology

Method for freely interconnecting process data via "stand-

ard" drive parameterization.

Binector Input

Binector input

Binector Output

Binector output

BOF

Bedienoberfläche

User interface

BTSS

Bedientafel-Schnittstelle

Operator panel interface

CCF

Common cause failure

Failure due to common cause

CFG

Konfigurations-Telegramm

Configuration telegram

Connector Input

Connector input

Connector Output

Connector output

CPU

Central Processing Unit

Central processing unit

CRC

Cyclic Redundancy Check

Checksum test

Control Unit

Control unit of the drive unit

Digitaler Ausgang

Digital output

DAU

Digital-Analog-Umsetzer

Digital/analog converter

Datenbaustein

Data block

Diagnostic coverage

Diagnostics coverage

DDS

DRIVE DATA SET

Drive parameters that can be changed over together as a

set

Digital Input

Digital input

SINUMERIK Operate acceptance test

120

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

Appendix

A.3 Abbreviations

Abbreviation

Derivation of the abbreviation

Meaning

Digital Output

Digital output

DKE-AK

Deutsche elektrotechnische Kommission-Ar-

German Electrotechnical Working Committee

beitskreis

Datum Links

Data left

DMS

Direct Measure System

Direct measuring system

Dezentrale Peripherie

Distributed I/O

DPM

DP-Master

Central component in the PROFIBUS DP data bus

DPR

Dual Port RAM

Dual port memory

Datum rechts

Data right

DRIVE-CLiQ

DRIVE Component Link with IQ

Communication system of the SINAMICS drive technolo-

gy for connecting the different drive components.

Datenwort

Data word

Eingangsbyte

Input byte

EMK

Elektromagnetische Kraft

Electromagnetic force

Europäische Norm

European standard

ENDAT

Encoder Data

Interface for absolute encoder

Enable Pulses

Pulse enable

EQN/ERN

Teil einer Bestellbezeichnung von absoluten/

Part of an order code for absolute/incremental encoders

inkrementellen Gebern der Fa. Heidenhain

made by Heidenhain

E/R

Einspeise-/Rückspeiseeinheit

Infeed/regenerative feedback unit

ESD

Electro Static Discharge

Electrostatic discharge

ESR

Erweitertes Stillsetzen und Rückziehen

Extended stop and retract

F...

Fault

Event which interrupts the proper operation of a techni-

cal component.

F-

Failsafe-...

Fail-safe

F-DI

Failsafe Digital Input

Failsafe input module

F-DO

Failsafe Digital Output

Failsafe output module

F_RCVDP

Fehlersichere Anlagenkommunikation (SIMAT-

Failsafe system communication (SIMATIC)

IC)

F_RECVDP

Fehlersichere Anlagenkommunikation, Emp-

Failsafe system communication, receiver (SINUMERIK)

fänger (SINUMERIK)

F_SENDDP

Fehlersichere Anlagenkommunikation, Sender

Failsafe system communication, sender (SINUMERIK, SI-

(SINUMERIK, SIMATIC)

MATIC)

FOC

Force Control

Travel with limited torque/force

FSR

F_SENDDP/F_RECVDP

Failsafe Values

Fail-safe values

FXS

Fixed stop

Travel to fixed stop

GSD

Geräte-Stammdaten

Device master data

GSTR

Geberstrichzahl

Number of encoder pulses

HMS

Hochauflösendes Messsystem

High-resolution measuring system

HSA

Hauptspindel-Antrieb

Main spindle drive

Hardware

IBN

Inbetriebnahme

Commissioning

SINUMERIK Operate acceptance test

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

121

Appendix

A.3 Abbreviations

Abbreviation

Derivation of the abbreviation

Meaning

Industrial Ethernet

IEC

International Electrotechnical Commision

International Electrotechnical Commission

IFA

Institut für Arbeitssicherheit

Institute for work safety

IMP

Impulssperre

Pulse inhibit

IMS

Indirect Measure System

Indirect measuring system

INSE

Eingangsdaten der Sicheren programmierbaren

Input data of the safe programmable logic (SPL) from the

Logik (SPL) von der Peripherie

I/O

INSI

Eingangsdaten der Sicheren programmierbaren

Input data of the safe programmable logic (SPL) from the

Logik (SPL) aus Ausgangsdaten der achsspezifi-

output data of the axis-specific monitoring functions

schen Überwachungsfunktionen

IPO

Interpolator

I/O

Input/Output

Input/output

Kanal_1-Reset

Kanal-Reset im 1. Kanal der NCU bwz. MCU

Channel reset in the 1st channel of the NCU or MCU

KDV

Kreuzweiser Datenvergleich

Crosswise data comparison

Failure rate

Error rate

LSB

Least Significant Bit

Least significant bit

LIFTFAST

Schnellabheben von der Kontur

Fast retraction from the contour

MAKSIP

Maschinen-Koordinaten-System-Istposition

Machine coordinate system actual position

MCP

Machine Control Panel = Maschinensteuertafel

Machine Control Panel

Maschinendaten bzw. Merkerdoppelwort

Machine Data or marker doubleword

MDD

Maschinendaten-Dialog

Machine Data Dialog

Mixed-IO

E/A-Baugruppe mit analogen und digitalen Sig-

I/O module with analog and digital signals

nalen

MLFB

Maschinenlesbare Fabrikate-Bezeichnung

Machine-readable product designation

Motor Module

Power module/power output module

MMC

Man Machine Communication

User interface for man-machine communication

MRL

Maschinenrichtlinie

Machinery directive

MSB

Most Significant Bit

Most significant bit

MTTFd

Mean time to dangerous failure

N...

Keine oder Interne Meldung

No message or internal message

Öffner

Normally closed contact

Numerical Control

Numerical control

Netzeinspeisung

Line infeed

Node-Id

Node-Identification Code

Unique identifier of each DRIVE-CLiQ node

NST

Nahtstellensignal

Interface signal

Operator Acknowledge

User know-how

Organisationsbaustein

Organization block

Obere Grenze

Upper limit

Operator Panel

Operator panel

p...

Einstellparameter

Setting parameters

PAA

Prozessabbild Ausgänge

Process image, outputs

PAE

Prozessabbild Eingänge

Process image, inputs

PFH_D

Probability of dangerous failure per hour

Probability of hazardous faults per hour

Performance Level

Performance level

SINUMERIK Operate acceptance test

122

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

Appendix

A.3 Abbreviations

Abbreviation

Derivation of the abbreviation

Meaning

PLC

Programmable Logic Control

Programmable Logic Controller

PM E-F

Powermodul Elektronic Failsafe

Power Module Electronic Failsafe

PNO

PROFIBUS Nutzerorganisation

PROFIBUS user organization

PROFIBUS

Bussystem zur Kommunikation zwischen Au-

Bus system for communication between automation

tomatisierungskomponenten

components

PROFIsafe

Kommunikationsprofil auf PROFIBUS-Basis zur

Communication profile based on PROFIBUS for safety-re-

sicherheitsgerichteten Kommunikation

lated communications

PST

PROFIsafe-Takt

PROFIsafe clock cycle

QVK

Querverkehr

Direct data exchange (peer-to-peer communication)

SA-Link

Sensor-Aktor-Link

Sensor-Actuator link

SAM

Safe Acceleration Monitor

Monitors the motor speed and triggers an STO at a spe-

cific speed.

SBC

Safe Brake Control

Provides safe output signals for activating external

brakes.

SBM

Safe Brake Management

Combines SBC and SBM.

SBR

Safe Brake Ramp

Safe brake ramp monitoring

SBT

Safe Brake Test

Safe brake test (diagnostic function)

The function checks whether the expected holding tor-

que is still available.

SCA

Safe Cam

Safe Cams

SCC

Safety Control Channel

SDI

Safe Direction

Prevents unintentional direction of the motor shaft.

Sicher reduzierte Geschwindigkeit

Safely reduced speed

SGA

Sicherheitsgerichteter Ausgang

Safety-related output

SGE

Sicherheitsgerichteter Eingang

Safety-related input

Sicherer Halt

Safe standstill

Safety Integrated^®

Integrated safety technology from SIEMENS.

SIC

Safety Info Channel

Safety Information Channel

SIL

Safety Integrity Level

SILCL

SIL claim limit

Name of a Safety Integrity Level

Softkey

SLP

Safely-Limited Position

Safely Limited Position

SLS

Safely-Limited Speed

SMC

Sensor Module Cabinet Mounted

External adapter box to connect an encoder to DRIVE-CLiQ

SME

Sensor Module Externally Mounted

Sensor Module with a high degree of protection for

mounting outside the electrical/control cabinet

SMI

Sensor Module Integrated

External adapter box to connect an encoder to DRIVE-

CLiQ, integrated in the motor

SMM

Safe Motion Monitoring

Safe motion monitoring

SMx

Zusammenfassung für SMI, SMC und SME

Common term for SMI, SMC and SME

SINUMERIK Operate acceptance test

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

123

Appendix

A.3 Abbreviations

Abbreviation

Derivation of the abbreviation

Meaning

Sicherer Software-Nocken, Sichere Nockenspur

Safe software cam, Safe Cam Track

SOS

Safe Operating Stop

Limits the stop position of the motor.

SPL

Sichere programmierbare Logik

Safe Programmable Logic

SPS

Speicherprogrammierbare Steuerung

Programmable Logic Controller

SS1

Safe Stop 1

Stops the motor safely and quickly and then switches it to

a torque-free state.

SS2

Safe Stop 2

SS2E

Safe Stop 2 mit externem Stop

Safe Stop 2 with external stop

SS2ESR

Safe Stop 2 Erweitertes Stillsetzen und Rückzie-

Safe Stop 2 Extended Stop and Retract

hen

SSM

Safe Speed Monitor

Checks whether the motor is operating below a defined

speed limit.

STO

Safe Torque Off

No power that might cause a rotation is supplied to the

motor.

STOP A, B, C, D,

Stopreaktion

In the event of a fault, the system responds correspond-

E, F

ing to the configured stop response

SSFK

Spindelsteigungs-Fehlerkompensation

Leadscrew Error Compensation

Stromversorgung

Power supply

Software

Lifetime

Service life (tech.)

Diagnostic test interval

Time of the test interval

TCP

Tool Center Point

Tool center point

TEA

Testing Data Active

Identifier for machine data

Untere Grenze

Lower limit

UPM

Umdrehungen pro Minute

Revolutions per minute

Übersetzung

Transmission ratio

VSA

Vorschub-Antrieb

Feed drive

WZM

Werkzeugmaschine

Machine tool

SINUMERIK Operate acceptance test

124

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

Table of contents

Introduction

1.1

The SINAMICS converter family

1.2

General information about SINAMICS documentation

1.3

Usage phases and their documents/tools

1.4

Where can the various topics be found?

1.5

Training and support

1.6

Using OpenSSL

1.7

General Data Protection Regulation

Fundamental safety instructions

2.1

Fundamental safety instructions

2.1.1

General safety instructions

2.1.2

Warranty and liability for application examples

2.1.3

Security information

2.2

Fundamental safety instructions for Safety Integrated

2.3

Residual risk

General information about SINAMICS Safety Integrated

3.1

Supported functions

3.1.1

Safety Integrated Basic Functions

3.1.2

Safety Integrated Extended Functions

3.1.3

Safety Integrated Advanced Functions

3.2

Supported functions: HLA module

3.2.1

HLA: Safety Integrated Basic Functions

3.2.2

HLA: Safety Integrated Extended Functions

3.2.3

HLA: Safety Integrated Advanced Functions

3.3

Drive products with integrated safety functions

3.4

Examples of how the safety/diagnostic functions can be applied

3.5

General information about operating components with Safety Integrated activated

3.6

Drive monitoring with or without encoder

Overview of Safety Integrated functions

4.1

Safety Integrated Basic Functions

4.1.1

Safe Torque Off (STO)

4.1.2

Safe Stop 1 (SS1)

4.1.3

Safe Brake Control (SBC)

4.2

Safety Integrated Extended Functions

4.2.1

Preconditions for Safety Integrated Extended Functions

4.2.2

Control possibilities

Safety Integrated

Function Manual, 06/2020, 6SL3097-5AR00-0BP3

Table of contents

4.2.3

Safe Torque Off (STO)

4.2.4

Safe Stop 1 (SS1)

4.2.5

Safe Operating Stop (SOS)

4.2.6

Safe Stop 2 (SS2)

4.2.7

Safely Limited Speed (SLS)

4.2.7.1

Selecting SLS when the motor is switched on

4.2.7.2

Selecting SLS at low velocities

4.2.7.3

Switching between monitoring thresholds

4.2.8

Safe Speed Monitor (SSM)

4.2.9

Safe Direction (SDI)

4.2.10

Safely-Limited Acceleration (SLA)

4.2.11

Safe Brake Test (SBT)

4.3

Safety Integrated Advanced Functions

4.3.1

Preconditions for Safety Integrated Advanced Functions

4.3.2

Safely-Limited Position (SLP)

4.3.3

Transferring safe position values (SP)

4.3.4

Safe referencing

4.3.5

Safe Cam (SCA)

Description of Safety Integrated functions

5.1

Safety Integrated basic functions

5.1.1

Safe Torque Off (STO)

5.1.1.1

Safe Torque Off (STO) for SINAMICS HLA

5.1.2

Safe Stop 1 (SS1, time controlled)

5.1.2.1

SS1 with OFF3

5.1.2.2

SS1 with external stop

5.1.2.3

Function diagrams and parameters

5.1.3

Safe Brake Control (SBC)

5.1.3.1

Description SBC

5.1.3.2

SBC for Motor Modules in the chassis format

5.1.3.3

Hardware required for SBC

5.1.3.4

Function diagrams and parameters

5.1.4

Safety faults

5.1.5

Forced checking procedure (test stop)

5.1.5.1

Forced checking procedure or test of the switch-off signal paths (test stop) for Safety

Integrated Basic

5.1.5.2

Forced checking procedure (test stop) with POWER ON

5.1.6

Function diagrams and parameters

5.2

Safety Integrated Extended Functions

5.2.1

License for Extended Functions or Advanced Functions

5.2.2

Differences between Extended Functions "with encoder" and "without encoder"

5.2.2.1

Specifics relating to Safety Integrated Functions "without encoder"

5.2.3

Safe Torque Off (STO)

103

5.2.4

Safe Stop 1 (SS1)

103

5.2.4.1

Safe Stop 1 with encoder

103

5.2.4.2

Safe Stop 1 without encoder

106

5.2.4.3

Safe Stop 1 with external stop

107

5.2.4.4

Function diagrams and parameters

108

5.2.5

Safe Brake Control (SBC)

108

5.2.6

Safe Operating Stop (SOS)

109

5.2.7

Safe Stop 2 (SS2)

111

Safety Integrated

Function Manual, 06/2020, 6SL3097-5AR00-0BP3

Table of contents

5.2.7.1

SS2 with external stop (SS2E)

113

5.2.7.2

Safe Stop 2 Extended Stop and Retract (SS2ESR)

115

5.2.7.3

Overview of important parameters

117

5.2.7.4

Interaction with EPOS

118

5.2.8

Safely-Limited Speed (SLS)

118

5.2.8.1

Safely Limited Speed (SLS)

120

5.2.8.2

Safely Limited Speed without encoder

123

5.2.8.3

Safely-Limited Speed without selection

124

5.2.8.4

Function diagrams and parameters

126

5.2.8.5

EPOS and safe setpoint velocity limitation

127

5.2.9

Safe Speed Monitor (SSM)

127

5.2.9.1

Safe Speed Monitor with encoder

129

5.2.9.2

Safe Speed Monitor without encoder

131

5.2.9.3

Function diagrams and parameters

134

5.2.10

Safe Direction (SDI)

134

5.2.10.1

Safe Direction with encoder

135

5.2.10.2

Safe Direction without encoder

137

5.2.10.3

Safe Direction without selection

139

5.2.10.4

Function diagrams and parameters

140

5.2.11

Safely Limited Acceleration (SLA)

140

5.2.11.1

Principle of operation

142

5.2.11.2

Transmission via PROFIsafe or SIC

143

5.2.12

Safe Brake Test (SBT)

144

5.2.12.1

Communication via SIC/SCC

152

5.2.12.2

Function diagrams and parameters

154

5.2.13

Safe Acceleration Monitor (SAM)

155

5.2.13.1

Description

155

5.2.13.2

Calculating the SAM tolerance of the actual velocity

156

5.2.13.3

Function diagrams and parameters

156

5.2.14

Safe Brake Ramp (SBR)

157

5.2.14.1

Introduction

157

5.2.14.2

Time response

158

5.2.14.3

Parameterization

159

5.2.14.4

Function diagrams and parameters

160

5.2.15

Reliable actual value acquisition with encoder system

160

5.2.15.1

Single-encoder system

160

5.2.15.2

2-encoder system

161

5.2.15.3

Encoder types for single and 2-encoder systems

163

5.2.15.4

Actual value synchronization

166

5.2.15.5

Safe motion monitoring

166

5.2.16

Safe actual value sensing without encoder

167

5.2.16.1

Evaluation delay time without encoder

168

5.2.16.2

Fault tolerance actual value acquisition without encoder

168

5.2.16.3

Voltage tolerance acceleration

169

5.2.16.4

Checking the settings

169

5.2.16.5

Overview of important parameters

170

5.2.17

Safe gearbox switchover

170

5.2.17.1

Gearbox switchover without increased position tolerance

172

5.2.17.2

Gearbox switchover with increased position tolerance

172

5.2.17.3

Overview of important parameters

174

5.2.18

Forced checking procedure (test stop)

174

5.2.18.1

General

174

Safety Integrated

Function Manual, 06/2020, 6SL3097-5AR00-0BP3

Table of contents

5.2.18.2

Performing a forced checking procedure (test stop)

175

5.2.18.3

Safety devices

176

5.2.18.4

Forced checking procedure (test stop) F-DI/F-DO of TM54F

176

5.3

Safety Integrated Advanced Functions

181

5.3.1

Note regarding PFH values

181

5.3.2

License for Extended Functions or Advanced Functions

181

5.3.3

Safely-Limited Position (SLP)

181

5.3.3.1

Controlling the Safely-Limited Position function

183

5.3.3.2

Retraction

185

5.3.3.3

Function diagrams and parameters

187

5.3.4

Transferring safe position values (SP)

188

5.3.4.1

Ranges of values

190

5.3.4.2

Synchronous transfer of safe position values

191

5.3.4.3

Function diagrams and parameters

192

5.3.5

Safe referencing

192

5.3.5.1

General

192

5.3.5.2

Referencing types

194

5.3.5.3

Function diagrams and parameters

196

5.3.6

Safe Cam (SCA)

196

5.3.7

Forced checking procedure (test stop)

199

5.3.7.1

Performing a forced checking procedure (test stop)

200

5.3.7.2

Safety devices

201

5.3.7.3

Forced checking procedure (test stop) F-DI/F-DO of TM54F

201

Control of the safety functions

207

6.1

Control possibilities

207

6.2

Control signals by way of terminals on the Control Unit and Motor / Power Module

208

6.2.1

Description of the two-channel structure

209

6.2.2

Grouping drives

210

6.2.3

Simultaneity and tolerance time of the two monitoring channels

211

6.2.3.1

Tolerance time

212

6.2.3.2

Overview of important parameters

213

6.2.4

Bit pattern test

214

6.2.5

STO via terminals of the Power Modules Blocksize

215

6.2.5.1

Terminals STO_A/STO_B and DIP switch

217

6.3

Activation via PROFIsafe

218

6.3.1

Assigning Safety Integrated Functions to PROFIsafe

218

6.3.2

Enabling of the control via PROFIsafe

219

6.3.3

Selecting a PROFIsafe telegram

220

6.3.4

Telegram format

221

6.3.5

Process data

224

6.3.5.1

S_STW1 and S_ZSW1 (Basic Functions)

224

6.3.5.2

S_STW2 and S_ZSW2 (Basic Functions)

226

6.3.5.3

S_STW1 and S_ZSW1 (Extended/Advanced Functions)

228

6.3.5.4

S_STW2 and S_ZSW2 (Extended/Advanced Functions)

230

6.3.5.5

Additional process data

234

6.3.6

Function diagrams and parameters

237

6.4

Control via TM54F

238

6.4.1

Assigning Safety Integrated Functions to the F-DI/TM54F

239

6.4.2

Fault acknowledgment

239

Safety Integrated

Function Manual, 06/2020, 6SL3097-5AR00-0BP3

Table of contents

6.4.3

Overview of the F-DIs

239

6.4.4

Function of the F-DO

242

6.4.4.1

Overview of the F-DOs

242

6.4.4.2

Signal sources

242

6.4.4.3

Function diagrams and parameters

243

6.5

Communication failure via PROFIsafe or with TM54F

245

6.5.1

STOP B as response to communication failure with PROFIsafe control

245

6.5.2

Initiating ESR for a communication failure

246

6.6

Control of the Extended/Advanced Functions via F-DI (for CU310-2)

248

6.6.1

Assigning Safety Integrated Functions to the F-DI/TM54F

249

6.6.2

F-DI function

249

6.6.2.1

Description

249

6.6.2.2

F-DI features

250

6.6.2.3

Function diagrams and parameters

252

6.6.3

Function of the F-DO

252

6.6.3.1

Description

252

6.6.3.2

Signal sources for the F-DO

253

6.6.3.3

Safe state signal selection

253

6.6.3.4

Function diagrams and parameters

254

6.7

Motion monitoring without selection

255

6.8

Safety Info Channel and Safety Control Channel

257

6.8.1

Safety Info Channel (SIC)

257

6.8.2

Safety Control Channel (SCC)

257

6.8.3

Possible telegram configuration (700, 701)

257

6.8.4

Configuring

259

6.8.5

Applications

262

6.8.6

Send data for SIC and SCC

264

6.8.7

Receive data for SCC

267

Commissioning

269

7.1

Safety Integrated firmware versions

269

7.2

Parameters, checksum, version

270

7.3

Handling the Safety password

272

7.4

DRIVE-CLiQ rules for Safety Integrated Functions

275

7.5

Forced checking procedure (test stop)

277

7.5.1

Setting the forced checking procedure (test stop)

277

7.5.2

Executing the forced checking procedure (test stop)

278

7.5.3

Examples for the instants in time that the forced checking procedure (test stop) is

performed

279

7.6

Safety Integrated and ESR

280

7.7

Commissioning Safety Integrated functions

282

7.7.1

General information

282

7.7.2

Notes

283

7.7.3

Prerequisites for commissioning the Safety Integrated functions

284

7.7.4

Default settings for commissioning Safety Integrated functions without encoder

284

7.7.5

Setting the sampling times

286

7.7.5.1

Rules

286

Safety Integrated

Function Manual, 06/2020, 6SL3097-5AR00-0BP3

Table of contents

7.7.5.2

Overview of important parameters

287

7.8

Commissioning: Basic procedure

288

7.8.1

Making basic settings

288

7.8.1.1

Starting the safety commissioning

288

7.8.1.2

Making basic safety settings

288

7.8.1.3

Accepting the settings in the drive

291

7.8.1.4

Changing the safety password

291

7.8.2

Basic Functions

293

7.8.2.1

Commissioning with Startdrive

293

7.8.2.2

Commissioning via direct parameter access

295

7.8.3

Extended and Advanced Functions

297

7.8.3.1

SS1 (Extended Functions)

298

7.8.4

General settings

299

7.8.4.1

Parameterizing the actual value acquisition / mechanical system

299

7.8.4.2

Configuring the control of the safety functions

302

7.8.4.3

Forced checking procedure (test stop)

304

7.8.4.4

Function status of the Safety Integrated settings

306

7.9

Commissioning CU310-2

308

7.9.1

Basic sequence of commissioning

308

7.9.2

Forced checking procedure (test stop) of the CU310-2

308

7.9.2.1

Test mode 1: Evaluation of internal diagnostic signal (passive load)

310

7.9.2.2

Test mode 2: Read back F-DO in DI (relay circuit)

311

7.9.2.3

Test mode 3: Read back F-DO into the DI (actuator with feedback signal)

312

7.9.2.4

Test stop mode parameters

313

7.10

Commissioning TM54F

314

7.10.1

Basic sequence of commissioning

314

7.10.2

Forced checking procedure (test stop) of the TM54F

314

7.10.2.1

Performing test stop

316

7.10.2.2

Test mode 1: Evaluation of internal diagnostic signal (passive load)

317

7.10.2.3

Test mode 2: Read back F-DO in DI (relay circuit)

318

7.10.2.4

Test mode 3: Read back F-DO into the DI (actuator with feedback signal)

319

7.10.2.5

Test stop mode: Function diagrams and parameters

320

7.11

PROFIsafe communication

321

7.11.1

PROFIsafe via PROFIBUS

321

7.11.2

PROFIsafe via PROFINET

322

7.11.3

PROFIsafe configuration with Startdrive

322

7.11.3.1

Selecting a PROFIsafe telegram

323

7.12

Modular machine concept Safety Integrated

325

7.13

Information pertaining to series commissioning

326

7.14

Application examples

328

Acceptance test

331

8.1

General information about the acceptance test

332

8.1.1

Requirements

332

8.1.2

Requirements for the acceptance test

333

8.1.3

Parts of the acceptance test

333

8.1.4

Documentation

333

8.1.5

More information

334

8.1.6

Acceptance test mode

334

Safety Integrated

Function Manual, 06/2020, 6SL3097-5AR00-0BP3

Table of contents

8.2

Contents and depth of the acceptance test

335

8.2.1

Content of the complete acceptance test

335

8.2.2

Content of the partial acceptance test

337

8.2.3

Test scope for specific measures

339

8.2.4

Relevant checksums for the acceptance

340

8.3

Acceptance test with Startdrive

343

8.3.1

Notes

343

8.3.2

Preparing the acceptance test

344

8.3.3

Performing the acceptance test (example)

345

8.3.4

Completing the acceptance test with report

346

8.3.5

Transferring acceptance test results

348

8.4

Safety logbook

349

System features

351

9.1

Latest information

351

9.2

Certification

353

9.3

Probability of failure of the safety functions (PFH value)

354

9.4

Response times

355

9.4.1

STO and SBC via terminals of the Power Modules Blocksize

356

9.4.2

Control of Basic Functions via terminals on the Control Unit and Motor Module (CU310-2

and CU320-2)

357

9.4.3

Control of Basic Functions via PROFIsafe (CU310-2 and CU320-2)

358

9.4.4

Control of Basic Functions via TM54F

359

9.4.5

Control of Extended Functions with encoder via PROFIsafe (CU310-2 and CU320-2)

360

9.4.6

Control of Extended Functions with encoder via TM54F (CU310-2 and CU320-2)

362

9.4.7

Control of Extended Functions with encoder via terminals (only CU310-2)

363

9.4.8

Control of Extended Functions without encoder via PROFIsafe (CU310-2 and CU320-2)

364

9.4.9

Control of Extended Functions without encoder via terminals (only CU310-2)

366

9.4.10

Control of Extended Functions without encoder via TM54F (CU310-2 and CU320-2)

367

9.4.11

Control of Advanced Functions with encoder via PROFIsafe (CU310-2 and CU320-2)

368

9.4.12

Control of Advanced Functions with encoder via TM54F (CU310-2 and CU320-2)

369

9.4.13

Control of Advanced Functions with encoder via terminals (only CU310-2)

370

9.4.14

Advanced Functions without encoder via PROFIsafe (CU310-2 and CU320-2)

371

Standards and regulations

373

10.1

General information

373

10.1.1

Aims

373

10.1.2

Functional safety

374

10.2

Safety of machinery in Europe

375

10.2.1

Machinery Directive

375

10.2.2

Harmonized European Standards

376

10.2.3

Standards for implementing safety-related controllers

377

10.2.4

DIN EN ISO 13849-1

379

10.2.5

EN 62061

379

10.2.6

Series of standards IEC 61508 (VDE 0803)

381

10.2.7

Risk analysis/assessment

382

10.2.8

Risk reduction

384

10.2.9

Residual risk

384

10.2.10

EC declaration of conformity

384

Safety Integrated

Function Manual, 06/2020, 6SL3097-5AR00-0BP3

Table of contents

10.3

Machine safety in the USA

385

10.3.1

Minimum requirements of the OSHA

385

10.3.2

NRTL listing

386

10.3.3

NFPA 79

387

10.3.4

ANSI B11

387

10.4

Machine safety in Japan

388

10.5

Equipment regulations

389

10.6

Other safety-related issues

390

10.6.1

Information sheets issued by the Employer's Liability Insurance Association

390

10.6.2

Additional references

390

Maintenance

391

11.1

Information pertaining to component replacements

391

11.1.1

Details on the replacement of individual components

391

11.1.2

Replacing motors for safety without encoder

393

11.1.3

Parameters and function diagrams

393

11.2

Note regarding firmware update

394

11.3

Safety faults

395

11.3.1

Stop responses

395

11.3.2

Stop response priorities

398

11.3.3

Acknowledging safety faults

400

11.4

Message buffer

402

Appendix

405

A.1

Modules available in Startdrive

405

A.2

List of abbreviations

406

A.3

Documentation overview

418

A.4

Change history

419

A.5

Stop versions

420

Index

423

Safety Integrated

Function Manual, 06/2020, 6SL3097-5AR00-0BP3

Introduction

1.1

The SINAMICS converter family

With the SINAMICS converter family, you can solve any individual drive task in the low-voltage,

medium-voltage and DC voltage range. From converters to motors and controllers, all Siemens

drive components are perfectly matched to each other and can be easily integrated into your

existing automation system. With SINAMICS you are prepared for digitization. You benefit from

highly efficient engineering with a variety of tools for the entire product development and

production process. And you also save space in the control cabinet - thanks to the integrated

safety technology.

You can find additional information about SINAMICS at the following address (http://

www.siemens.com/sinamics ).

Safety Integrated

Function Manual, 06/2020, 6SL3097-5AR00-0BP3

Introduction

1.2 General information about SINAMICS documentation

1.2

General information about SINAMICS documentation

SINAMICS documentation

The SINAMICS documentation is organized in the following categories:

● General documentation/catalogs

● User documentation

● Manufacturer/service documentation

Standard scope

The scope of the functionality described in this document can differ from that of the drive system

that is actually supplied.

● Other functions not described in this documentation might be able to be executed in the

drive system. However, no claim can be made regarding the availability of these functions

when the equipment is first supplied or in the event of service.

● The documentation can also contain descriptions of functions that are not available in a

particular product version of the drive system. Please refer to the ordering documentation

only for the functionality of the supplied drive system.

● Extensions or changes made by the machine manufacturer must be documented by the

machine manufacturer.

For reasons of clarity, this documentation does not contain all of the detailed information on all

of the product types, and cannot take into consideration every conceivable type of installation,

operation and service/maintenance.

Target group

This documentation is intended for machine manufacturers, commissioning engineers, and

service personnel who use the SINAMICS drive system.

Benefits

This manual provides all of the information, procedures and operator actions required for the

particular usage phase.

Siemens MySupport/Documentation

You can find information on how to create your own individual documentation based on

Siemens content and adapt it for your own machine documentation at the following address

(https://support.industry.siemens.com/My/ww/en/documentation ).

Safety Integrated

Function Manual, 06/2020, 6SL3097-5AR00-0BP3

Introduction

1.3 Usage phases and their documents/tools

1.3

Usage phases and their documents/tools

Usage phase

Document/tool

Orientation

SINAMICS S Sales Documentation

Planning/configuration

● SIZER Engineering Tool

● Configuration Manuals, Motors

Deciding/ordering

SINAMICS S120 catalogs

●

SINAMICS S120 and SIMOTICS (Catalog D 21.4)

●

SINAMICS Converters for Single-Axis Drives and SIMOTICS Motors (Catalog D 31)

●

SINAMICS Converters for Single-Axis Drives - Built-In Units (D 31.1)

●

SINAMICS Converters for Single-Axis Drives - Distributed Converters (D 31.2)

●

SINAMICS S210 Servo Drive System (D 32)

●

SINUMERIK 840 Equipment for Machine Tools (Catalog NC 62)

Installation/assembly

●

SINAMICS S120 Equipment Manual for Control Units and Supplementary System

Components

●

SINAMICS S120 Equipment Manual for Booksize Power Units

●

SINAMICS S120 Equipment Manual for Chassis Power Units

●

SINAMICS S120 Equipment Manual for Chassis Power Units, Liquid-cooled

●

SINAMICS S120 Equipment Manual water-cooled chassis power units for common

cooling circuits

●

SINAMICS S120 Equipment Manual for Chassis Power Units, Air-cooled

●

SINAMICS S120 Equipment Manual for AC Drives

●

SINAMICS S120 Equipment Manual Combi

●

SINAMICS S120M Equipment Manual Distributed Drive Technology

●

SINAMICS HLA System Manual Hydraulic Drives

Commissioning

●

Startdrive Commissioning Tool

●

SINAMICS S120 Getting Started with Startdrive

●

SINAMICS S120 Commissioning Manual with Startdrive

●

SINAMICS S120 Function Manual Drive Functions

●

SINAMICS S120 Safety Integrated Function Manual

●

SINAMICS S120 Function Manual Communication

●

SINAMICS S120/S150 List Manual

●

SINAMICS HLA System Manual Hydraulic Drives

Usage/operation

●

SINAMICS S120 Commissioning Manual with Startdrive

●

SINAMICS S120/S150 List Manual

●

SINAMICS HLA System Manual Hydraulic Drives

Maintenance/servicing

●

SINAMICS S120 Commissioning Manual with Startdrive

●

SINAMICS S120/S150 List Manual

References

●

SINAMICS S120/S150 List Manual

Safety Integrated

Function Manual, 06/2020, 6SL3097-5AR00-0BP3

Introduction

1.4 Where can the various topics be found?

1.4

Where can the various topics be found?

Software

Manual

Alarms

Described in order of ascending numbers

SINAMICS S120/S150 List Manual

Parameters

Described in order of ascending numbers

SINAMICS S120/S150 List Manual

Function block di-

Sorted according to topic

SINAMICS S120/S150 List Manual

agrams

Described in order of ascending numbers

Drive functions

SINAMICS S120 Function Manual Drive Functions

Communication topics

SINAMICS S120 Function Manual Communication²⁾

Safety Integrated

Basic and Extended Functions

SINAMICS S120 Safety Integrated Function Manual

Basic Functions

SINAMICS S120 Function Manual Drive Functions

Commissioning

Of a simple SINAMICS S120 drive with

Getting Started¹⁾

STARTER

Commissioning

With STARTER

SINAMICS S120 Commissioning Manual¹⁾

Commissioning

Of a simple SINAMICS S120 drive with

Getting Started with Startdrive²⁾

Startdrive

Commissioning

With Startdrive

SINAMICS S120 Commissioning Manual with Startdrive²⁾

Web server

SINAMICS S120 Function Manual Drive Functions

Hardware

Manual

Control Units

● Control Units

● DRIVE-CLiQ HUB

SINAMICS S120 Equipment Manual for Control Units

and expansion

Modules

and Supplementary System Components

● Option Boards

components

● VSM10

● Terminal Modules

● Encoder system

connection

Booksize

● Line connection

● DC link compo-

SINAMICS S120 Equipment Manual for Booksize

power units

nents

Power Units

● Line Modules

● Braking resistors

● Motor Modules

● Control cabinet de-

sign

Chassis power units

SINAMICS S120 Equipment Manual for Chassis Power

Units, air, liquid or water cooled

AC drive components

SINAMICS S120 Equipment Manual for AC Drives

S120 Combi components

SINAMICS S120 Equipment Manual Combi

Diagnostics via

STARTER

SINAMICS S120 Commissioning Manual¹⁾

LEDs

Startdrive

SINAMICS S120 Commissioning Manual with Start-

drive²⁾

Meaning of the LEDs

Equipment Manuals

High Frequency Drive components

SINAMICS S120 System Manual High Frequency Drives

Up to firmware version 5.1 SP1

From firmware version 5.2

Safety Integrated

Function Manual, 06/2020, 6SL3097-5AR00-0BP3

Introduction

1.7 General Data Protection Regulation

1.7

General Data Protection Regulation

Compliance with the General Data Protection Regulation

Siemens respects the principles of data protection, in particular the data minimization rules

(privacy by design).

For this product, this means:

The product does not process neither store any person-related data, only technical function

data (e.g. time stamps). If the user links these data with other data (e.g. shift plans) or if he

stores person-related data on the same data medium (e.g. hard disk), thus personalizing these

data, he has to ensure compliance with the applicable data protection stipulations.

Safety Integrated

Function Manual, 06/2020, 6SL3097-5AR00-0BP3

Fundamental safety instructions

2.1

Fundamental safety instructions

2.1.1

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.

2.1.2

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.

2.1.3

Security information

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

secure operation of plants, systems, machines and networks.

Safety Integrated

Function Manual, 06/2020, 6SL3097-5AR00-0BP3

Fundamental safety instructions

2.1 Fundamental safety instructions

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.

Safety Integrated

Function Manual, 06/2020, 6SL3097-5AR00-0BP3

Fundamental safety instructions

2.2 Fundamental safety instructions for Safety Integrated

2.2

Fundamental safety instructions for Safety Integrated

Additional safety information and residual risks not specified in this chapter are included in the

relevant sections of this Function Manual.

DANGER

Risk minimization through Safety Integrated

Safety Integrated can be used to minimize the level of risk associated with machines and

plants.

Machines and plants can only be operated safely in conjunction with Safety Integrated,

however, when the machine manufacturer:

● Precisely knows and observes this technical user documentation - including the

documented limitations, safety information and residual risks.

● Carefully constructs and configures the machine/plant. A careful and thorough acceptance

test must then be performed by qualified personnel and the results documented.

● Implements and validates all the measures required in accordance with the machine/plant

risk analysis by means of the programmed and configured Safety Integrated Functions or

by other means.

The use of Safety Integrated does not replace the machine/plant risk assessment carried out

by the machine manufacturer as required by the EC machinery directive.

In addition to using Safety Integrated Functions, further risk reduction measures must be

implemented.

NOTICE

Danger to life as a result of inactive Safety Integrated Functions after powering up

The Safety Integrated Functions are only activated after the system has completely powered

up. System startup is a critical operating state with increased risk. When accidents occur, this

can result in death or severe injury.

● Make sure that the machine is safe during the system start-up.

WARNING

Danger to life as a result of undesirable motor movement when automatically restarting

The Emergency Stop function must bring the machine to a standstill according to Stop

Category 0 or 1 (STO or SS1) (EN 60204-1).

It is not permissible that the motor automatically restarts after an Emergency Stop, as this

represents danger to life as a result of the associated undesirable motor motion.

When individual safety functions (Safety Integrated Extended Functions or Safety Integrated

Advanced Functions) are deactivated, an automatic restart is permitted under certain

circumstances depending on the risk analysis (except when Emergency Stop is reset). An

automatic start is permitted when a protective door is closed, for example.

● For the cases listed above, ensure that an automatic restart is absolutely not possible.

Safety Integrated

Function Manual, 06/2020, 6SL3097-5AR00-0BP3

Fundamental safety instructions

2.2 Fundamental safety instructions for Safety Integrated

WARNING

Danger to life as a result of undesirable motor motion when the system powers up and the

drives are activated after changing or replacing hardware and/or software

After hardware and/or software components have been modified or replaced, it is only

permissible for the system to run up and the drives to be activated with the protective devices

closed. Personnel shall not be present within the danger zone.

● It may be necessary to carry out a partial or complete acceptance test or a simplified

functional test after having made certain changes or replacements.

● Before personnel may re-enter the hazardous area, all of the drives should be tested to

ensure that they exhibit stable control behavior by briefly moving them in both the plus and

minus directions (+/-).

● When switching on carefully observed the following:

The Safety Integrated Functions are only available and can only be selected after the

system has completely powered up.

WARNING

Parameterizing the encoder system

Encoder faults are detected using different hardware and software monitoring functions.

● It is not permissible to disable these monitoring functions (i.e. the encoder monitoring in the

Sensor Module) and they must be parameterized carefully. Depending on the fault type

and responding monitoring function, stop function Category 0 or 1 in accordance with

EN 60204-1 (fault response functions STOP A or STOP B in accordance with Safety

Integrated) is selected (see "Table 11-1 Overview of stop responses (Page 395)").

Note

EDS switchover for safe motion monitoring

An encoder which is used for safety functions must not be switched over when a drive data set

(DDS) is switched over.

The safety functions check the safety-relevant encoder data for changes when data sets are

switched over. If a change is detected, fault F01670 is displayed with a fault value of 10, which

results in a non-acknowledgeable STOP A.

● The safety-relevant encoder data in the various data sets must therefore be identical.

Safety Integrated

Function Manual, 06/2020, 6SL3097-5AR00-0BP3

Fundamental safety instructions

2.2 Fundamental safety instructions for Safety Integrated

WARNING

Converter operation despite active messages

With activated safety functions, there are a number of system messages that still permit the

drive to be traversed. In these cases, you must ensure that the causes of the messages are

corrected immediately. These messages include, among others, the following:

● A01774 SI Motion CU: Test stop required

A01697 SI Motion: Motion monitoring test required

Perform the required test stop.

● F13000 licensing is insufficient.

Purchase the license required for operation of the Extended/Advanced Functions or

activate a Trial License.

● A01669 (F, N) SI Motion: Unsuitable combination of motor and power unit.

The motor / power unit combination can result in decreased robustness (incorrect

detection of errors) in the system when operating with SI Motion.

Safety Integrated

Function Manual, 06/2020, 6SL3097-5AR00-0BP3

Fundamental safety instructions

2.3 Residual risk

2.3

Residual risk

The fault analysis enables machine manufacturers to determine the residual risk at their

machine with regard to the drive unit. The following residual risks are known:

WARNING

Danger due to short, limited movements

If two power transistors simultaneously fail in the power unit (one in the upper and one in the

lower inverter bridge), then this can cause cause brief, limited movement.

The maximum movement can be:

● Synchronous rotary motors: Max. movement = 180° / no. of pole pairs

● Synchronous linear motors: Max. movement = pole width

NOTICE

Material damage due to overshooting the speed or position that briefly violates the limit value.

Violation of limits may briefly lead to a speed higher than the speed setpoint, or the axis may

pass the defined position to a certain extent, depending on the dynamic response of the drive

and on parameter settings.

● Design your machine appropriately.

Safety Integrated

Function Manual, 06/2020, 6SL3097-5AR00-0BP3

Fundamental safety instructions

2.3 Residual risk

WARNING

Residual risk for a single-encoder system

Within a single-encoder system:

a) A single electrical fault in the encoder

b) A break of the encoder shaft (or loose encoder shaft coupling), or a loose encoder housing

will cause the encoder signals to remain static (that is, they no longer follow a movement while

still returning a correct level), and prevent fault detection while the drive is in stop state (for

example, drive in SOS state).

Generally, the drive is held by the active closed-loop control. Especially for drives with

suspended load, from a closed-loop control perspective, it is conceivable that drives such as

these move without this being detected.

The risk of an electrical fault in the encoder as described under a) is only present for few

encoder types employing a specific principal of operation.

● All of the faults described above must be included in the risk analysis of the machine

manufacturer. Additional safety measures have to be taken for drives with suspended/

vertical or pulling loads - e.g. in order to exclude faults under a):

- Use of an encoder with analog signal generation

- Use of a two-encoder system

● Failsafe detection of slip on the encoder shaft - or a broken encoder shaft connection.

You can implement failsafe detection of slip on the encoder shaft or a broken motor-

encoder shaft by checking the plausibility of the acquired safety-relevant actual value with

respect to the expected setpoint. If the actual value does not lie within a configurable

tolerance bandwidth around the setpoint within a defined time, then it can be assumed that

there is either slip - or that there is a broken connection between the encoder and the

motor. You must ensure this monitoring functionality in the safety user program according

to SIL 2 or PL d.

● For excluding the fault under b):

- Perform an FMEA regarding encoder shaft breakage (or slip of the encoder shaft

coupling) as well as loose encoder housings and use a fault exclusion process

according to IEC 61800-5-2, or

- Implementation of a two-encoder system (the encoders must not be mounted on the

same shaft).

Safety Integrated

Function Manual, 06/2020, 6SL3097-5AR00-0BP3

General information about SINAMICS Safety

Integrated

3.1

Supported functions

All of the Safety Integrated Functions available under SINAMICS S120 are listed in this chapter.

The safety functions listed here conform to:

● Safety Integrity Level (SIL) 2 according to IEC 61508

● Category 3 according to DIN EN ISO 13849-1

● Performance level (PL) d according to DIN EN ISO 13849-1

The safety functions correspond to the functions according to DIN EN 61800-5-2 (under the

assumption that they are defined there).

Note

Parallel use of Safety Integrated Functions

All Safety Integrated Functions can be used simultaneously.

Exception: If SOS and SLS are activated simultaneously, SOS has higher priority and overrides

the SLS reaction.

SINAMICS makes a distinction between the following function groups:

● Safety Integrated Basic Functions (Page 30)

● Safety Integrated Extended Functions (Page 31)

● Safety Integrated Advanced Functions (Page 32)

Safety Integrated

Function Manual, 06/2020, 6SL3097-5AR00-0BP3

General information about SINAMICS Safety Integrated

3.1 Supported functions

3.1.1

Safety Integrated Basic Functions

The Safety Integrated Basic Functions are part of the standard scope of the drive and can be

used without an additional license. These functions are always available. These functions do

not require an encoder and/or do not place any special requirements on the encoder used.

● Safe Torque Off (STO)

Safe Torque Off is a safety function to avoid unexpected startup in accordance with

EN 60204-1. STO prevents the supply of power to the motor, which can produce a torque.

This is equivalent to stop category 0.

● Safe Stop 1 (SS1, time-controlled)

Safe Stop 1 is based on the "Safe Torque Off" function. This means that a Category 1 stop

in accordance with EN 60204-1 can be implemented.

● Safe Brake Control (SBC)

Safe Brake Control is used to safely control a holding brake.^{1) 2)}

¹⁾ Note regarding Power/Motor Modules in the chassis format: For the chassis format, SBC is

only supported by Power/Motor Modules with article number ...3 or higher. A Safe Brake

Adapter is also needed for this design.

²⁾ Note regarding Power/Motor Modules in the blocksize format: Blocksize Power Modules also

require a Safe Brake Relay for this function.

Safety Integrated

Function Manual, 06/2020, 6SL3097-5AR00-0BP3

General information about SINAMICS Safety Integrated

3.1 Supported functions

3.1.2

Safety Integrated Extended Functions

The Safety Integrated Extended Functions require an additional Safety Extended license.

Extended Functions with encoder require an encoder with safety capability (see Chapter

"Reliable actual value acquisition with encoder system (Page 160)").

●

Safe Torque Off (STO)

Safe Torque Off is a safety function to avoid unexpected starting in accordance with

EN 60204-1.

●

Safe Stop 1 (SS1, time and acceleration controlled)

Safe Stop 1 is based on the "Safe Torque Off" function. This means that a Category 1 stop

in accordance with EN 60204-1 can be implemented.

●

Safe Brake Control (SBC)

Safe Brake Control is used to safely control a holding brake.^{1) 2)}

●

Safe Operating Stop (SOS)

Safe Operating Stop is used to protect against unintentional movement. The drive is in

closed-loop control mode and is not disconnected from the power supply.

●

Safe Stop 2 (SS2)

Safe Stop 2 is used to safely brake the motor with a subsequent transition into the "Safe

Operating Stop" state (SOS). This means that a Category 2 stop in accordance with EN

60204-1 can be implemented.

●

Safely-Limited Speed (SLS)

Safely-Limited Speed ensures that the drive does not exceed a preset speed/velocity limit.

●

Safe Speed Monitor (SSM)

Safe Speed Monitor is used for safely identifying when a speed limit is undershot in both

directions of motion, e.g. to identify zero speed. A failsafe output signal is available for

further processing.

●

Safe Direction (SDI)

Safe Direction is used to safely monitor the direction of motion.

●

Safe gearbox stage switchover

The "Safe gearbox stage switchover" function facilitates reliable switching between different

gearbox stages. The switchover is only possible via PROFIsafe.

●

Safely-Limited Acceleration (SLA)

Safely-Limited Acceleration monitors (the same as SLS) the acceleration, and intervenes

when a limit value is violated. SLA cannot prevent that the acceleration threshold is briefly

exceeded.

●

Safe Brake Test (SBT)

The diagnostic function "Safe Brake Test" function (SBT) checks the required holding

torque of a brake (operating or holding brake).

¹⁾ Note regarding Power/Motor Modules in the chassis format: For the chassis format, SBC is

only supported by Power/Motor Modules with article number ...3 or higher. A Safe Brake

Adapter is also needed for this design.

²⁾ Note regarding Power/Motor Modules in the blocksize format: Blocksize Power Modules also

require a Safe Brake Relay for this function.

Safety Integrated

Function Manual, 06/2020, 6SL3097-5AR00-0BP3

General information about SINAMICS Safety Integrated

3.1 Supported functions

3.1.3

Safety Integrated Advanced Functions

The Safety Integrated Advanced Functions require an additional Safety Advanced license.

Advanced Functions with encoder require an encoder with safety capability (see Chapter

"Reliable actual value acquisition with encoder system (Page 160)").

● Safely Limited Position (SLP)

Safely Limited Position ensures that a freely definable traversing range is not left.

● Transferring safe position values (SP)

The "Transfer safe position values (SP)" function enables you to transfer a safe position to

the higher-level control via PROFIsafe.

● Safe Cam (SCA)

The "Safe Cam" function outputs a safe signal if the drive is within a specified position range.

It facilitates the realization of safe axis-specific range detection.

Safety Integrated

Function Manual, 06/2020, 6SL3097-5AR00-0BP3

General information about SINAMICS Safety Integrated

3.2 Supported functions: HLA module

3.2

Supported functions: HLA module

SINAMICS HLA supports the following Safety Integrated Functions:

● Safety Integrated Basic Functions

● Safety Integrated Extended Functions

● Safety Integrated Advanced Functions

Note

Only "linear" axis type permitted

For SINAMICS HLA, only the "linear" axis type is permitted.

Note

Commissioning

SINAMICS HLA can only be commissioned with STARTER.

Comparison, description of electric ↔ hydraulic drives

In the Safety Integrated Function Manual, Safety Integrated Functions are described from the

perspective of an electric drive. However, these descriptions essentially also apply in the same

way for hydraulic systems. You will find parameters and messages for the drive object HLA in

the SINAMICS S120/S150 List Manual.

SINUMERIK 840D sl. Service - Safety Integrated. Manual (2020) - page 19