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Siemens SINUMERIK 828D Function Manual
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Siemens SINUMERIK 828D Function Manual

Siemens SINUMERIK 828D Function Manual

Siemens sinamics s120 safety integrated
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Download this manual See also: Diagnostic Manual, Function Manual
Safety Integrated

SINUMERIK
SINUMERIK 828D,
SINAMICS S120
Safety Integrated
Function Manual
Valid for:
SINUMERIK
CNC software Version 4.5 SP1
07/2012
6FC5397-3EP40-3BA0

___________________
Preface
General information about
___________________
SINAMICS Safety Integrated
___________________
Description of Safety
Integrated Basic Functions
___________
Description of the Safety
Integrated Extended
Functions
___________________
Commissioning the functions
___________________
Example of commissioning
with SINUMERIK 828D
___________________
Acceptance tests and
acceptance reports
___________________
Service graphics for
SI diagnostics
___________________
System Features
___________________
Standards and specifications
___________________
Appendix
1
2
3
4
5
6
7
8
9
A

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Summary of Contents for Siemens SINUMERIK 828D

  • Page 1 Description of the Safety Integrated Extended Functions SINUMERIK 828D, SINAMICS S120 ___________________ Commissioning the functions Safety Integrated ___________________ Example of commissioning with SINUMERIK 828D Function Manual ___________________ Acceptance tests and acceptance reports ___________________ Service graphics for SI diagnostics ___________________ System Features...
  • Page 2 Note the following: WARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems.

  • Page 3: Preface

    Siemens content: MDM (www.siemens.com/mdm) Training For information about the range of training courses, refer under: ● SITRAIN (www.siemens.com/sitrain) - training courses from Siemens for automation products, systems and solutions ● SinuTrain (www.siemens.com/sinutrain) - training software for SINUMERIK FAQs You can find Frequently Asked Questions in the Service&Support pages under Product...
  • Page 4 EC Declaration of Conformity The EC declaration of conformity for the EMC directive can be found in the Internet (www.siemens.com/automation/service&support). There, as search term, enter the number 15257461 or contact your local Siemens office. Safety Integrated Function Manual, 07/2012, 6FC5397-3EP40-3BA0...

  • Page 5: Table Of Contents

    Safe Operating Stop (SOS) ......................24 Safely Limited Speed (SLS)......................25 Safe Speed Monitor (SSM) ......................29 Safe Direction (SDI) ........................31 Commissioning the functions ........................33 Example of commissioning with SINUMERIK 828D................. 35 Planning ............................35 5.1.1 Creating a function table ......................35 5.1.2 From the function table to the logic diagram................37 Preconditions for commissioning ....................39...
  • Page 6 Table of contents 5.5.3 Setting parameters SLS1-4, SBC, SS1, SS2................60 SINUMERIK 828D control system ....................62 5.6.1 Signals between SINUMERIK and SINAMICS Safety Integrated..........62 5.6.2 Selecting SLS speeds ......................... 63 5.6.3 Wiring the terminals to the NCK inputs ..................64 Acceptance tests and acceptance reports ....................

  • Page 7: General Information About Sinamics Safety Integrated

    General information about SINAMICS Safety Integrated Supported functions All of the Safety Integrated functions available under SINUMERIK 828D/SINAMICS S120 are listed in this chapter. SINAMICS makes a distinction between Safety Integrated Basic Functions and Safety Integrated Extended Functions. The safety functions listed here conform to: ●...
  • Page 8 General information about SINAMICS Safety Integrated 1.1 Supported functions ● Safety Integrated Extended Functions These functions require an additional Safety license: Extended Functions with encoder require an encoder with Safety capability (see section "Reliable actual value acquisition with encoder system"). –...

  • Page 9: Examples Of How The Safety Functions Can Be Applied

    When a crane trolley is at the operating limit switch then it may only start in the opposite direction. NOTICE PROFIsafe function The PROFIsafe function for the SINUMERIK 828D has not been released. Safety Integrated Function Manual, 07/2012, 6FC5397-3EP40-3BA0...

  • Page 10: Drive Monitoring With Encoder

    General information about SINAMICS Safety Integrated 1.3 Drive monitoring with encoder Drive monitoring with encoder Overview of the Safety Integrated functions Functions Abbreviation Brief description Basic Safe Torque Off Safe torque off Functions Safe Stop 1 Safe stopping process in accordance with stop category 1 Safe Brake Control Safe brake control...

  • Page 11: Description Of Safety Integrated Basic Functions

    Description of Safety Integrated Basic Functions Overview This chapter should provide first-time users with a quick overview of the principle mode of operation of safety functions. The entry into the description of the safety functions is based on the definition according to standard EN 61800-5-2 and some simple examples for using the function.

  • Page 12: Safe Torque Off (Sto)

    Description of Safety Integrated Basic Functions 2.1 Safe Torque Off (STO) Safe Torque Off (STO) Definition Definition according to EN 61800-5-2: "The STO function prevents energy from being supplied to the motor, which can generate a torque." Select STO Examples of how the function can be used Example Possible solution After an Emergency Stop button has been...

  • Page 13: Safe Stop 1 (Ss1)

    Description of Safety Integrated Basic Functions 2.2 Safe Stop 1 (SS1) Safe Stop 1 (SS1) Definition Definition according to EN 61800-5-2: "The function SS1 brakes the motor and trips the function STO after a delay time." Select SS1 Example of how the function can be used Example Possible solution It is only permissible to open a protective door if the...

  • Page 14: Safe Brake Control (Sbc)

    Description of Safety Integrated Basic Functions 2.3 Safe Brake Control (SBC) Safe Brake Control (SBC) Overview The "Safe Brake Control" function (SBC) is used to control holding brakes that function according to the closed-circuit principle (e.g. motor holding brake). SBC is (if configured) initiated together with STO. he Motor Module/Safe Brake Relay then carries out the action and activates the outputs for the brake.
  • Page 15 Description of Safety Integrated Basic Functions 2.3 Safe Brake Control (SBC) For the "Safe Brake Control" function, the Motor/Power Module assumes a monitoring function to ensure that when the Control Unit fails or malfunctions the brake current is interrupted therefore closing the brake. The brake diagnostics can only reliably detect a malfunction in either of the switches (TB+, TB–) when the status changes, i.e.
  • Page 16 Description of Safety Integrated Basic Functions 2.3 Safe Brake Control (SBC) Safety Integrated Function Manual, 07/2012, 6FC5397-3EP40-3BA0...

  • Page 17: Description Of The Safety Integrated Extended Functions

    You require the following software option in order to use this function: "drive based SI-axis/spindle additional 1 axis/spindle" (MLFB: 6FC5800-0AC50-0YB0). Enter the associated license key via the operating software SINUMERIK Operate. References SINUMERIK 828D Turning and Milling Commissioning Manual, Chapter "Checking and entering licenses" Safety Integrated Function Manual, 07/2012, 6FC5397-3EP40-3BA0...

  • Page 18: Safe Torque Off (Sto)

    Description of the Safety Integrated Extended Functions 3.1 Safe Torque Off (STO) Safe Torque Off (STO) See also: For the control options and the functionality for "Safe Torque Off" (STO), refer to chapter "Description of Safety Integrated Basic Functions (Page 12)". Safety Integrated Function Manual, 07/2012, 6FC5397-3EP40-3BA0...

  • Page 19: Safe Stop 1 (Ss1)

    Description of the Safety Integrated Extended Functions 3.2 Safe Stop 1 (SS1) Safe Stop 1 (SS1) Definition Definition according to EN 61800-5-2: "The function SS1 brakes the motor, monitors the magnitude of the motor deceleration, and after a delay time, initiates the STO function." Select SS1 Example of how the function can be used Example...
  • Page 20 Description of the Safety Integrated Extended Functions 3.2 Safe Stop 1 (SS1) Acceleration monitoring with encoder For Extended Functions with encoder, there is only the "acceleration monitoring" mode: ● The inverter monitors the motor speed using the function SAM (Safe Acceleration Monitor).

  • Page 21: Safe Brake Control (Sbc)

    Description of the Safety Integrated Extended Functions 3.3 Safe Brake Control (SBC) Safe Brake Control (SBC) See also: For the control options and the functionality for "Safe Brake Control" (SBC), refer to chapter "Description of Safety Integrated Basic Functions (Page 14)". Safety Integrated Function Manual, 07/2012, 6FC5397-3EP40-3BA0...

  • Page 22: Safe Stop 2 (Ss2)

    Description of the Safety Integrated Extended Functions 3.4 Safe Stop 2 (SS2) Safe Stop 2 (SS2) Definition Definition according to EN 61800-5-2: "The function SS2 brakes the motor, monitors the magnitude of the motor deceleration, and after a delay time, initiates the SOS function." Select SS2 Example of how the function can be used Example...
  • Page 23 Description of the Safety Integrated Extended Functions 3.4 Safe Stop 2 (SS2) How does SS2 function in detail? The SS2 safety function operates as follows: ● The machine control selects the SS2 safety function using a fail-safe input: – If the motor is already at a standstill when selecting SS2, after a delay time, the inverter activates the Safe Operating Stop function (SOS).

  • Page 24: Safe Operating Stop (Sos)

    Description of the Safety Integrated Extended Functions 3.5 Safe Operating Stop (SOS) Safe Operating Stop (SOS) How does SOS function? This function serves for fail-safe monitoring of the standstill position of a drive. The protected machine areas can be entered without having to shut down the machine as long as SOS is active.

  • Page 25: Safely Limited Speed (Sls)

    Description of the Safety Integrated Extended Functions 3.6 Safely Limited Speed (SLS) Safely Limited Speed (SLS) Definition Definition according to EN 61800-5-2: "The SLS function prevents the motor from exceeding the specified speed limit." Select SLS Examples of how the function can be used Example Possible solution After opening a protective door, the machine...
  • Page 26 Description of the Safety Integrated Extended Functions 3.6 Safely Limited Speed (SLS) Note As an alternative to control via terminals, there is also an option to parameterize the SLS without selection function. In this case, the SLS function is permanently active after POWER See also: SINAMICS S120 Safety Integrated Function Manual, Chapter: "Commissioning the functions"...
  • Page 27 Description of the Safety Integrated Extended Functions 3.6 Safely Limited Speed (SLS) ● Without brake ramp monitoring with encoder: The inverter monitors the load velocity after the "delay time for SLS changeover" has expired. Advantage: Commissioning is simplified, because instead of the subfunction SBR or SAM of the alternative brake ramp monitoring, you only have to set the delay time.
  • Page 28 Description of the Safety Integrated Extended Functions 3.6 Safely Limited Speed (SLS) Switching over the monitoring limits When SLS is active, you can switch over between four different speed levels. An exception is "SLS without selection": In this case, there is only one limit. ●...

  • Page 29: Safe Speed Monitor (Ssm)

    Description of the Safety Integrated Extended Functions 3.7 Safe Speed Monitor (SSM) Safe Speed Monitor (SSM) Definition Definition according to EN 61800-5-2: "The SSM function supplies a safe output signal to indicate whether the motor speed is below a specified limit value." Example of how the function can be used Example Possible solution...
  • Page 30 Description of the Safety Integrated Extended Functions 3.7 Safe Speed Monitor (SSM) How does SSM function in detail? Prerequisites: ● The safety function SSM cannot be selected or deselected using external control signals. ● SSM is active, if you have set a monitoring speed > 0 for SSM . Evaluating the speed The inverter compares the load speed with the speed limit and signals if the limit value falls below the higher-level control.

  • Page 31: Safe Direction (Sdi)

    Description of the Safety Integrated Extended Functions 3.8 Safe Direction (SDI) Safe Direction (SDI) Definition Definition according to EN 61800-5-2: "The SDI function prevents that the motor shaft rotates in the unintended direction." Examples of how the function can be used Example Possible solution A protective door must only be opened if a drive moves...
  • Page 32 Description of the Safety Integrated Extended Functions 3.8 Safe Direction (SDI) Selecting and deselecting SDI Prerequisite: Adjust the inverter so that after selecting SDI it limits the speed to the direction of rotation permitted. As soon as the inverter detects the selection of SDI via a fail-safe input, the following happens: ●...

  • Page 33: Commissioning The Functions

    Commissioning the functions References A complete description of how to commission Safety Integrated functions can be found in: SINAMICS S120 Safety Integrated Function Manual, Chapter: "Commissioning the functions" Safety Integrated Function Manual, 07/2012, 6FC5397-3EP40-3BA0...
  • Page 34 Commissioning the functions Safety Integrated Function Manual, 07/2012, 6FC5397-3EP40-3BA0...

  • Page 35: Example Of Commissioning With Sinumerik 828D

    Example of commissioning with SINUMERIK 828D Planning 5.1.1 Creating a function table Identifying movements If Safety Integrated is to be used on a machine in order to estimate the danger caused by moving parts, all possible dangerous movements should be listed. Not only NC axes/spindles move, but also components such as the tool changer or chip conveyor.
  • Page 36 Example of commissioning with SINUMERIK 828D 5.1 Planning Example of a function table: State of the machine Drive Which state should be Is the function active? Check the NC active? response Doors closed SLS4 Movements not enabled controlled from the NC...

  • Page 37: From The Function Table To The Logic Diagram

    Example of commissioning with SINUMERIK 828D 5.1 Planning 5.1.2 From the function table to the logic diagram Creating a logic diagram In the next step, a simple logic diagram is made from the function table. The fail-safe inputs of the TM54F must be connected and this diagram serves as the basis for this.
  • Page 38 Example of commissioning with SINUMERIK 828D 5.1 Planning Example, logic diagram Figure 5-1 Logic diagram Safety Integrated Function Manual, 07/2012, 6FC5397-3EP40-3BA0...

  • Page 39: Preconditions For Commissioning

    Wiring the terminals and setting the machine data Topology The TM54F is supplied with 24 V and connected to the SINUMERIK 828D via DRIVE-CLiQ. For the SINUMERIK 828D, TM54F is connected to X101; for operation with a S120 Combi, the TM54F is connected to X102.
  • Page 40 Example of commissioning with SINUMERIK 828D 5.2 Preconditions for commissioning Configuration for commissioning Based on the following configuration, a commissioning example is described below: Figure 5-2 Basic configuration S120 Combi with 4 axes and Safety Integrated See also System Features (Page 77)

  • Page 41: Programming Of The Tm54F

    Example of commissioning with SINUMERIK 828D 5.3 Programming of the TM54F Programming of the TM54F 5.3.1 Configuring the drive groups Assigning the drive groups The drives are assigned to drive groups. Frequently, the feed axes are assigned to drive group 1, and the spindle to drive group 2. This is due to the fact that when the door is open, the spindle may not have to go into SOS, but into STO.
  • Page 42 Example of commissioning with SINUMERIK 828D 5.3 Programming of the TM54F Also in the "configuration" diagram, the safe input should be specified, with which the safety alarms are acknowledged. Furthermore, it must be specified as to which input should trigger the forced dormant error detection of the F-DI and F-DO.
  • Page 43 Example of commissioning with SINUMERIK 828D 5.3 Programming of the TM54F Some Extended Functions are assigned fixed levels, e.g. STO is not used in group 1 for the feed axes. In this case, the function must be permanently deselected or have level "1", "Statically inactive"...
  • Page 44 Example of commissioning with SINUMERIK 828D 5.3 Programming of the TM54F The following diagram shows the assignment of the F-DI for drive group 2. This group usually only includes the spindle of the machine tool. In the following figure, you can see that: ●...

  • Page 45: Connecting Safe Outputs

    Example of commissioning with SINUMERIK 828D 5.3 Programming of the TM54F 5.3.2 Connecting safe outputs F-DO "Internal event" This signal changes from "1" to "0" when a safety alarm occurs in the drive group, irrespective from which axis. The signal can be considered as a group error. The individual "Internal event"...

  • Page 46: Tm54F Terminal Description

    Example of commissioning with SINUMERIK 828D 5.3 Programming of the TM54F 5.3.3 TM54F terminal description Wiring the TM54F The logic is established with this hardware, which is shown as example in Chapter "From the function table to the logic diagram (Page 37) ". The inputs should be wired with two channels.
  • Page 47 Example of commissioning with SINUMERIK 828D 5.3 Programming of the TM54F Figure 5-8 Connection diagram for TM54F Safety Integrated Function Manual, 07/2012, 6FC5397-3EP40-3BA0...

  • Page 48: Control With Sirius 3Tk Or With Sirius 3Rk Relays

    Example of commissioning with SINUMERIK 828D 5.4 Control with SIRIUS 3TK or with SIRIUS 3RK relays Control with SIRIUS 3TK or with SIRIUS 3RK relays 5.4.1 Control of the TM54F with SIRIUS 3TK Hardware configuration Relays and also safety relays, such as the SIRIUS 3TK28, are used in this variant:...
  • Page 49 Example of commissioning with SINUMERIK 828D 5.4 Control with SIRIUS 3TK or with SIRIUS 3RK relays Circuit diagram for Emergency Stop with relay 3TK The diagram shows the wiring for the Emergency Stop, which is implemented in Safety Integrated as SS1 (Safe Stop 1):...
  • Page 50 Example of commissioning with SINUMERIK 828D 5.4 Control with SIRIUS 3TK or with SIRIUS 3RK relays Circuit diagram for door relay 3TK This diagram shows the wiring for the safety relay for the doors. DANGER A risk analysis must be made for each type of machine in order to estimate the hazards for personnel.
  • Page 51 Example of commissioning with SINUMERIK 828D 5.4 Control with SIRIUS 3TK or with SIRIUS 3RK relays Circuit diagram for F-DI of the TM54F The following diagram shows the wiring of the F-DI and the F-DO connections of the TM54F. Use the key-operated switch to select the operating mode: ●...
  • Page 52 Example of commissioning with SINUMERIK 828D 5.4 Control with SIRIUS 3TK or with SIRIUS 3RK relays Circuit diagram for the door switch 3SE5 322-0SD21 This diagram shows the wiring of the door switch: Actuator contact 3TK2821, +24V terminal A1 3TK2823,...

  • Page 53: Control Of The Tm54F With Sirius 3Rk

    Example of commissioning with SINUMERIK 828D 5.4 Control with SIRIUS 3TK or with SIRIUS 3RK relays 5.4.2 Control of the TM54F with SIRIUS 3RK Hardware configuration The SIRIUS 3RK3 Modular Safety System (MSS) is a further option that can be used to...
  • Page 54 Example of commissioning with SINUMERIK 828D 5.4 Control with SIRIUS 3TK or with SIRIUS 3RK relays Circuit diagram for the SIRIUS 3RK3 This diagram shows the wiring of the base module and the expansion modules: F-DI 1 deselect SOS X521...
  • Page 55 Example of commissioning with SINUMERIK 828D 5.4 Control with SIRIUS 3TK or with SIRIUS 3RK relays Circuit diagram for F-DI of the TM54F The following diagram shows the wiring of the F-DI and the F-DO connections of the TM54F: TM54F...

  • Page 56: Configuration Of The Si Functions For The Drive

    Example of commissioning with SINUMERIK 828D 5.5 Configuration of the SI functions for the drive Configuration of the SI functions for the drive 5.5.1 Activating Safety Integrated Activating Safety Integrated In addition to the settings for the TM54F, the parameters must also be set in the drive. With the first setting in the drive, the type of safety monitoring type is defined: ●...
  • Page 57 Example of commissioning with SINUMERIK 828D 5.5 Configuration of the SI functions for the drive Parameters on the "Configuration" tab Parameters for test stop, e.g. signal source for the test stop trigger, and parameters for Safe Speed Monitor (SSM) are adapted in the "Configuration" dialog box.
  • Page 58 Example of commissioning with SINUMERIK 828D 5.5 Configuration of the SI functions for the drive For a drive (here "rotary axis/spindle"), the output should also be assigned to "Forced dormant error detection". As parameter, a terminal on the PPU can be entered, e.g. X122.9...

  • Page 59: Encoder Parameterization

    Example of commissioning with SINUMERIK 828D 5.5 Configuration of the SI functions for the drive 5.5.2 Encoder parameterization Encoder parameterization Encoder data, gear ratios and leadscrew pitch are entered at "Encoder parameterization". The settings of gear ratio or spindle pitch must be assigned the same values as in the axis machine data.

  • Page 60: Setting Parameters Sls1-4, Sbc, Ss1, Ss2

    Example of commissioning with SINUMERIK 828D 5.5 Configuration of the SI functions for the drive 5.5.3 Setting parameters SLS1-4, SBC, SS1, SS2 Checking and adapting motion monitoring Further settings are required for the configuration of the safely-limited speed. ● For SLS, the four SLS levels must be checked.
  • Page 61 Example of commissioning with SINUMERIK 828D 5.5 Configuration of the SI functions for the drive Safe Brake Control (SBC) Safe Brake Control (SBC) can be enabled for axes with a holding brake. Figure 5-23 SERVO: Safe brake control Then copy the parameters and activate the settings.

  • Page 62: Sinumerik 828D Control System

    Some signals that display Safety Integrated states in the drive must be communicated to the SINUMERIK 828D so that it does not try to traverse an axis when, for example, SOS is active. A Safety Integrated monitoring function responds in this case.

  • Page 63: Selecting Sls Speeds

    Example of commissioning with SINUMERIK 828D 5.6 SINUMERIK 828D control system 5.6.2 Selecting SLS speeds Setting machine data The machine data for speeds must be set so that the active SLS is not exceeded in normal operation. SLS4 Machine data...

  • Page 64: Wiring The Terminals To The Nck Inputs

    The following diagram shows a recommendation for the interface wiring between the PLC and SINAMICS: X122 Start test stop LM ready for power X132 X242 SLS limit 2 Test stop overdue SOS selected SS1 active Figure 5-24 Wiring the terminals of the SINUMERIK 828D Safety Integrated Function Manual, 07/2012, 6FC5397-3EP40-3BA0...
  • Page 65 Example of commissioning with SINUMERIK 828D 5.6 SINUMERIK 828D control system For the following settings, p0728 must be changed to define a terminal as input or output: Terminal Signal Parameters in the drive X122.2 OFF3 is not connected. p0849[0]=2 Emergency Stop is connected via SS1.
  • Page 66 Example of commissioning with SINUMERIK 828D 5.6 SINUMERIK 828D control system Safety Integrated Function Manual, 07/2012, 6FC5397-3EP40-3BA0...

  • Page 67: Acceptance Tests And Acceptance Reports

    Acceptance tests and acceptance reports General requirements Overview The acceptance test requirements (configuration check) for the safety functions of electric drives are based on DIN EN 61800-5-2). The acceptance test "configuration check" is named in this standard. ● Description of the application including a picture ●...

  • Page 68: Acceptance Test Structure

    • The information in Chapter, "Commissioning the functions" must be taken into account. • The subsequent acceptance report represents an example or a recommendation. • An acceptance report template in electronic format is available at your local Siemens sales office.
  • Page 69 Acceptance tests and acceptance reports 6.2 Acceptance test structure What is meant by "acceptance test mode"? The acceptance test mode can be activated for a definable period (p9358/p9558) by setting the appropriate parameters (p9370/p9570). It tolerates deliberate limit violations during the acceptance test.
  • Page 70 Acceptance tests and acceptance reports 6.2 Acceptance test structure Safety Integrated Function Manual, 07/2012, 6FC5397-3EP40-3BA0...

  • Page 71: Service Graphics For Si Diagnostics

    Service graphics for SI diagnostics This is how you display the status for SI diagnostics Precondition The "Safety Integrated" function is activated. Select status display Procedure: 1. Select the "Diagnostics" operating area. 2. Press the menu forward key and the "Safety" softkey. The "Safety Integrated Status (Drive)"...
  • Page 72 Service graphics for SI diagnostics 7.1 This is how you display the status for SI diagnostics Example of Basic Functions Figure 7-1 Status display Safety Integrated Function Manual, 07/2012, 6FC5397-3EP40-3BA0...
  • Page 73 Service graphics for SI diagnostics 7.1 This is how you display the status for SI diagnostics Example of Basic and Extended Functions Figure 7-2 Status display Safety Integrated Function Manual, 07/2012, 6FC5397-3EP40-3BA0...
  • Page 74 Service graphics for SI diagnostics 7.1 This is how you display the status for SI diagnostics Displaying checksums Procedure: 1. Select the "Diagnostics" operating area. 2. Press the menu forward key and the "Safety" softkey. 3. Press the "SI checksum" softkey. The dialog "Safety Integrated checksums"...

  • Page 75: This Is How You Confirm The Replacement Of Si Hardware

    Service graphics for SI diagnostics 7.2 This is how you confirm the replacement of SI hardware This is how you confirm the replacement of SI hardware Preconditions Safety Integrated Extended Functions have been configured. The access level is as a minimum key-operated switch level 3. Replacing hardware when necessary Error messages are output, if, for a drive with assigned Safety Integrated Extended Functions, the Motor Module or the TM54F Terminal Module is replaced using a spare part.

  • Page 76: Safety Integrated Alarms

    SINUMERIK Operate , then you can appropriately adapt the following machine data: MD13150 $MNS_SINAMICS_ALARM_MASK. The display of SINAMICS faults and alarms in SINUMERIK Operate is controlled using parameter p3117 = 1 according to the default setting. References SINUMERIK 828D, Diagnostics Manual "Alarms" Safety Integrated Function Manual, 07/2012, 6FC5397-3EP40-3BA0...

  • Page 77: System Features

    Go into the Internet under: http://automation.siemens.com To subscribe to the newsletter, please proceed as follows: 1. Select the desired language for the webpage.
  • Page 78 System Features 8.1 Latest information 7. Open the subject area "Safety Engineering - Safety Integrated". You will now be shown which newsletter is available for this particular subject area or topic. You can subscribe to the appropriate newsletter by clicking on the box. If you require more detailed information on the newsletters then please click on these.

  • Page 79: Certification

    ● EN 61800-5-2 In addition, most of the safety functions of the SINAMICS S have been certified by independent institutes. An up-to-date list of certified components is available on request from your local Siemens office. Safety Integrated Function Manual, 07/2012, 6FC5397-3EP40-3BA0...

  • Page 80: Safety Instructions

    System Features 8.3 Safety instructions Safety instructions Note Additional safety information and residual risks not specified in this section are included in the relevant sections of this Function Manual. DANGER Safety Integrated can be used to minimize the level of risk associated with machines and plants.
  • Page 81 System Features 8.3 Safety instructions WARNING EN 60204-1 The Emergency Stop function must bring the machine to a standstill in accordance with stop category 0 or 1 (STO or SS1). The machine must not restart automatically after EMERGENCY STOP. When individual safety functions (Extended Functions) are deactivated, an automatic restart is permitted under certain circumstances depending on the risk analysis (except when Emergency Stop is reset).
  • Page 82 System Features 8.3 Safety instructions WARNING • For a 1-encoder system, encoder faults are detected using different hardware and software monitoring functions. It is not permissible to disable these monitoring functions and they must be parameterized carefully. Depending on the fault type and the responding monitoring function, stop function category 0 or 1 to EN 60204-1 (fault response functions STOP A or STOP B to Safety Integrated) is selected (see table "Overview of stop responses"...

  • Page 83: Probability Of Failure Of The Safety Functions (Pfh Value)

    (number of drives, control type, number of encoders used). The various integrated safety functions are not differentiated. The PHF values can be requested from your local sales office. The PFH values of all Safety components from Siemens are available in the "Safety Evaluation Tool"; see: https://www.automation.siemens.com/mcms/safety- integrated/de/maschinensicherheit/safety-evaluation-tool/Seiten/Default.aspx...

  • Page 84: Residual Risk

    System Features 8.5 Residual risk Residual risk The fault analysis enables the machine manufacturer to determine the residual risk at his machine with regard to the drive unit. The following residual risks are known: WARNING Due to the intrinsic potential of hardware faults, electrical systems are subject to additional residual risk, which can be expressed by means of the PFH value.
  • Page 85 System Features 8.5 Residual risk WARNING 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).
  • Page 86 System Features 8.5 Residual risk Safety Integrated Function Manual, 07/2012, 6FC5397-3EP40-3BA0...

  • Page 87: Standards And Specifications

    Standards and specifications General Objective Manufacturers and operators of technical equipment and products are responsible in minimizing the risk from plants, machines and other technical equipment corresponding to state-of-the-art technology. Regulations and standards are essential documents that define the minimum requirements to minimize risks. By maintaining these minimum requirements, the company erecting a plant or a manufacturer of a machine or a piece of equipment can prove that they have fulfilled their obligation to exercise care and diligence.
  • Page 88 Standards and specifications 9.1 General In this case, it is necessary to use specially qualified technology that fulfills the requirements described in the associated Standards. The requirements to achieve functional safety are based on the following basic goals: ● Avoiding systematic faults ●...

  • Page 89: Safety Of Machinery In Europe

    Standards and specifications 9.2 Safety of machinery in Europe Safety of machinery in Europe 9.2.1 Safety of machinery in Europe The EU Directives that apply to the implementation of products are based on Article 95 of the EU contract, which regulates the free exchange of goods. These are based on a new global concept ("new approach", "global approach"): ●...
  • Page 90 Standards and specifications 9.2 Safety of machinery in Europe Type A standards/basic standards A standards include basic terminology and definitions relating to all types of machine. This includes EN ISO 12100-1 (previously EN 292-1) "Safety of Machines, Basic Terminology, General Design Principles." A standards are aimed primarily at the bodies responsible for setting the B and C standards.

  • Page 91: Machine Safety In The Usa

    Standards and specifications 9.3 Machine safety in the USA Machine safety in the USA 9.3.1 Machine safety in the USA A key difference between the USA and Europe in the legal requirements regarding safety at work is that, in the USA, no legislation exists regarding machinery safety that is applicable in all of the states and that defines the responsibility of the manufacturer/supplier.

  • Page 92: Nrtl Listing

    Standards and specifications 9.3 Machine safety in the USA 9.3.3 NRTL listing To protect employees, all electrical equipment used in the USA must be certified for the planned application by a "Nationally Recognized Testing Laboratory" (NRTL) certified by the OSHA. NRTLs are authorized to certify equipment and material by means of listing, labeling, or similar.

  • Page 93: Ansi B11

    Standards and specifications 9.3 Machine safety in the USA 9.3.5 ANSI B11 ANSI B11 standards are joint standards developed by associations such as the Association for Manufacturing Technology (AMT) and the Robotic Industries Association (RIA). The hazards of a machine are evaluated by means of a risk analysis/assessment. The risk analysis is an important requirement in accordance with NFPA 79, ANSI/RIA 15.06, ANSI B11.TR-3 and SEMI S10 (semiconductors).

  • Page 94: Machine Safety In Japan

    Standards and specifications 9.4 Machine safety in Japan Machine safety in Japan 9.4.1 Machine safety in Japan The situation in Japan is different from that in Europe and the US. Legislation such as that prescribed in Europe does not exist. Similarly, product liability does not play such an important role as it does in the US.

  • Page 95: Equipment Regulations

    Standards and specifications 9.5 Equipment regulations Equipment regulations 9.5.1 Equipment regulations In addition to the requirements of the guidelines and standards, company-specific requirements must be taken into account. Large corporations in particular (e.g. automobile manufacturers) make stringent demands regarding automation components, which are often listed in their own equipment specifications.

  • Page 96: Other Safety-Related Issues

    Standards and specifications 9.6 Other safety-related issues Other safety-related issues 9.6.1 Information sheets issued by the Employer's Liability Insurance Association Safety-related measures to be implemented cannot always be derived from directives, standards, or regulations. In this case, supplementary information and explanations are required.

  • Page 97: Appendix

    Appendix Abbreviations Safety Integrated Function Manual, 07/2012, 6FC5397-3EP40-3BA0...
  • Page 98 Appendix A.1 Abbreviations Safety Integrated Function Manual, 07/2012, 6FC5397-3EP40-3BA0...
  • Page 99 Appendix A.1 Abbreviations Safety Integrated Function Manual, 07/2012, 6FC5397-3EP40-3BA0...
  • Page 100 Appendix A.1 Abbreviations Safety Integrated Function Manual, 07/2012, 6FC5397-3EP40-3BA0...
  • Page 101 Appendix A.1 Abbreviations Safety Integrated Function Manual, 07/2012, 6FC5397-3EP40-3BA0...
  • Page 102 Appendix A.1 Abbreviations Safety Integrated Function Manual, 07/2012, 6FC5397-3EP40-3BA0...
  • Page 103 Appendix A.1 Abbreviations Safety Integrated Function Manual, 07/2012, 6FC5397-3EP40-3BA0...
  • Page 104 Appendix A.1 Abbreviations Safety Integrated Function Manual, 07/2012, 6FC5397-3EP40-3BA0...
  • Page 105 Appendix A.1 Abbreviations Safety Integrated Function Manual, 07/2012, 6FC5397-3EP40-3BA0...

  • Page 106: Documentation Overview Sinumerik 828D

    Appendix A.2 Documentation overview SINUMERIK 828D Documentation overview SINUMERIK 828D Safety Integrated Function Manual, 07/2012, 6FC5397-3EP40-3BA0...

  • Page 107: Index

    Index Replacing the hardware, 75 Residual risk, 85 Acknowledging alarms, 42 Acknowledgment button, 36 S120 Combi, 39 Safe Acceleration Monitor (SAM) Basic Functions for SS1, 20 SBC, 14 For SS2, 23 SS1, 13 Safe Brake Control STO, 12 Extended Functions, 21 SBC, 14, 21 Safe Direction, 31 Safe Operating Stop...
  • Page 108 Index Safe Operating Stop, 24 Basic Functions, 13 Delay time, 20 Enable, 20 Extended Functions, 19 Principle of operation, 13, 19 Protective door, 9, 13, 19 Safe Stop 1, 13, 19 Shutdown speed, 20 Time response, 13, 19 Tolerance, 20 SS2, 22 Braking behavior, 23 Diagnostics, 23...

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