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Siemens SINUMERIK Series Function Manual

Safety integrated
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SINUMERIK
SINUMERIK 828D, SINAMICS S120
Safety Integrated
Function Manual
Valid for:
CNC software
Version 4.7 SP2
10/2015
6FC5397-3EP40-5BA3
Preface
Safety instructions
Overview of Safety
Integrated functions
Commissioning - drive-based
Commissioning - TM54F
Commissioning - acceptance
tests
Commissioning - application
example
Diagnostics
System Features
Standards and specifications
Appendix
1
2
3
4
5
6
7
8
9
A
Table of Contents
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Summary of Contents for Siemens SINUMERIK Series

  • Page 1 Preface Safety instructions Overview of Safety Integrated functions SINUMERIK Commissioning - drive-based SINUMERIK 828D, SINAMICS S120 Safety Integrated Commissioning - TM54F Commissioning - acceptance tests Function Manual Commissioning - application example Diagnostics System Features Standards and specifications Appendix Valid for: CNC software Version 4.7 SP2 10/2015...
  • 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, 10/2015, 6FC5397-3EP40-5BA3...

  • Page 5: Table Of Contents

    Table of contents Preface.................................3 Safety instructions............................9 Fundamental safety instructions....................9 1.1.1 General safety instructions.......................9 1.1.2 Handling electrostatic sensitive devices (ESD)..............12 1.1.3 Industrial security........................13 1.1.4 Residual risks of power drive systems...................13 Safety Integrated safety instructions..................16 Probability of failure of the safety functions................19 Residual risk...........................20 Overview of Safety Integrated functions.....................23 Supported functions.......................24...
  • Page 6 Table of contents 3.7.4 Safety Integrated overview - checksums................60 Making the basic safety settings....................62 3.8.1 Calling the basic setting dialog....................62 3.8.2 Options...........................64 3.8.3 Configuration..........................66 3.8.4 Encoder parameterization......................67 3.8.5 Telegram configuration......................70 Safety Integrated functions....................71 3.9.1 Calling function dialogs......................71 3.9.2 Safe Torque Off (STO)/Safe Stop 1 (SS1) - basis function............72 3.9.3 Safe Torque Off (STO) - extended function................73 3.9.4...
  • Page 7 Table of contents Parameterizing the TM54F....................139 6.3.1 Configuring the drive groups....................139 6.3.2 Connecting safe outputs......................142 6.3.3 TM54F terminal description....................144 Controlling with the SIRIUS 3SK or SIRIUS 3RK relay............146 6.4.1 Controlling the TM54F with SIRIUS 3SK................146 6.4.2 Control of the TM54F with SIRIUS 3RK................151 Configuration of the SI functions for the drive..............154 6.5.1 Activating Safety Integrated....................154...
  • Page 8 Table of contents 9.3.4 NFPA 79..........................192 9.3.5 ANSI B11..........................193 Machine safety in Japan......................194 9.4.1 Machine safety in Japan......................194 Equipment regulations......................195 9.5.1 Equipment regulations......................195 Other safety-related issues....................196 9.6.1 Information sheets issued by the Employer's Liability Insurance Association......196 9.6.2 Additional references......................196 Appendix..............................197 Abbreviations........................197 Documentation overview SINUMERIK 828D...............200 Index.................................201...

  • Page 9: Safety Instructions

    Safety instructions Fundamental safety instructions 1.1.1 General safety instructions DANGER Danger to life due to live parts and other energy sources Death or serious injury can result when live parts are touched. ● Only work on electrical devices when you are qualified for this job. ●...
  • Page 10 Safety instructions 1.1 Fundamental safety instructions WARNING Danger to life when live parts are touched on damaged devices Improper handling of devices can cause damage. For damaged devices, hazardous voltages can be present at the enclosure or at exposed components; if touched, this can result in death or severe injury. ●...
  • Page 11 Safety instructions 1.1 Fundamental safety instructions WARNING Danger to life through unexpected movement of machines when using mobile wireless devices or mobile phones Using mobile wireless devices or mobile phones with a transmit power > 1 W closer than approx. 2 m to the components may cause the devices to malfunction, influence the functional safety of machines therefore putting people at risk or causing material damage.

  • Page 12: Handling Electrostatic Sensitive Devices (Esd)

    Safety instructions 1.1 Fundamental safety instructions WARNING Danger to life or malfunctions of the machine as a result of incorrect or changed parameterization As a result of incorrect or changed parameterization, machines can malfunction, which in turn can lead to injuries or death. ●...

  • Page 13: Industrial Security

    Siemens recommends strongly that you regularly check for product updates. For the secure operation of Siemens products and solutions, it is necessary to take suitable preventive action (e.g. cell protection concept) and integrate each component into a holistic, state-of-the-art industrial security concept.
  • Page 14 Safety instructions 1.1 Fundamental safety instructions When assessing the machine's risk in accordance with the respective local regulations (e.g., EC Machinery Directive), the machine manufacturer must take into account the following residual risks emanating from the control and drive components of a drive system: 1.
  • Page 15 Safety instructions 1.1 Fundamental safety instructions Note The components must be protected against conductive contamination (e.g. by installing them in a control cabinet with degree of protection IP54 according to IEC 60529 or NEMA 12). Assuming that conductive contamination at the installation site can definitely be excluded, a lower degree of cabinet protection may be permitted.

  • Page 16: Safety Integrated Safety Instructions

    Safety instructions 1.2 Safety Integrated safety instructions Safety Integrated safety instructions Additional safety instructions and residual risks Additional safety information and residual risks not specified in this section 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.
  • Page 17 Safety instructions 1.2 Safety Integrated safety instructions WARNING Danger to life when the system powers up after hardware and/or software has been changed or replaced 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.
  • Page 18 Safety instructions 1.2 Safety Integrated safety instructions WARNING Danger to life as a result of different responses of the Safety Integrated functions when replacing a Motor Module or a motor Motor Modules or the motor must be replaced with a device of the same type, as the parameter settings will otherwise lead to an incorrect response of the Safety Integrated functions.

  • Page 19: Probability Of Failure Of The Safety Functions

    ● The PFH values of the individual safety components of SINUMERIK 828 and SINAMICS S120 are available in theInternet (https://support.industry.siemens.com/cs/ document/76254308?lc=en-WW). ● The PFH values of all safety components from Siemens are available in the Safety Evaluation Tool (http://www.industry.siemens.com/topics/global/en/safety-integrated/ machine-safety/safety-evaluation-tool/Pages/default.aspx).

  • Page 20: Residual Risk

    Safety instructions 1.4 Residual risk 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 to life as a result of hardware faults relating to the intrinsic principle: PFH value 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 21 Safety instructions 1.4 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).
  • Page 22 Safety instructions 1.4 Residual risk Safety Integrated Function Manual, 10/2015, 6FC5397-3EP40-5BA3...

  • Page 23: Overview Of Safety Integrated Functions

    Overview of Safety Integrated functions 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 24: Supported Functions

    Overview of Safety Integrated functions 2.1 Supported functions Supported functions All of the Safety Integrated functions available under SINUMERIK 828D/SINAMICS S120 are listed in this chapter. A distinction is made between Safety Integrated basic functions and Safety Integrated extended functions. The safety functions listed are in compliance with international safety requirements (see Chapter Certifications (Page 185)).
  • Page 25 Overview of Safety Integrated functions 2.1 Supported functions The following Safety Integrated functions (SI functions) are available: ● Safety Integrated basic functions Safety Integrated basic functions are included as standard in the drive and can be used without requiring an additional license. They are always available. These functions do not require an encoder and/or do not place any special requirements on the encoder used.
  • Page 26 Overview of Safety Integrated functions 2.1 Supported functions – Safe Brake Test (SBT) The "Safe Brake Test" function (SBT) checks the required holding torque of a brake (operational or holding brake). This function is in conformance with SIL 1 according to IEC 61508 and to PLd/Cat.

  • Page 27: Safety Integrated Basic Functions

    Overview of Safety Integrated functions 2.2 Safety Integrated Basic Functions Safety Integrated Basic Functions 2.2.1 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."...

  • Page 28: Safe Stop 1 (Ss1)

    Overview of Safety Integrated functions 2.2 Safety Integrated Basic Functions 2.2.2 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 ●...

  • Page 29: Safe Brake Control (Sbc)

    Overview of Safety Integrated functions 2.2 Safety Integrated Basic Functions 2.2.3 Safe Brake Control (SBC) Definition according to EN 61800-5-2: "The SBC function supplies a safe output signal to control a holding brake." Figure 2-1 Safe Brake Control (SBC) Example of how the function can be used ●...

  • Page 30: Safety Integrated Extended Functions

    Overview of Safety Integrated functions 2.3 Safety Integrated Extended Functions Safety Integrated Extended Functions Precondition A license is required to use the Safety Integrated Extended Functions. Software option You require the following software option in order to use this function: "drive based SI-axis/spindle additional 1 axis/spindle".
  • Page 31 Overview of Safety Integrated functions 2.3 Safety Integrated Extended Functions Example of how the function can be used ● For an Emergency Stop, a drive must be braked as quickly as possible, and then transitioned into STO. How does SS1 function in detail? Using the SS1 function, the inverter brakes the motor and monitors the absolute speed.

  • Page 32: Safe Brake Control (Sbc)

    Overview of Safety Integrated functions 2.3 Safety Integrated Extended Functions Acceleration monitoring For Extended Functions, there is only the "Acceleration monitoring" mode: ● The inverter monitors the motor speed using the function SAM (Safe Acceleration Monitor). ● The inverter prevents the motor from re-accelerating by continuously adjusting the monitoring threshold to the decreasing speed.

  • Page 33: Safe Operating Stop (Sos)

    Overview of Safety Integrated functions 2.3 Safety Integrated Extended Functions 2.3.4 Safe Operating Stop (SOS) Definition Definition according to EN 61800-5-2: "The function is used to safely monitor the standstill position of a drive." SOS selection Example of how the function can be used ●...

  • Page 34: Safe Stop 2 (Ss2)

    Overview of Safety Integrated functions 2.3 Safety Integrated Extended Functions Figure 2-2 Standstill tolerance 2.3.5 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 Safety Integrated Function Manual, 10/2015, 6FC5397-3EP40-5BA3...
  • Page 35 Overview of Safety Integrated functions 2.3 Safety Integrated Extended Functions Example of how the function can be used ● Controlled braking of a drive in SOS. How does SS2 function in detail? Overview The safety function SS2 monitors the load speed and initiates the SOS function if the SS2 delay time has expired.

  • Page 36: Safely Limited Speed (Sls)

    Overview of Safety Integrated functions 2.3 Safety Integrated Extended Functions Braking response Figure 2-3 Braking behavior and diagnostics of the safety function SS2 (Safe Stop 2) 2.3.6 Safely Limited Speed (SLS) Definition Definition according to EN 61800-5-2: "The SLS function prevents the motor from exceeding the specified speed limit." Safety Integrated Function Manual, 10/2015, 6FC5397-3EP40-5BA3...
  • Page 37 Overview of Safety Integrated functions 2.3 Safety Integrated Extended Functions Select SLS Examples of how the function can be used ● Traversing axes in the setting up mode with the protective doors open. How does SLS function in detail? 1. The inverter detects the selection of SLS using a fail-safe input. 2.
  • Page 38 Overview of Safety Integrated functions 2.3 Safety Integrated Extended Functions If the setpoint velocity limit is interconnected to the ramp-function generator, then the inverter limits the velocity to a value below the SLS monitoring threshold and brakes the motor with the AUS3 ramp-down time.
  • Page 39 Overview of Safety Integrated functions 2.3 Safety Integrated Extended Functions For SLS, as monitoring function only SAM (Safe Acceleration Monitor) is available. ● Without brake ramp monitoring: The inverter monitors the load velocity after the "delay time for SLS changeover" has expired.

  • Page 40: Safe Speed Monitor (Ssm)

    Overview of Safety Integrated functions 2.3 Safety Integrated Extended Functions Switching over 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 41 Overview of Safety Integrated functions 2.3 Safety Integrated Extended Functions Note SSM is a pure signaling function. Contrary to other Safety Integrated functions, a violation of the SSM limit does not result in a drive-based stop response. Example of how the function can be used ●...

  • Page 42: Safe Direction (Sdi)

    Overview of Safety Integrated functions 2.3 Safety Integrated Extended Functions Figure 2-4 Time response of the safety function SSM (Safe Speed Monitor) 2.3.8 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 ●...
  • Page 43 Overview of Safety Integrated functions 2.3 Safety Integrated Extended Functions In addition, you can parameterize SDI so that SDI limits the speed to values in the permitted direction. Independently of one another, you can parameterize as to whether SDI limits the values in the positive and/or negative direction.

  • Page 44: Safely-Limited Position (Slp)

    Overview of Safety Integrated functions 2.3 Safety Integrated Extended Functions Selecting and deselecting SDI As soon as the inverter detects the selection of SDI via a fail-safe input, the following happens: ● You can also set a delay time, within which time you can ensure that the inverter moves in the enabled (safe) direction.

  • Page 45: Safe Brake Test (Sbt)

    Overview of Safety Integrated functions 2.3 Safety Integrated Extended Functions Function Safely-Limited Position (safely limited position, SLP) is used to safely monitor the limits of two traversing or positioning ranges that are switched between using a safe signal. Examples of how the function can be used ●...
  • Page 46 Overview of Safety Integrated functions 2.3 Safety Integrated Extended Functions Safety Integrated Function Manual, 10/2015, 6FC5397-3EP40-5BA3...

  • Page 47: Commissioning - Drive-Based

    Commissioning - drive-based Introduction Commissioning mode As long as the displayed drive is not in the commissioning mode, most of the entry fields are deactivated. This mode is subsequently called the view mode. The drive must be in the commissioning mode in order to commission the safety functions. This has the following special feature: The safety-relevant parameters are monitored by the real-time software using an actual checksum.
  • Page 48 Commissioning - drive-based 3.1 Introduction Hardware replacement If a hardware component is replaced after completing the safety commissioning then the hardware replacement must be confirmed. Confirmation is required when replacing the following hardware components: ● Control Unit ● Motor Module ●...

  • Page 49: Activating The Commissioning Mode

    Commissioning - drive-based 3.2 Activating the commissioning mode Activating the commissioning mode You can call the commissioning mode both for the safety settings as well as for the individual safety functions. Procedure Select the "Start-up" operating area. Press the menu forward key and the "Safety" softkey. Press the "Settings"...
  • Page 50 Commissioning - drive-based 3.2 Activating the commissioning mode Press the "Activate for all drives" softkey to activate the commissioning mode for all drives. This softkey is only visible if there are several drives. - OR - Press the "OK" softkey to activate the commissioning mode for the actual drive.

  • Page 51: Canceling The Commissioning Mode

    Commissioning - drive-based 3.3 Canceling the commissioning mode Canceling the commissioning mode The commissioning mode can be immediately exited if no safety parameters were changed. If safety parameters were changed, before exiting the commissioning mode, it still has to be defined what should happen with the modified safety parameters.

  • Page 52: Exit The Commissioning Mode

    Commissioning - drive-based 3.4 Exit the commissioning mode Exit the commissioning mode The commissioning mode can be immediately exited if no safety parameters were changed. If safety parameters were changed, before exiting the commissioning mode, it still has to be defined what should happen with the modified safety parameters.
  • Page 53 Commissioning - drive-based 3.4 Exit the commissioning mode Press the "Copy all drives" softkey. In the commissioning mode, modified SI data of all drives is copied to the 2nd safety monitoring channel. This softkey is only visible if there are several drives. For both copy options, a prompt is then issued for subsequent actions, which are necessary to exit the commissioning mode.

  • Page 54: Copying Or Confirming Si Data

    Commissioning - drive-based 3.5 Copying or confirming SI data Copying or confirming SI data As soon as the commissioning mode has been activated for a drive, the appropriate parameters can be changed. The parameters are acquired for the first monitoring channel. Using the "Copy SI data"...
  • Page 55 Commissioning - drive-based 3.5 Copying or confirming SI data Confirm SI data The commissioning mode is active. You wish to confirm the SI data ac‐ quired and exit the commissioning mode. Press the ">>" softkey to display the softkeys of the second vertical soft‐ key bar.

  • Page 56: Working With Parameter Lists

    Commissioning - drive-based 3.6 Working with parameter lists Working with parameter lists As alternative to the dialog windows, you can also configure the basic safety settings and functions directly via a parameter list. The parameter list can be called from the dialog window of the particular safety basic setting or safety function.

  • Page 57: Safety Overview

    Commissioning - drive-based 3.7 Safety overview Safety overview 3.7.1 Calling the overview and detailed views Procedure Select the "Start-up" operating area. Press the menu forward key and the "Safety" softkey. Press the "Overview" softkey if the "Overview" setting area is not active. Overview - calling the details Press the "Details"...

  • Page 58: Safety Integrated Overview

    Commissioning - drive-based 3.7 Safety overview 3.7.2 Safety Integrated overview The most important information about the active safety functions is displayed in the "Overview" window: Figure 3-2 Overview ● Axis/drive All NC axes and drives in the system are displayed in this column. ●...

  • Page 59: Safety Integrated Overview - Details

    Commissioning - drive-based 3.7 Safety overview Other options You can supplement or switch over the display in the "Overview" window: ● Using the "Safe drives" softkey, you can toggle between the displays of "All drives" and "Safe drives". ● Using the "Confirm SI HW" softkey, you can confirm that hardware components have been replaced after safety commissioning has been completed.

  • Page 60: Safety Integrated Overview - Checksums

    Commissioning - drive-based 3.7 Safety overview ● Status symbols: The parameters are evaluated through two channels. The status symbols indicate as to whether the parameters are identical in both channels. – Green: Parameterization identical in the 1st and 2nd monitoring channels –...
  • Page 61 Commissioning - drive-based 3.7 Safety overview The checksums are read from the SI parameters. An overview is provided below: Monitoring channel 1 (Control Unit) Monitoring channel 2 (Motor Module) Actual checksum Reference checksum Actual checksum Reference checksum Extended functions Motion monitoring r9728[0] p9729[0] r9398[0]...

  • Page 62: Making The Basic Safety Settings

    Commissioning - drive-based 3.8 Making the basic safety settings Making the basic safety settings 3.8.1 Calling the basic setting dialog Procedure Select the "Start-up" operating area. Press the menu forward key and the "Safety" softkey. Press the "Settings" softkey. Safety Integrated Function Manual, 10/2015, 6FC5397-3EP40-5BA3...
  • Page 63 Commissioning - drive-based 3.8 Making the basic safety settings For each drive, the required basic setting ranges can be called using softkeys with the same name. Press the appropriate softkey: ● "Options" ● "Configuration" ● "Encoder parameterization" ● "Telegram configuration" Select the required drive using softkey "Drive+", or "Drive-".

  • Page 64: Options

    Commissioning - drive-based 3.8 Making the basic safety settings 3.8.2 Options In the "Settings - Options" window, you can select and enable the safety functions for the selected drive. Figure 3-5 Options Safety Integrated Function Manual, 10/2015, 6FC5397-3EP40-5BA3...
  • Page 65 Commissioning - drive-based 3.8 Making the basic safety settings The following settings are possible: ● Selecting a safety function: – The selected safety function defines the remaining setting options for the safety functions. – The selection of "Function specification" is orientated according to the activated safety function.

  • Page 66: Configuration

    Commissioning - drive-based 3.8 Making the basic safety settings 3.8.3 Configuration Precondition The "Settings - Configuration" window is only available if beforehand an extended safety function was selected for the actual drive (see Options (Page 64)). Settings You can make the following settings in the "Settings - Configuration" window: Figure 3-6 Configuration ●...

  • Page 67: Encoder Parameterization

    Commissioning - drive-based 3.8 Making the basic safety settings ● Test time, pulse cancellation (p9557) Sets the time in ms when, after the test stop has been initiated, STO must become active. ● Forced checking procedure timer (p9559) Sets the time interval in hours for carrying out dynamization and testing the safety motion monitoring functions integrated in the drive.
  • Page 68 Commissioning - drive-based 3.8 Making the basic safety settings Setting range "Encoder selection, encoder data and actual value synchronization" The following settings are possible in the window "Settings - encoder parameterization": Figure 3-7 Encoder parameterization: Encoder selection, encoder data, actual value synchronization ●...
  • Page 69 Commissioning - drive-based 3.8 Making the basic safety settings ● Encoder 2nd monitoring channel – Encoder type (p9316.0) Sets the configuration for encoder and position actual value. The encoder, which is used for safe motion monitoring on the Motor Module must be parameterized in this parameter. –...

  • Page 70: Telegram Configuration

    Commissioning - drive-based 3.8 Making the basic safety settings 3.8.5 Telegram configuration Precondition The "Settings - telegram configuration" window is only available if the commissioning mode (Page 49) has been activated for the drive. Settings You can make the following settings in the "Settings - Telegram configuration" window: Figure 3-8 Telegram configuration ●...

  • Page 71: Safety Integrated Functions

    Commissioning - drive-based 3.9 Safety Integrated functions Safety Integrated functions 3.9.1 Calling function dialogs Procedure Select the "Start-up" operating area. Press the menu forward key and the "Safety" softkey. Press the "Functions" softkey. Press the softkey of the required safety function: ●...

  • Page 72: Safe Torque Off (Sto)/Safe Stop 1 (Ss1) - Basis Function

    Commissioning - drive-based 3.9 Safety Integrated functions 3.9.2 Safe Torque Off (STO)/Safe Stop 1 (SS1) - basis function In conjunction with a machine function or in the event of a fault, the "Safe Torque Off" (STO) function is used to safely disconnect the torque-generating energy supply to the motor. Precondition The commissioning mode (Page 49) must be activated so that the parameters of this safety function can be changed.

  • Page 73: Safe Torque Off (Sto) - Extended Function

    Commissioning - drive-based 3.9 Safety Integrated functions ● F-DI input filter (p9651) Setting the debounce time in ms for the fail-safe digital inputs to control STO/SBC/SS1. ● Simultaneity monitoring (p9650) Sets the discrepancy time in ms for the switchover of the safety-relevant inputs (SGE) on the Control Unit.
  • Page 74 Commissioning - drive-based 3.9 Safety Integrated functions Precondition The commissioning mode (Page 49) must be activated so that the parameters of this safety function can be changed. An extended function must be set in the options (Page 64). Settings You can make the following settings in this window: Figure 3-10 Safe Torque Off ●...

  • Page 75: Safe Brake Control (Sbc)

    Commissioning - drive-based 3.9 Safety Integrated functions ● STO active (r9773.1) Setting "STO active in the drive" ● Forced checking procedure required (r9773.31) Setting “Switch-off signal paths must be tested" Parameter list When required, alternatively you can use a parameter list for each setting in this window. You can access the parameter list (Page 56) using the ">>"...
  • Page 76 Commissioning - drive-based 3.9 Safety Integrated functions Settings You can only make one setting in this window: Figure 3-11 Safe brake control - SBC ● Safe brake control (p9602) The safe brake control can be enabled or inhibited using this selection list. This selection list is deactivated if a motor holding brake is not included in the configuration (p1215).

  • Page 77: Safe Stop 1 (Ss1) Extended Function

    Commissioning - drive-based 3.9 Safety Integrated functions 3.9.5 Safe Stop 1 (SS1) Extended Function For function "Safe Stop 1 (SS1) of the Extended Safety Functions, braking monitoring is included. The SAM function is used. A Category 1 stop in accordance with EN 60204-1 can be implemented when using SS1. The drive brakes with the OFF3 ramp (p1135) once "Safe Stop 1"...

  • Page 78: Safe Stop 2 (Ss2)/Safe Operating Stop (Sos)

    Commissioning - drive-based 3.9 Safety Integrated functions ● Shutdown speed SS1 (p9560). Depending on the axis type, setting of the shutdown velocity (mm/min) or shutdown speed (rpm) for SS1 ● SS1 monitoring (p9507.3) Selecting the brake response for SS1 For the following parameters, the status symbols indicate the actual state (blue = active; gray = inactive): ●...
  • Page 79 Commissioning - drive-based 3.9 Safety Integrated functions Settings You can make the following settings for the drive in this window: Figure 3-13 Safe Stop 2 - Safe Operating Stop - SS2/SOS ● Standstill tolerance SOS (p9530) Sets the tolerance for the "Safe operating stop" function (SOS) in mm for a linear axis or in degrees for a rotary axis.

  • Page 80: Safely Limited Speed (Sls)

    Commissioning - drive-based 3.9 Safety Integrated functions Parameter list When required, alternatively you can use a parameter list for each setting in this window. You can access the parameter list (Page 56) using the ">>" softkey followed by the "Parameter list" softkey.

  • Page 81: Safe Speed Monitor (Ssm)

    Commissioning - drive-based 3.9 Safety Integrated functions ● Delay time for selection of SLS -> SLS active (p9551) Sets the delay time for the SLS changeover and for the activation of SOS for the functions "Safely limited speed"(SLS) and "Safe operating stop" (SOS) in ms. Is effective at all 4 levels.
  • Page 82 Commissioning - drive-based 3.9 Safety Integrated functions Settings You can make the following settings for the drive in this window: Figure 3-15 Safe Speed Monitoring - SSM ● SSM with hysteresis (p9501.16) Sets the enable signals for the safety-related motion monitoring functions. "Enable SSM (n <...

  • Page 83: Safe Acceleration Monitor (Sam)

    Commissioning - drive-based 3.9 Safety Integrated functions 3.9.9 Safe Acceleration Monitor (SAM) The "Safe Acceleration Monitor" (SAM) function is responsible for safety monitoring braking along the OFF ramp. This function is active for SS1, SS2 or STOP B and STOP C. Precondition The commissioning mode (Page 49) must be activated so that the parameters of this safety function can be changed.

  • Page 84: Safe Direction (Sdi)

    Commissioning - drive-based 3.9 Safety Integrated functions column with the recommended value in the "Recommended value" column. You can change the recommended values and accept them in the previous dialog. You can accept these recommended values by pressing the "Yes" softkey. You can exit the dialog with "No" without accepting the values.

  • Page 85: Safely Limited Position (Slp)

    Commissioning - drive-based 3.9 Safety Integrated functions ● SDI (p9501.17) Sets the enable signals for the safety-related motion monitoring functions. "Enable SDI" can be activated using the checkbox. ● Delay time selection SDI -> SDI active (p9565) Sets the delay time for the "Safe direction" function (SDI) in ms. ●...
  • Page 86 Commissioning - drive-based 3.9 Safety Integrated functions Settings You can make the following settings for the drive in this window: Figure 3-18 Safe limit positions - Safe Position - SLP/SP ● SLP (p9501.1) Sets the enable signals for the safety-related motion monitoring functions. "Enable SOS/ SLS"...
  • Page 87 Commissioning - drive-based 3.9 Safety Integrated functions ● Position range 2 – Pmin (p9535[1]) Sets the lower limit value for the "Safely limited position" function (SLP) in mm for a linear axis or in degrees for a rotary axis. – Pmax (p9534[1]) Sets the upper limit value for the "Safely limited position"...

  • Page 88: Safe Brake Test (Sbt)

    Commissioning - drive-based 3.9 Safety Integrated functions 3.9.12 Safe Brake Test (SBT) The "Safe Brake Test" function (SBT) checks the holding torque of a brake (operational or holding brake). The drive purposely generates a configurable torque against the applied brake. If the brake is operating correctly, the axis motion remains within a parameterized tolerance.
  • Page 89 Commissioning - drive-based 3.9 Safety Integrated functions ● SBT selection (p10203) Selects the control of the safe brake test. ● Brake test Selecting the brake to be tested. – Brake 1 (p10202[0]) – Brake 2 (p10202[1]) ● Holding torque Setting the effective holding torque on the motor side of the brake to be tested Nm. –...
  • Page 90 Commissioning - drive-based 3.9 Safety Integrated functions ● Position tolerance - test frequency 2 Sets the tolerated position deviation for sequence 2 for the safe brake test in mm for a linear axis or in degrees for a rotary axis. –...
  • Page 91 Commissioning - drive-based 3.9 Safety Integrated functions Significance of the SBT parameters Figure 3-20 Display of the SBT parameters Depending on the particular drive type, the following terminology is used: ● "Torque" This term is used for rotating drives. ● "Force" This term is used for linear drives.
  • Page 92 Commissioning - drive-based 3.9 Safety Integrated functions Safety Integrated Function Manual, 10/2015, 6FC5397-3EP40-5BA3...

  • Page 93: Commissioning - Tm54F

    Commissioning - TM54F Introduction The TM54F Terminal Module is a terminal expansion board. The TM54F provides fail-safe digital inputs and outputs for controlling the safety functions. Each Control Unit can be assigned exactly one TM54F, which is connected via DRIVE-CLiQ. The TM54F provides 4 fail-safe digital outputs and 10 fail-safe digital inputs.
  • Page 94 Commissioning - TM54F 4.1 Introduction You must activate the commissioning mode (Page 95) to change the parameterization of the TM54F data. You can change the parameters of a selected TM54F in the commissioning mode. TM54F parameter lists Alternative to parameter changes using the screen forms, you can also check or correct parameters using the parameter lists (Page 110).

  • Page 95: Activating The Commissioning Mode

    Commissioning - TM54F 4.2 Activating the commissioning mode Activating the commissioning mode The TM54F commissioning mode can only be activated from the "Configuration" window. Procedure Select the "Start-up" operating area. Press the menu forward key and the "Safety" softkey. Generally, the "Configuration" area is active. If not, then press the "Con‐ figuration"...
  • Page 96 Commissioning - TM54F 4.2 Activating the commissioning mode Press the "OK" softkey. There are several TM54F If several TM54F are being used, additional softkeys are displayed where you can set the required TM54F. Press the "TM54F" softkey – and using the "TM54F+", or "TM54F-" soft‐ key, select the required terminal expansion module.

  • Page 97: Canceling The Commissioning Mode

    Commissioning - TM54F 4.3 Canceling the commissioning mode Canceling the commissioning mode The commissioning mode can be immediately exited if no safety parameters were changed. If safety parameters were changed, before exiting the commissioning mode, it still has to be defined what should happen with the modified safety parameters.
  • Page 98 Commissioning - TM54F 4.3 Canceling the commissioning mode Press the "Confirm all TM54F" softkey to confirm the SI data of all TM54F and to exit the commissioning mode. The actual checksum of all TM54F is copied over to the reference checksum. This softkey is only visible if there are several TM54F devices are in your drive system.

  • Page 99: Exit The Commissioning Mode

    Commissioning - TM54F 4.4 Exit the commissioning mode Exit the commissioning mode You can immediately exit the commissioning mode if no safety parameters were changed. If safety parameters were changed, before exiting the commissioning mode, it still has to be defined what should happen with the modified safety parameters.
  • Page 100 Commissioning - TM54F 4.4 Exit the commissioning mode Objective: Only confirm data If you do not wish to copy the SI data from the master to the slave, then proceed as follows: Press the "Confirm SI data" softkey. As a consequence, the SI data of the actual TM54F are confirmed, and the commissioning mode is exited.
  • Page 101 Commissioning - TM54F 4.4 Exit the commissioning mode If you do not wish to duplicate the SI data from the master to the slave, then proceed as follows: Press the "OK" softkey. The modified SI data of the TM54F master are copied to the TM54F slave. - OR - Press the "Copy all TM54F"...

  • Page 102: Configuring The Tm54F

    Commissioning - TM54F 4.5 Configuring the TM54F Configuring the TM54F 4.5.1 Calling the configuration range Figure 4-2 Example: TM54F configuration Procedure You can open the required configuration range after you have activated the commissioning mode (Page 95) for TM54F. For each TM54F, the 4 configuration ranges can be called using softkeys with the same name.

  • Page 103: Configuration

    Commissioning - TM54F 4.5 Configuring the TM54F Press the "<< Back" softkey to exit the view of the checksums. 4.5.2 Configuration You can make the following settings in the "Configuration" window: Figure 4-3 TM54F configuration ● Assigning drive objects (p10010) Sets the drive object number for the existing drives.
  • Page 104 Commissioning - TM54F 4.5 Configuring the TM54F ● Safety sampling time TM54F (p10000) The safety sampling time corresponds to the sampling time of the TM54F. Note Setting the safety clock cycle The safety clock cycle (p10000) of the TM54F must be set so it is the same as the monitoring cycle in p9500 for all the drives controlled by the TM54F.

  • Page 105: Inputs

    Commissioning - TM54F 4.5 Configuring the TM54F 4.5.3 Inputs The input terminals of the actual TM54F are shown in the the "Inputs" window. This involves the following terminals: ● X521 ● X522 ● X531 ● X532 These terminals are on the front side of the module. The terminals are displayed one above the other in the window.

  • Page 106: Outputs

    Commissioning - TM54F 4.5 Configuring the TM54F ● NC/NO contact (p10040) Terminal property F-DI 0-9 (p10040.0 = F-DI 0, ... p10040.9 = F-DI 9). Only the property of the second (lower) digital input is set. An NC contact is always connected to digital input 1 (upper).
  • Page 107 Commissioning - TM54F 4.5 Configuring the TM54F Figure 4-5 TM54F outputs ● Signal source for F-DO (p10042 - p10045) A 6-way AND is connected upstream of every output terminal pair of an F-DO. The signal sources for the inputs of the AND can be selected: –...

  • Page 108: Drive Groups

    Commissioning - TM54F 4.5 Configuring the TM54F 4.5.5 Drive groups Only one drive group is displayed in the "Drive groups" window. You can display other drive groups using the "Drive group+" and "Drive group-" softkeys. You can make the following settings in the "Drive group 1" window: Figure 4-6 TM54F drive groups Safety Integrated...
  • Page 109 Commissioning - TM54F 4.5 Configuring the TM54F ● Selecting an F-DI (for the displayed drive group) – for the STO, SS1, SS2, SOS, SLS functions – for selecting SLS (levels SLS1 to SLS4; p10022 to10028) as well as SDI (p10030 and p10031) and SLP (p10032 and p10033) An F-DI can be assigned several functions in several drive groups.

  • Page 110: Working With Parameter Lists

    Commissioning - TM54F 4.5 Configuring the TM54F 4.5.6 Working with parameter lists As alternative to the dialog windows, you can also configure the TM54F functions directly via a parameter list. The parameter list can be called from the dialog window of the particular TM54F function.

  • Page 111: Tm54F Checksums

    Commissioning - TM54F 4.5 Configuring the TM54F 4.5.7 TM54F checksums The reference and actual checksums for the master and slave are displayed in the "Checksums" window. Figure 4-8 Example: TM54F checksums Status symbols are used to flag differences between reference and actual checksums: ●...
  • Page 112 Commissioning - TM54F 4.5 Configuring the TM54F Safety Integrated Function Manual, 10/2015, 6FC5397-3EP40-5BA3...

  • Page 113: Commissioning - Acceptance Tests

    Commissioning - acceptance tests Introduction General information Requirements regarding acceptance tests are derived from the EU Machinery Directive (and DIN EN ISO 13849‑1). Accordingly, the machine manufacturer (OEM) is responsible for the following measures: ● Perform an acceptance test for safety-related functions and machine parts, ●...
  • Page 114 Commissioning - acceptance tests 5.1 Introduction Authorized person, acceptance report The test of each SI function must be carried out by an authorized person and logged in the acceptance report. The report must be signed by the person who carried out the acceptance tests.

  • Page 115: Content Of The Complete Acceptance Test

    Commissioning - acceptance tests 5.2 Content of the complete acceptance test Content of the complete acceptance test Content of the complete acceptance test DOCUMENTATION Documentation of the machine including the safety functions Machine description (with overview diagram) Details about the control system Configuration diagram Function table Active monitoring functions depending on the operating mode, the protective doors and...
  • Page 116 Commissioning - acceptance tests 5.2 Content of the complete acceptance test 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. ● Testing the safety-relevant actual value sensing With the motion monitoring functions activated, the drive is briefly moved in both directions.
  • Page 117 Commissioning - acceptance tests 5.2 Content of the complete acceptance test Measure Documentation Function test Part Function test, Part Supplementary Completion of the measures report Replacing the Inclusion of hard‐ Point 4.1 Countersignature PPU hardware ware data/ soft‐ ware version data Replacing the NX Inclusion of hard‐...
  • Page 118 Commissioning - acceptance tests 5.2 Content of the complete acceptance test Note If the results of function test, Part 2 are taken from another identical machine, then this is the sole responsibility of the machine manufacturer and must be appropriately commented in the acceptance report.

  • Page 119: Sequence Of An Acceptance Test

    Commissioning - acceptance tests 5.3 Sequence of an acceptance test Sequence of an acceptance test 5.3.1 Calling an acceptance test You can test the correct mode of operation of all Safety Integrated functions using the "Safety Acceptance" window. The results are displayed in a tabular form. Once you have successfully tested all of the relevant functions, you can summarize the corresponding results in the form of a report and save as RTF file.

  • Page 120: Setting Areas Of The Acceptance Test

    Commissioning - acceptance tests 5.3 Sequence of an acceptance test Navigation using the following softkeys Press the "First test" softkey to display the first acceptance test. Press the "Next test" softkey to display the following acceptance test. Press the "Previous test" softkey to display the previous acceptance test. In the "Finished"...
  • Page 121 Commissioning - acceptance tests 5.3 Sequence of an acceptance test Figure 5-1 Overview of the machine data Safety Integrated Function Manual, 10/2015, 6FC5397-3EP40-5BA3...
  • Page 122 Commissioning - acceptance tests 5.3 Sequence of an acceptance test "Switch-off signal path" setting area You can test the switch-off signal paths in the “Switch-off signal path" setting area. Follow the instructions in the detailed display. Figure 5-2 Switch-off signal path setting area You can make the following settings here: ●...
  • Page 123 Commissioning - acceptance tests 5.3 Sequence of an acceptance test Figure 5-3 Functional relationship setting area You can make the following settings here: ● Define a test name ● Enter conditions to initiate the test ● Select acquired alarms that should appear in the report ●...
  • Page 124 Commissioning - acceptance tests 5.3 Sequence of an acceptance test Figure 5-4 Example: SOS acceptance test After the acceptance test, the alarms that occurred are listed and a trace generated with the relevant signals. You must then subsequently check the list as to whether all of the expected alarms have occurred, and whether the results in the trace recording are correct.
  • Page 125 Commissioning - acceptance tests 5.3 Sequence of an acceptance test Figure 5-5 Example: SOS acceptance test - user confirmation for the alarms You can make the following settings here: ● Define a test name ● Enter conditions to initiate the test ●...

  • Page 126: Configuring And Performing An Acceptance Test

    Commissioning - acceptance tests 5.3 Sequence of an acceptance test 5.3.3 Configuring and performing an acceptance test Sequence: Performing an acceptance test 1. Enter the required machine data in the "Overview" setting area. Figure 5-6 Overview setting area 2. Press the "First test" softkey. The "Switch-off signal path"...
  • Page 127 Commissioning - acceptance tests 5.3 Sequence of an acceptance test 3. Press the "Start test" softkey. A list of all of the activities required for the test are shown to the right in the detailed display. Figure 5-7 First test: Switch-off signal path setting area 4.
  • Page 128 Commissioning - acceptance tests 5.3 Sequence of an acceptance test 5. Press the "Finished" softkey. The alarms that have been acquired are then listed in the detailed display. Figure 5-8 Acceptance test completed In most cases, each alarm is listed twice in the "Collected alarms" field – more precisely one alarm for each monitoring channel.
  • Page 129 Commissioning - acceptance tests 5.3 Sequence of an acceptance test 9. Then evaluate the test result. Check the list as to whether all of the expected alarms have occurred, and whether the results in the trace recording are correct. Using the selection box at the lower right in the detailed display, define as to whether the test (in this particular case: the switch-off signal paths) was successful.
  • Page 130 Commissioning - acceptance tests 5.3 Sequence of an acceptance test ● Save results Saves the results in a directory. ● Load results Loads the saved results from a directory. This function is useful if the test is exited before completion and you wish to continue at the position where you left off. ●...
  • Page 131 Commissioning - acceptance tests 5.3 Sequence of an acceptance test Generating and saving an acceptance report After completing all of the acceptance tests, in the "Finished" setting area, you can generate a certificate for the acceptance report and save it. 1.
  • Page 132 Commissioning - acceptance tests 5.3 Sequence of an acceptance test Figure 5-11 Saving a certificate 3. Select a directory or create a new one. Then press the "OK" softkey to confirm your selection. You are prompted to assign a name for the future certificate. 4.

  • Page 133: Commissioning - Application Example

    Commissioning - application example Planning 6.1.1 Creating a function table Identifying movements If Safety Integrated is to be used for a machine in order to minimize the risk presented by moving parts, then all of the possible hazardous movements should be carefully listed. Not only do NC axes/spindles move, but also components such as the tool changer or chip conveyor.

  • Page 134: From The Function Table To The Logic Diagram

    Commissioning - application example 6.1 Planning State of the machine Drive Which state should be ac‐ Is the function active? Check the NC re‐ tive? sponse Doors open and auto‐ X, Z matic mode Spindles Movements not con‐ inhibited trolled from the NC Doors open and auto‐...
  • Page 135 Commissioning - application example 6.1 Planning When configuring the TM54F, SLS selection bit 0 is permanently set to "1", i.e. "statically inactive" The inputs for the TM54F can be assigned as follows: Input Function F-DI 0 Emergency stop, deselection of SS1 F-DI 1 Deselection of SOS (Safe Operating Stop)
  • Page 136 Commissioning - application example 6.1 Planning Example, logic diagram Figure 6-1 Logic diagram Safety Integrated Function Manual, 10/2015, 6FC5397-3EP40-5BA3...

  • Page 137: Preconditions For Commissioning

    Commissioning - application example 6.2 Preconditions for commissioning Preconditions for commissioning Precondition The following preconditions are satisfied for commissioning: ● The commissioning of the axes without Safety Integrated functions has been completed. ● When connecting-up the safety-relevant inputs of the TM54F we recommend SIRIUS 3SK safety relays as well as the modular 3RK safety system.
  • Page 138 Commissioning - application example 6.2 Preconditions for commissioning Configuration for commissioning Based on the following configuration, a commissioning example is described below: Figure 6-2 Basic configuration S120 Combi with 4 axes and Safety Integrated Safety Integrated Function Manual, 10/2015, 6FC5397-3EP40-5BA3...

  • Page 139: Parameterizing The Tm54F

    Commissioning - application example 6.3 Parameterizing the TM54F Parameterizing the TM54F 6.3.1 Configuring the drive groups Assigning the drive groups The drives are assigned to drive groups. The feed axes are assigned to drive group 1, and the spindle to drive group 2. This guarantees that when the door is open, the spindle goes into STO instead of SOS.
  • Page 140 Commissioning - application example 6.3 Parameterizing the TM54F Figure 6-4 TM54F: Assignment of the drives to the drive groups Assign the extended functions to the fail-safe inputs (F-DI) for each group. Note For further details and information on how to parameterize this function, see Section Configuring the TM54F (Page 102).
  • Page 141 Commissioning - application example 6.3 Parameterizing the TM54F Figure 6-5 TM54F: Drive group 1 Note For further details and information on how to parameterize this function, see Section Drive groups (Page 108). 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.

  • Page 142: Connecting Safe Outputs

    Commissioning - application example 6.3 Parameterizing the TM54F Figure 6-6 TM54F: Drive group 2 6.3.2 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" signals of each drive group should be ANDed and output via an F-DO.
  • Page 143 Commissioning - application example 6.3 Parameterizing the TM54F Figure 6-7 TM54F: Fail-safe outputs Safety Integrated Function Manual, 10/2015, 6FC5397-3EP40-5BA3...

  • Page 144: Tm54F Terminal Description

    Commissioning - application example 6.3 Parameterizing the TM54F 6.3.3 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 134)". The inputs should be wired with two channels. The 24 V power supply for the inputs is important, in order that the forced checking procedure can be performed.
  • Page 145 Commissioning - application example 6.3 Parameterizing the TM54F Figure 6-8 Connection diagram for TM54F Safety Integrated Function Manual, 10/2015, 6FC5397-3EP40-5BA3...

  • Page 146: Controlling With The Sirius 3Sk Or Sirius 3Rk Relay

    Commissioning - application example 6.4 Controlling with the SIRIUS 3SK or SIRIUS 3RK relay Controlling with the SIRIUS 3SK or SIRIUS 3RK relay 6.4.1 Controlling the TM54F with SIRIUS 3SK Hardware configuration Relays and also safety relays, such as the SIRIUS 3SK, are used in this version: Figure 6-9 SIRIUS 3SK Circuit diagrams:...
  • Page 147 Commissioning - application example 6.4 Controlling with the SIRIUS 3SK or SIRIUS 3RK relay Circuit diagram for Emergency Stop with relay 3SK The diagram shows the wiring for the Emergency Stop, which is implemented in Safety Integrated as SS1 (Safe Stop 1): Acknowledge TM54F Emergency Stop button...
  • Page 148 Commissioning - application example 6.4 Controlling with the SIRIUS 3SK or SIRIUS 3RK relay Protective door switch A1+ T1 INF/S 3SK1111-AB30 ICO1_00274 Figure 6-11 Circuit diagram: Door relay 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. Safety Integrated Function Manual, 10/2015, 6FC5397-3EP40-5BA3...
  • Page 149 Commissioning - application example 6.4 Controlling with the SIRIUS 3SK or SIRIUS 3RK relay Use the key-operated switch to select the operating mode: ● Automatic mode: Contacts are open. ● Setup mode: Contacts are closed. TM54F +24 VDC Key-operated switch F-DI 0 Deselect SS1 F-DI 1...
  • Page 150 Commissioning - application example 6.4 Controlling with the SIRIUS 3SK or SIRIUS 3RK relay Circuit diagram for the door switch 3SE5 322-0SD21 This diagram shows the wiring of the door switch: Actuator contact 3SK, 3SK, terminal T1 terminal IN1 3SK, 3SK, terminal T2 terminal IN2...

  • Page 151: Control Of The Tm54F With Sirius 3Rk

    Commissioning - application example 6.4 Controlling with the SIRIUS 3SK or SIRIUS 3RK relay 6.4.2 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 connect the TM54F: Figure 6-14 SIRIUS 3RK3...
  • Page 152 Commissioning - application example 6.4 Controlling with the SIRIUS 3SK or SIRIUS 3RK relay Circuit diagram for the SIRIUS 3RK3 This diagram shows the wiring of the basis module and the expansion modules: F-DI 1 deselect SOS X521 F-DI 2 SLS level 2 X522 IN8 Q1...
  • Page 153 Commissioning - application example 6.4 Controlling with the SIRIUS 3SK or SIRIUS 3RK relay Circuit diagram for F-DI of the TM54F The following diagram shows the wiring of the F-DI connections of the TM54F: TM54F +24V DC 3RK3-111 basis F-DI 0 deselect SS1 3RK3-231 expansion 3RK3-342 expansion...

  • Page 154: Configuration Of The Si Functions For The Drive

    Commissioning - application example 6.5 Configuration of the SI functions for the drive Configuration of the SI functions for the drive 6.5.1 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 155 Commissioning - application example 6.5 Configuration of the SI functions for the drive "Configuration" window In the "Configuration" window, additional basic Safety Integrated settings can be checked and modified. The safe output signal "Forced checking procedure required" does not have to be connected, as the signal is already included in the Safety Info Channel (SIC).

  • Page 156: Encoder Parameterization

    Commissioning - application example 6.5 Configuration of the SI functions for the drive "Encoder parameterization" window In the "Encoder parameterization" window, you select as to whether it involves a linear or rotary axis under "Drive type". Figure 6-20 SPINDLE: Configuration for a rotary axis 6.5.2 Encoder parameterization Encoder parameterization...
  • Page 157 Commissioning - application example 6.5 Configuration of the SI functions for the drive Figure 6-21 SERVO: Setting the leadscrew pitch Safety Integrated Function Manual, 10/2015, 6FC5397-3EP40-5BA3...

  • Page 158: Setting Parameters Sls1-4, Sbc, Ss1, Ss2

    Commissioning - application example 6.5 Configuration of the SI functions for the drive 6.5.3 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. Figure 6-22 SERVO: Setting SLS levels Safety Integrated...
  • Page 159 Commissioning - application example 6.5 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 6-23 SERVO: Safe brake control Emergency Stop via SS1 and handling OFF3 The SINAMICS safety function Safe Stop 1 (SS1) is ideal for an Emergency Stop function.

  • Page 160: Sinumerik 828D Control System

    Commissioning - application example 6.6 SINUMERIK 828D control system SINUMERIK 828D control system 6.6.1 SIC/SCC interface Definition The following information channels are used to transfer data between the drive and control: ● Safety Control Channel (SCC) Control information (S_STW1B and S_STW3B) can be transferred from the higher-level control system to the safety functions of the drive using the Safety Control Channel (SCC).

  • Page 161: Diagnostics

    Diagnostics Calling diagnostic views Procedure Select the "Diagnostics" operating area. Press the menu forward key and the "Safety" softkey. The "Safety Integrated diagnostics overview" window is opened. Calling the diag‐ Displaying the status of safety drives for Safety Integrated functions nostics area: Press the "SI drives"...
  • Page 162 Diagnostics 7.1 Calling diagnostic views Press the "Select TM54F" softkey. This softkey is only visible if there are several TM54F devices are in your drive system. A selection of all of the TM54F devices that exist in the drive system is displayed. Select the required TM54F.

  • Page 163: Safety Integrated Diagnostics Overview

    Diagnostics 7.2 Safety Integrated diagnostics overview Safety Integrated diagnostics overview The following signal information is displayed in the "Safety Integrated diagnostics overview" window. Figure 7-1 Diagnostics: Status overview ● General – Safety operating mode (which operating mode is set) – Number of safety NC axes –...

  • Page 164: Safety Integrated Drives

    Diagnostics 7.3 Safety Integrated drives Safety Integrated drives 7.3.1 Basic functions The following information about the Motor Modules and the Control Unit are displayed in the "Status safe drives - basic functions" window: Figure 7-2 Diagnostics: Drives basic functions Signal information for Safety Integrated basic functions: ●...

  • Page 165: Extended Functions

    Diagnostics 7.3 Safety Integrated drives Note Changing the view In this diagnostics view, you can display the signal information of various drives. You can select the required drive using softkeys "Drive-", "Drive +" or "Select drive". See Chapter Setting another drive unit for the diagnostics view (Page 161). 7.3.2 Extended functions The following information about the Motor Modules is displayed in the "Status safe drives -...
  • Page 166 Diagnostics 7.3 Safety Integrated drives ● SS1 active ● SS2 active ● SOS active ● SLS active ● Active SLS level ● Actual speed limit ● Setpoint speed limiting ● SSM active ● Fault cause STOP F ● Pulses enabled ●...

  • Page 167: Tm54F

    Diagnostics 7.4 TM54F TM54F 7.4.1 Configuration The following information is provided in the "Configuration" window: Figure 7-4 Diagnostics: TM54F configuration ● Drive object assignment Display of the drive object number for existing drives. ● Drive groups Display of the drive group for existing drives. ●...

  • Page 168: Inputs

    Diagnostics 7.4 TM54F ● Signal source, forced checking procedure (test stop) Display of the set input terminal to start a test stop/forced checking procedure. ● Test cycle dynamization F-DO Display of the defined time interval to check for fail safety. ●...

  • Page 169: Outputs

    Diagnostics 7.4 TM54F ● NC/NO contact Display of the terminal property F-DI 0-9 (p10040.0 = F-DI 0, ..., p10040.9 = F-DI 9). An NC contact is always connected to digital input 1 (upper). Digital input 2 indicates whether an NC or NO contact has been selected. ●...
  • Page 170 Diagnostics 7.4 TM54F Figure 7-6 Diagnostics: TM54F outputs ● Signal source for F-DO A 6-way AND is connected upstream of every output terminal pair of an F-DO. The following information is displayed for the signal sources of the AND logic gate inputs: –...

  • Page 171: Drive Groups

    Diagnostics 7.4 TM54F 7.4.4 Drive groups Only one drive group is displayed in the "Drive groups" window. You can display other drive groups using the "Drive group+" and "Drive group-" softkeys. The following information is provided in the "Drive group 1" window: Figure 7-7 Diagnostics: TM54F drive group Safety Integrated...
  • Page 172 Diagnostics 7.4 TM54F ● Display of an F-DI (for the displayed drive group) – for the STO, SS1, SS2, SOS, SLS functions – for selecting SLS (levels SLS1 to SLS4) as well as SDI and SLP An F-DI can be assigned several functions in several drive groups. Static selection/deselection of functions –...

  • Page 173: Safety Integrated Checksums

    Diagnostics 7.5 Safety Integrated checksums Safety Integrated checksums 7.5.1 Safety Integrated checksum The following information is provided in the "Safety Integrated checksum overview" window: Figure 7-8 Diagnostics: SI checksums ● Details about global checksums Checksum and data for the global checksums: –...

  • Page 174: Safety Integrated Global Checksums

    Diagnostics 7.5 Safety Integrated checksums 7.5.2 Safety Integrated global checksums Information about the following global checksums integrated in the drive is available in the "Details on the global checksums" window: Figure 7-9 Diagnostics: Global checksums Engineering checksum ● TM54F checksum (if a TM54F is available) or F-CPU master checksum TM54F and F-CPU cannot be simultaneously active.

  • Page 175: Tm54F Checksums

    Diagnostics 7.5 Safety Integrated checksums Hardware checksum ● Safety-relevant hardware checksum Comprises the following checksums: – Checksum across SI parameters for hardware (r9728[2]) – Checksum across SI parameters with hardware reference (r9398[1]) – Checksum, hardware-dependent TM54F parameters (MM) (r10004[1]) ‑ if a TM54F is available Note Determining checksums...
  • Page 176 Diagnostics 7.5 Safety Integrated checksums ● Master checksums The reference values and actual values of functions and hardware are compared here. ● Slave checksums The reference values and actual values of functions and hardware are compared here. In the column "Reference = Act", based on the status symbol you can identify as to whether for the particular information, the actual checksum matches the reference checksum.

  • Page 177: Drive Checksums

    Diagnostics 7.5 Safety Integrated checksums 7.5.4 Drive checksums Information about the checksums of the basic functions and extended functions is provided in the "Drive checksums" window: Figure 7-11 Diagnostics: Drive checksums The following checksums are displayed: ● Checksums of the extended functions Here, for monitoring channel 1 (Control Unit) and monitoring channel 2 (Motor Module), the actual and reference checksums for the following extended functions are compared with one another.
  • Page 178 Diagnostics 7.5 Safety Integrated checksums Note Changing the view In this diagnostics view, you can display the signal information of various drives. You can select the required drive using softkeys "Drive-", "Drive +" or "Select drive". See Setting another drive for the diagnostics view (Page 161).

  • Page 179: Safety Integrated Alarms

    Diagnostics 7.6 Safety Integrated alarms Safety Integrated alarms The following alarms can occur for drive-based Safety Integrated: 201600 - 201799 Safety Integrated: Faults and alarms 230600 - 230799 400000 - 400022 PLC alarms In the basic setting, the alarm list in the "Alarms" window only lists Safety Integrated alarms. You can change the view so that all alarms are listed (unfiltered) using the "All alarms"...

  • Page 180: Acknowledging Hardware Replacement

    Diagnostics 7.7 Acknowledging hardware replacement Acknowledging hardware replacement Preconditions ● The 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 181 Diagnostics 7.7 Acknowledging hardware replacement Note The hardware replacement can also be confirmed in the "Startup" operating area. The procedure is similar. Safety Integrated Function Manual, 10/2015, 6FC5397-3EP40-5BA3...
  • Page 182 Diagnostics 7.7 Acknowledging hardware replacement Safety Integrated Function Manual, 10/2015, 6FC5397-3EP40-5BA3...

  • Page 183: System Features

    ● You should subscribe to the corresponding newsletter in order to obtain the latest information and to allow you to modify your equipment accordingly. Subscribing to the Safety Newsletter 1. Go to the following Internet address in your browser: Siemens automation (http://w3.siemens.com/mcms/mc-systems/en/automation-systems/ cnc-sinumerik/Pages/cnc-systems.aspx) 2. Select the desired language for the Web page.
  • Page 184 System Features 8.1 Latest information 8. Open the topic "Products and solutions". 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 "Subscribe" entry. If you require more detailed information on the newsletters, then please use the supplementary function on the website.

  • Page 185: Certifications

    ● Safety integrity level 2 (SIL 2) to IEC 61508 ● DIN EN 61800-5-2 In addition, most of these safety functions 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, 10/2015, 6FC5397-3EP40-5BA3...
  • Page 186 System Features 8.2 Certifications Safety Integrated Function Manual, 10/2015, 6FC5397-3EP40-5BA3...

  • Page 187: 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 188 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 189: 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 190 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 191: 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 192: 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 193: 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 194: 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 195: 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 196: 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 197: Appendix

    Appendix Abbreviations The following list of abbreviations includes all of the relevant abbreviations for the safety functionality of the SINUMERIK 828D. Abbreviation Source of abbreviation Meaning Active Interface Module Active Interface Module Active Line Module Active Line Module Induction motor Induction motor BERO Contactless proximity switch...
  • Page 198 Appendix A.1 Abbreviations Abbreviation Source of abbreviation Meaning Light-Emitting Diode Light emitting diode Motor Module Motor Module Numerical Control Kernel Numeric Control Kernel Line side converter Line side converter p... ‑ Setting parameters PC Unit Computer unit PELV Protective Extra Low Voltage Safe extra low voltage Programming device Programming device...
  • Page 199 Appendix A.1 Abbreviations Abbreviation Source of abbreviation Meaning Zero Mark Zero mark Status Word Status Word Safety Integrated Function Manual, 10/2015, 6FC5397-3EP40-5BA3...

  • Page 200: Documentation Overview Sinumerik 828D

    Appendix A.2 Documentation overview SINUMERIK 828D Documentation overview SINUMERIK 828D Safety Integrated Function Manual, 10/2015, 6FC5397-3EP40-5BA3...

  • Page 201: Index

    Index TM54F checksums, 111 TM54F configuration, 103 TM54F parameter lists, 110 Configuration, 66 Acceptance report Confirm all drives, 51, 52, 54 Generating and saving, 131 Confirm all TM54F, 97, 99 Acceptance test Confirm SI data, 52, 54, 99 Authorized person, 114 Copy all drives, 52, 54 Calling, 119 Copy all TM54F, 99...
  • Page 202 Index Safe outputs TM54F, 106 Safe speed, 158 Safe Speed Monitor, 40 Safe Stop 2, 34 Forced dormant error detection, 139 Safe Torque Off, 27 Function dialogs STO, 30 Safety Integrated, 71 Safely Limited Position, 44 Safely Limited Speed, 36 Safety Control Channel, 160 Safety Evaluation Tool, 19 Global checksum, 174...
  • Page 203 Index SBT, 26, 45, 88 Trace, 91 SCC, 26, 160 SDI, 25, 42, 84 Telegram configuration General, 42 Safety Integrated, 70 Safe Direction, 42 Terminal expansion module, 93 Time response, 42 Test stop, 155 Selecting a drive, 49 TM54F, 93 Selecting TM54F, 95 Configuration, 139 SIC, 26, 160...
  • Page 204 Index Safety Integrated Function Manual, 10/2015, 6FC5397-3EP40-5BA3...

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Sinumerik 828dSinamics s120

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