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

Siemens SINUMERIK 828D Function Manual

Sinumerik operate acceptance test
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Download this manual See also: Diagnostic Manual, Function Manual
SINUMERIK
SINUMERIK 828D / 840D sl
SINUMERIK Operate acceptance
test
Function Manual
Valid for
Control system
SINUMERIK 828D / 840D sl
CNC software
Version 4.8 SP4
08/2018
A5E39460574B AC
Preface
Fundamental safety
instructions
Introduction
Acceptance test wizard of
SINUMERIK Operate
Managing templates and
results
Actions for hardware
replacement and
modifications
Tips and tricks
Appendix
1
2
3
4
5
6
A

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Summary of Contents for Siemens SINUMERIK 828D

  • Page 1 Preface Fundamental safety instructions Introduction SINUMERIK Acceptance test wizard of SINUMERIK Operate SINUMERIK 828D / 840D sl SINUMERIK Operate acceptance Managing templates and test results Actions for hardware replacement and Function Manual modifications Tips and tricks Appendix Valid for Control system...
  • 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, and adapt it for your own machine documentation. Training At the following address (http://www.siemens.com/sitrain), you can find information about SITRAIN (Siemens training on products, systems and solutions for automation and drives). FAQs You can find Frequently Asked Questions in the Service&Support pages under Product Support (https://support.industry.siemens.com/cs/de/en/ps/faq).
  • Page 4 Note regarding the General Data Protection Regulation Siemens observes standard data protection principles, in particular the principle of privacy by design. That means that this product does not process / store any personal data, only technical functional data (e.g.

  • Page 5: Table Of Contents

    Purpose and requirements.....................15 Preconditions for the acceptance test..................16 Documentation, data archiving and authorized persons............17 Acceptance test wizard of SINUMERIK Operate..................19 Introduction..........................19 SINUMERIK 828D/840D sl - drive-based Safety functions............23 3.2.1 Criteria for conducting an acceptance test................23 3.2.2 Acceptance test Wizard......................24 3.2.3 Test types..........................26...
  • Page 6 Actions for hardware replacement and modifications.................75 Necessity of a new acceptance test..................75 Effect of the acceptance test for specific measures...............76 5.2.1 Effects with SINUMERIK 828D Safety Integrated..............76 5.2.2 Effects with SINUMERIK 840D sl Safety Integrated (system-integrated)......78 5.2.3 Effects with SINUMERIK 840D sl Safety Integrated plus............80 Tips and tricks............................83...

  • Page 7: Fundamental Safety Instructions

    Fundamental safety instructions General safety instructions WARNING Electric shock and danger to life due to other energy sources Touching live components can result in death or severe injury. ● Only work on electrical devices when you are qualified for this job. ●...
  • Page 8 Fundamental safety instructions 1.1 General safety instructions WARNING Electric shock due to equipment damage Improper handling may cause damage to equipment. 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 9 ● If you come closer than around 2 m to such components, switch off any radios or mobile phones. ● Use the "SIEMENS Industry Online Support app" only on equipment that has already been switched off. WARNING...

  • Page 10: Equipment Damage Due To Electric Fields Or Electrostatic Discharge

    Fundamental safety instructions 1.3 Warranty and liability for application examples WARNING Malfunctions of the machine as a result of incorrect or changed parameter settings As a result of incorrect or changed parameterization, machines can malfunction, which in turn can lead to injuries or death. ●...

  • Page 11: Industrial Security

    Siemens’ products and solutions undergo continuous development to make them more secure. Siemens strongly recommends that product updates are applied as soon as they are available and that the latest product versions are used. Use of product versions that are no longer supported, and failure to apply the latest updates may increase customer’s exposure to cyber...

  • Page 12: Residual Risks Of Power Drive Systems

    Fundamental safety instructions 1.5 Residual risks of power drive systems WARNING Unsafe operating states resulting from software manipulation Software manipulations (e.g. viruses, trojans, malware or worms) can cause unsafe operating states in your system that may lead to death, serious injury, and property damage. ●...
  • Page 13 Fundamental safety instructions 1.5 Residual risks of power drive systems 3. Hazardous shock voltages caused by, for example: – Component failure – Influence during electrostatic charging – Induction of voltages in moving motors – Operation and/or environmental conditions outside the specification –...
  • Page 14 Fundamental safety instructions 1.5 Residual risks of power drive systems SINUMERIK Operate acceptance test Function Manual, 08/2018, A5E39460574B AC...

  • Page 15: Introduction

    Introduction Purpose and requirements The goal of the acceptance test is to check the correct parameterization and mode of operation of the safety functions and to detect potential configuration errors or to document the correctness of the configuration. During this acceptance test, the limit values entered for all of the activated safety functions must be violated so that the proper execution of the function can be checked and verified.

  • Page 16: Preconditions For The Acceptance Test

    The configuration and programming must be carried out as described in the associated documentation. ● SINUMERIK 828D Safety Integrated and SINUMERIK 840D sl Safety Integrated plus: The F-PLC (for SINUMERIK 840D sl only) or fail-safe I/O must be configured in the hardware and network editor of the TIA Portal.

  • Page 17: Documentation, Data Archiving And Authorized Persons

    Introduction 2.3 Documentation, data archiving and authorized persons Documentation, data archiving and authorized persons The results of the acceptance test as well as all hardware and software changes must be documented in a suitable form (as an acceptance report). Within the scope of the acceptance report, the alarm displays must be checked or the alarm reports must be incorporated into the acceptance report.
  • Page 18 Introduction 2.3 Documentation, data archiving and authorized persons SINUMERIK Operate acceptance test Function Manual, 08/2018, A5E39460574B AC...

  • Page 19: Acceptance Test Wizard Of Sinumerik Operate

    Introduction This chapter describes the acceptance test wizard of SINUMERIK Operate. A distinction is made here between the drive-based Safety for the SINUMERIK 828D and SINUMERIK 840D and the system-integrated Safety for the SINUMERIK 840D sl. The following table gives you an overview of the available test types, depending on the respective SINUMERIK controllers.
  • Page 20 Acceptance test wizard of SINUMERIK Operate 3.1 Introduction SINUMERIK 840D sl SINUMERIK 828D Safe Stop 1 (SS1) Testing of the SS1 - Safe Stop 1 (SS1) verifies the following points for an axis/drive: ● The hardware is functioning properly ● Correct wiring of the switch-off signal paths ●...
  • Page 21 Acceptance test wizard of SINUMERIK Operate 3.1 Introduction SINUMERIK 840D sl SINUMERIK 828D Safe Stop 1 (SS1) Testing of the SS1 - Safe Stop 1 (SS1) verifies the following points for an axis/drive: ● The hardware is functioning properly ● Correct SS1 grouping (if available) ●...
  • Page 22 Acceptance test wizard of SINUMERIK Operate 3.1 Introduction SINUMERIK 840D sl SINUMERIK 828D Safe Brake Test (SBT) The Safe Brake Test (SBT) function verifies whether the brake is function‐ ing correctly and that the required holding torque is observed. Safe Direction (SDI)

  • Page 23: Sinumerik 828D/840D Sl - Drive-Based Safety Functions

    Acceptance test wizard of SINUMERIK Operate 3.2 SINUMERIK 828D/840D sl - drive-based Safety functions SINUMERIK 840D sl SINUMERIK 828D Safely reduced speed (SG) This test checks whether an overshoot of the safely reduced speed (SG) is detected. Safe software limit switches (SE) This test checks whether ●...

  • Page 24: Acceptance Test Wizard

    Acceptance test wizard of SINUMERIK Operate 3.2 SINUMERIK 828D/840D sl - drive-based Safety functions ● Test the communication – Check the correctness of the communication configuring – Test the mode of operation of the communication relationships ● Test and check other properties –...
  • Page 25 Acceptance test wizard of SINUMERIK Operate 3.2 SINUMERIK 828D/840D sl - drive-based Safety functions Calling the acceptance test wizard MENU SELECT > Commissioning > Safety > Acceptance test Figure 3-1 SINUMERIK Operate - Acceptance test wizard Descriptions of the individual test cases and information to be entered in the acceptance test wizard can be found directly in the respective input screens.

  • Page 26: Test Types

    Acceptance test wizard of SINUMERIK Operate 3.2 SINUMERIK 828D/840D sl - drive-based Safety functions Special cases Gantry axes As part of an acceptance test, when compared to "standard" SI axes, gantry axes are not handled in a special way, and are also not specifically designated in the acceptance test user interface.

  • Page 27: Test Type Required/Not Required

    Acceptance test wizard of SINUMERIK Operate 3.2 SINUMERIK 828D/840D sl - drive-based Safety functions Figure 3-2 Test type/setting area overview 3.2.3.2 Test type required/not required An acceptance test can be carried out for every safety function used on the machine. Not all of the Safety functions listed in the dialog are used on the machine.
  • Page 28 Acceptance test wizard of SINUMERIK Operate 3.2 SINUMERIK 828D/840D sl - drive-based Safety functions Figure 3-3 Test type required/not required If the test type is selected as "required", press the "Start test" softkey. If the selected test type is set at "not required", press the "Next test" softkey.

  • Page 29: Switch-Off Signal Path

    Acceptance test wizard of SINUMERIK Operate 3.2 SINUMERIK 828D/840D sl - drive-based Safety functions 3.2.3.3 Switch-off signal path You can test the switch-off signal paths in the "Switch-off signal path" setting area. Follow the instructions in the detailed display. Figure 3-4...

  • Page 30: Application Example

    Acceptance test wizard of SINUMERIK Operate 3.2 SINUMERIK 828D/840D sl - drive-based Safety functions Trace When creating a test instance, a trace can be activated, which documents the signal characteristic of the signals that are relevant for the particular test case.
  • Page 31 Acceptance test wizard of SINUMERIK Operate 3.2 SINUMERIK 828D/840D sl - drive-based Safety functions Procedure: 1. Enter the information required for the machine in the "Overview" setting area. Figure 3-5 Example - Safety acceptance test: Overview 2. Press the "First test" softkey.
  • Page 32 Acceptance test wizard of SINUMERIK Operate 3.2 SINUMERIK 828D/840D sl - drive-based Safety functions 3. If you do not want to begin with the test type "Switch-off signal path", select the desired test type; SOS in the example. Figure 3-6...
  • Page 33 Acceptance test wizard of SINUMERIK Operate 3.2 SINUMERIK 828D/840D sl - drive-based Safety functions 4. 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.
  • Page 34 Acceptance test wizard of SINUMERIK Operate 3.2 SINUMERIK 828D/840D sl - drive-based Safety functions 5. Press the "Collect data" softkey. Then follow the instructions which appear on your screen. Figure 3-8 Example - Safety acceptance test: SOS, acquire data Data acquisition is concluded automatically as soon as limit value violation is detected. The alarms that have been acquired are then listed in the detailed display.
  • Page 35 Acceptance test wizard of SINUMERIK Operate 3.2 SINUMERIK 828D/840D sl - drive-based Safety functions Figure 3-9 Example - Safety acceptance test: SOS, acquired alarms 6. Press the "Go to results" softkey. After the acceptance test, the alarms that occurred are listed and a trace generated with the relevant signals.
  • Page 36 Acceptance test wizard of SINUMERIK Operate 3.2 SINUMERIK 828D/840D sl - drive-based Safety functions 8. Then evaluate the test result. Then check the list as to whether all of the expected alarms have occurred, and whether the results in the trace recording are correct.
  • Page 37 Acceptance test wizard of SINUMERIK Operate 3.2 SINUMERIK 828D/840D sl - drive-based Safety functions 9. Make a selection in the bottom right of the default view to define whether the test (in this case: SOS) was successful. Figure 3-11 Example - Safety acceptance test: SOS, evaluate result The test name is allocated a green checkmark if the test was evaluated to be positive.

  • Page 38: Generating And Saving An Acceptance Report

    Acceptance test wizard of SINUMERIK Operate 3.2 SINUMERIK 828D/840D sl - drive-based Safety functions Supplementary functions ● Full screen Hides the list of the setting areas and displays the detail settings of the currently selected setting area over the complete screen width.
  • Page 39 Acceptance test wizard of SINUMERIK Operate 3.2 SINUMERIK 828D/840D sl - drive-based Safety functions Procedure 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. Activate the corresponding option in the detailed display if you wish to integrate a certificate into the acceptance report.

  • Page 40: Acceptance Test Mode

    Acceptance test wizard of SINUMERIK Operate 3.2 SINUMERIK 828D/840D sl - drive-based Safety functions Figure 3-13 Example - Safety acceptance, save certificate 3. Select a directory or create a new one. Then press the "OK" softkey to confirm your selection.

  • Page 41: Manufacturer-Specific Configurations (Slatw.ini)

    Acceptance test wizard of SINUMERIK Operate 3.2 SINUMERIK 828D/840D sl - drive-based Safety functions The SINAMICS acceptance test mode is integrated in the SINUMERIK Operate acceptance test wizard, where you parameterize the time and activate the mode in the associated SINUMERIK Operate input screens, rather than directly via parameters.
  • Page 42 Acceptance test wizard of SINUMERIK Operate 3.2 SINUMERIK 828D/840D sl - drive-based Safety functions NC/PLC interface signals (only SINUMERIK 840D sl) The following NC/PLC interface signals can be defined in section [General]: ● Interface signal PLC → NC: "PLC commissioning completed"...
  • Page 43 Acceptance test wizard of SINUMERIK Operate 3.2 SINUMERIK 828D/840D sl - drive-based Safety functions Table 3-2 File: .../user/sinumerik/hmi/cfg/slatw.ini Program code [TESTFR] TestName=open door, axis = %1, number = %4 Two test cases are performed in the acceptance test for test type "Function relations"...

  • Page 44: Sinumerik 840D Sl - System-Integrated Safety Functions

    3.3 SINUMERIK 840D sl - system-integrated Safety Functions Note User-specific changes We urgently recommend that only the changes regarding the file supplied from Siemens .../ siemens/sinumerik/hmi/cfg/slatw.ini are incorporated in the user-specific file.../user/sinumerik/ hmi/cfg/slatw.ini. SINUMERIK 840D sl - system-integrated Safety Functions 3.3.1...

  • Page 45: Acceptance Test Wizard

    Acceptance test wizard of SINUMERIK Operate 3.3 SINUMERIK 840D sl - system-integrated Safety Functions 3.3.2 Acceptance test Wizard SINUMERIK Operate has an acceptance test wizard, which uses specific input screens to guide the person authorized by the machine manufacturer through the acceptance test. After all of the relevant data has been entered and the test cases are concluded, a log template is generated, which must be completely filled in, checked, and signed.
  • Page 46 Acceptance test wizard of SINUMERIK Operate 3.3 SINUMERIK 840D sl - system-integrated Safety Functions Calling the acceptance test wizard MENU SELECT > Commissioning > Safety > Acceptance test Figure 3-14 SINUMERIK Operate - Acceptance test wizard Descriptions of the individual test cases and information to be entered in the acceptance test wizard can be found directly in the respective input screens.

  • Page 47: Test Types

    Acceptance test wizard of SINUMERIK Operate 3.3 SINUMERIK 840D sl - system-integrated Safety Functions Special cases Gantry axes As part of an acceptance test, when compared to "standard" SI axes, gantry axes are not handled in a special way, and are also not specifically designated in the acceptance test user interface.

  • Page 48: Test Type Required/Not Required

    Acceptance test wizard of SINUMERIK Operate 3.3 SINUMERIK 840D sl - system-integrated Safety Functions Figure 3-15 Test type/setting area overview 3.3.3.2 Test type required/not required An acceptance test can be carried out for every safety function used on the machine. Not all of the Safety functions listed in the dialog are used on the machine.
  • Page 49 Acceptance test wizard of SINUMERIK Operate 3.3 SINUMERIK 840D sl - system-integrated Safety Functions Figure 3-16 Test type required/not required If the test type is selected as "required", press the "Start test" softkey. If the selected test type is set at "not required", press the "Next test" softkey. SINUMERIK Operate acceptance test Function Manual, 08/2018, A5E39460574B AC...

  • Page 50: Switch-Off Signal Path

    Acceptance test wizard of SINUMERIK Operate 3.3 SINUMERIK 840D sl - system-integrated Safety Functions 3.3.3.3 Switch-off signal path You can test the switch-off signal paths in the "Switch-off signal path" setting area. Follow the instructions in the detailed display. Figure 3-17 Test type/setting range switch-off signal path You can make the following settings here, for example: ●...

  • Page 51: Application Example

    Acceptance test wizard of SINUMERIK Operate 3.3 SINUMERIK 840D sl - system-integrated Safety Functions Trace When creating a test instance, a trace can be activated, which documents the signal characteristic of the signals that are relevant for the particular test case. A trace can be parameterized for the "Functional relations"...
  • Page 52 Acceptance test wizard of SINUMERIK Operate 3.3 SINUMERIK 840D sl - system-integrated Safety Functions Procedure: 1. Enter the information required for the machine in the "Overview" setting area. Figure 3-18 Example - Safety acceptance test overview 2. Press the "First test" softkey. The "Switch-off signal path"...
  • Page 53 Acceptance test wizard of SINUMERIK Operate 3.3 SINUMERIK 840D sl - system-integrated Safety Functions 3. If you do not want to begin with the test type "Switch-off signal path", select the desired test type; SBH in the example. Figure 3-19 Example - Test type: SOS - Safe Operating Stop SINUMERIK Operate acceptance test Function Manual, 08/2018, A5E39460574B AC...
  • Page 54 Acceptance test wizard of SINUMERIK Operate 3.3 SINUMERIK 840D sl - system-integrated Safety Functions 4. 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 3-20 Example - Safety acceptance test: SOS (Safe Operating Stop) Check the "Status overview"...
  • Page 55 Acceptance test wizard of SINUMERIK Operate 3.3 SINUMERIK 840D sl - system-integrated Safety Functions 5. Press the "Collect data" softkey. Then follow the instructions which appear on your screen. Figure 3-21 Example - Safety acceptance test: SOS, acquire data Data acquisition is concluded automatically as soon as limit value violation is detected. The alarms that have been acquired are then listed in the detailed display.
  • Page 56 Acceptance test wizard of SINUMERIK Operate 3.3 SINUMERIK 840D sl - system-integrated Safety Functions Figure 3-22 Example - Safety acceptance test: SOS, acquired alarms 6. Press the "Go to results" softkey. After the acceptance test, the alarms that occurred are listed and a trace generated with the relevant signals.
  • Page 57 Acceptance test wizard of SINUMERIK Operate 3.3 SINUMERIK 840D sl - system-integrated Safety Functions 8. Then evaluate the test result. Then check the list as to whether all of the expected alarms have occurred, and whether the results in the trace recording are correct. –...
  • Page 58 Acceptance test wizard of SINUMERIK Operate 3.3 SINUMERIK 840D sl - system-integrated Safety Functions 9. Make a selection in the bottom right of the default view to define whether the test (in this case: SBH) was successful. Figure 3-24 Example - Safety acceptance test: SBH, evaluate result The test name is allocated a green checkmark if the test was evaluated to be positive.

  • Page 59: Generating And Saving An Acceptance Report

    Acceptance test wizard of SINUMERIK Operate 3.3 SINUMERIK 840D sl - system-integrated Safety Functions Supplementary functions ● Full screen Hides the list of the setting areas and displays the detail settings of the currently selected setting area over the complete screen width. ●...
  • Page 60 Acceptance test wizard of SINUMERIK Operate 3.3 SINUMERIK 840D sl - system-integrated Safety Functions Procedure 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. Activate the corresponding option in the detailed display if you wish to integrate a certificate into the acceptance report.

  • Page 61: Acceptance Test Mode

    Acceptance test wizard of SINUMERIK Operate 3.3 SINUMERIK 840D sl - system-integrated Safety Functions Figure 3-26 Example - Safety acceptance, save 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.

  • Page 62: Manufacturer-Specific Configurations (Slatw.ini)

    General user-specific and test-specific settings can be made in file slatw.ini. For SINUMERIK Operate, the file is located under the following directory: ● .../siemens/sinumerik/hmi/cfg To activate user-specific settings, a file must be created under the same name in the user directory: ●...
  • Page 63 Acceptance test wizard of SINUMERIK Operate 3.3 SINUMERIK 840D sl - system-integrated Safety Functions NC/PLC interface signals (only SINUMERIK 840D sl) The following NC/PLC interface signals can be defined in section [General]: ● Interface signal PLC → NC: "PLC commissioning completed" Entry: PLCCommCompleteBit=<DBxy.DBXy.z>...
  • Page 64 [TESTSBH] SBT (SINAMICS) - Safe Brake Test [TESTSDI] SDI - Safe Direction File information File name: slatw.ini Siemens path (source): .../siemens/sinumerik/hmi/cfg User path (target): .../user/sinumerik/hmi/cfg Editor: Any editor, saved in the ASCII format SINUMERIK Operate acceptance test Function Manual, 08/2018, A5E39460574B AC...
  • Page 65 Acceptance test wizard of SINUMERIK Operate 3.3 SINUMERIK 840D sl - system-integrated Safety Functions Note User-specific changes We urgently recommend that only the changes regarding the file supplied from Siemens .../ siemens/sinumerik/hmi/cfg/slatw.ini are incorporated in the user-specific file.../user/sinumerik/ hmi/cfg/slatw.ini. SINUMERIK Operate acceptance test...
  • Page 66 Acceptance test wizard of SINUMERIK Operate 3.3 SINUMERIK 840D sl - system-integrated Safety Functions SINUMERIK Operate acceptance test Function Manual, 08/2018, A5E39460574B AC...

  • Page 67: Managing Templates And Results

    Managing templates and results Figure 4-1 Sequence of an acceptance test and generating a certificate Template editor With the template editor of SINUMERIK Operate, you can create or edit customer-specific templates (Page 68) (Customizing Template) for an acceptance test. SINUMERIK 840D sl with Safety Integrated (system-integrated) You can continue to use templates created using the CT Editor (Customizing Template Editor).

  • Page 68: Customizing Templates

    Managing templates and results 4.2 Customizing templates See also Customizing templates (Page 68) Customizing templates 4.2.1 Customizing templates A customizing template is a user-specific XML file for an acceptance test, in which all of the required test types and instances – together with the corresponding parameters, limit values, alarms and handling instructions –...

  • Page 69: Customizing Template (Sinucomnc)

    Managing templates and results 4.2 Customizing templates 3. Press the "Export template" softkey. Then a file explorer appears with the default storage path "...\user\sinumerik\hmi\data\safety \atw\templates". 4. Select a different target directory as needed. 5. Create a subdirectory for the template as needed. 6.

  • Page 70: Result File

    Managing templates and results 4.3 Result file Result file Function The result file (.atw) is an archive, and is used to backup tests that have been performed. The result file consists of the following information: ● Session file ● Customer-specific template (if available) ●...
  • Page 71 Managing templates and results 4.3 Result file Tests The tests performed by the acceptance test are classified according to test types and test instances: ● Test types are responsible for testing different machine mechanisms. This can require various steps for tests and different machine data/parameters. Examples of different test types include: Safe operating stop (SBH) and safely reduced speed (SG).

  • Page 72: Certificate Template

    Managing templates and results 4.4 Certificate template Save results In order to save the test results in a file, proceed as follows: 1. Press the softkey >>. 2. Press the "Save results" softkey. Then a file explorer appears with the default storage path "...\user\sinumerik\hmi\data\atw \results".

  • Page 73: Certificate

    Menu "Insert" > Group "Hyperlinks" > "Text mark" File information File name: atcerttpl_<language code>.rtf Path: .../siemens/sinumerik/hmi/lng Editor: RTF-capable editor, e.g. Microsoft Word See Programming Manual Fundamentals; Chapter "Tables" > "Current languages in HMI" Certificate The acceptance test provides, with the finally generated certificate (acceptance report), a confirmation for the machine manufacturer or the acceptance test engineer about the state of the SI functions of the system when supplied.
  • Page 74 Managing templates and results 4.5 Certificate Generating The certificate can be subsequently generated as part of the acceptance test after any arbitrary test has been completed. 1. In the acceptance test, select the setting range "Finish". 2. Press the "Generate certificate" softkey. See also Generating and saving an acceptance report (Page 38).

  • Page 75: Actions For Hardware Replacement And Modifications

    Actions for hardware replacement and modifications Necessity of a new acceptance test A complete acceptance test is required for the first commissioning of the Safety Integrated functionality on a machine. If you carry out certain measures after the acceptance test, it may be necessary to carry out a new (complete or partial) acceptance test.

  • Page 76: Effect Of The Acceptance Test For Specific Measures

    Effect of the acceptance test for specific measures 5.2.1 Effects with SINUMERIK 828D Safety Integrated The effects of the acceptance test with certain measures are described in the following table. Function test parts 1 and 2, as well as the supplementary measures relate to the section Example contents of the acceptance test (Page 85).
  • Page 77 Actions for hardware replacement and modifications 5.2 Effect of the acceptance test for specific measures Measure Documentation Function test Function test Supplementary Completion of the Part 1 Part 2 measures report Changing the mon‐ Inclusion of config‐ Inclusion of the itoring clock cycle uration data new checksum...

  • Page 78: Effects With Sinumerik 840D Sl Safety Integrated (System-Integrated)

    Actions for hardware replacement and modifications 5.2 Effect of the acceptance test for specific measures 5.2.2 Effects with SINUMERIK 840D sl Safety Integrated (system-integrated) The effects of the acceptance test with certain measures are described in the following table. Function test parts 1 and 2, as well as the supplementary measures relate to the section Example contents of the acceptance test (Page 87).
  • Page 79 Actions for hardware replacement and modifications 5.2 Effect of the acceptance test for specific measures Measure Documentation Function test Function test Supplementary Completion of the Part 1 Part 2 measures report Changed system Inclusion of config‐ clock cycle (SI uration data clock cycle, IPO re‐...

  • Page 80: Effects With Sinumerik 840D Sl Safety Integrated Plus

    Actions for hardware replacement and modifications 5.2 Effect of the acceptance test for specific measures Measure Documentation Function test Function test Supplementary Completion of the Part 1 Part 2 measures report SPL change Inclusion of the SI Yes, only Point 2.6 Document function per axis, (Page 87)
  • Page 81 Actions for hardware replacement and modifications 5.2 Effect of the acceptance test for specific measures Measure Documentation Function test Function test Supplemen‐ Completion of Part 1 Part 2 tary meas‐ the report ures Replacing the Motor Module Supplement hardware Yes, only Point 4.1 data/software version da‐...
  • Page 82 Actions for hardware replacement and modifications 5.2 Effect of the acceptance test for specific measures Measure Documentation Function test Function test Supplemen‐ Completion of Part 1 Part 2 tary meas‐ the report ures Function expansion or new Inclusion of the SI func‐ Yes, only for Yes, only Document...

  • Page 83: Tips And Tricks

    Tips and tricks Trace does not start n < n (SINUMERIK 840D sl with Safety Integrated) If n < n ,, then the trace cannot start. The most common reason for this is the machine data MD36060 (n<n ). The machine data is not Safety machine data, is seldom used, and is therefore overlooked.
  • Page 84 Tips and tricks Performing a trace for the test type "Function relations" To ensure that a trace is carried out for the test type "Function relations", the following prerequisite is necessary: The trace definition for this type of test must be saved in the "Acceptance test/Trace" folder. Figure 6-1 Folder for traces SINUMERIK Operate acceptance test...

  • Page 85: Appendix

    The acceptance report is divided into the following sections: ● Plant/system description ● Description of the safety functions ● Test of safety functions A.1.2 SINUMERIK 828D with Safety Integrated DOCUMENTATION Documentation of the machine including the safety functions Machine description (with overview diagram) Details about the control system...
  • Page 86 Appendix A.1 Example contents of the acceptance test Testing the Emergency Stop function and the safety circuits Testing the function table FUNCTION TEST PART 2 Detailed function test incl. checking the values of the individual SI functions used Testing the SI Safe Torque Off function (safe operating stop, SBH) - STO Testing the SI function Safe Stop 1 - SS1 Testing the SI function Safe Stop 2 - SS2 Testing the SI function Safe Operating Stop - SOS...

  • Page 87: Sinumerik 840D Sl With Safety Integrated (System-Integrated)

    Appendix A.1 Example contents of the acceptance test A.1.3 SINUMERIK 840D sl with Safety Integrated (system-integrated) 1) DOCUMENTATION Documentation of the machine including the safety functions 1.1 Machine description (with overview diagram) 1.2 Details about the control system 1.3 Configuration diagram 1.4 Function table Active monitoring functions depending on the operating mode, the protective doors and other sensors/CPU-CPU communication...
  • Page 88 Appendix A.1 Example contents of the acceptance test 3.5 Test of the SI function Safe Cams – SN (check using the diagnostics display or assigned SGAs or with the evaluated measuring diagrams and measured values) 3.6 If necessary, test the SI function external stops (with evaluated measurement diagram or measured values) 3.7 Test the SI function SBC/SBT (with evaluated measurement diagram or measured values / PROFIsafe I/O)
  • Page 89 Appendix A.1 Example contents of the acceptance test Function table Active monitoring functions depending on the operating mode, the protective doors and other sensors/CPU-CPU communication. It makes sense that this table is part of the documentation of the engineering work that has been carried out.

  • Page 90: Sinumerik 840D Sl With Safety Integrated Plus

    Appendix A.1 Example contents of the acceptance test 3.10 Testing the SI function Safe Brake Control/Safe Brake Test ‑ SBC/SBT (with evaluated measurement diagram or measured values) Supplementary measures Function test, actual value acquisition ● General checking of the actual value acquisition After replacing a component, the system is switched on and briefly operated in both directions.
  • Page 91 Appendix A.1 Example contents of the acceptance test Function table Active monitoring functions depending on the operating mode, the protective doors and other sensors/CPU-CPU communication. It makes sense that this table is part of the documentation of the engineering work that has been carried out.
  • Page 92 Appendix A.1 Example contents of the acceptance test 3.10 Testing the SI function Safe Brake Control/Safe Brake Test ‑ SBC/SBT (with evaluated measurement diagram or measured values) Supplementary measures 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.

  • Page 93: Sl / 828D Documentation Overview

    Appendix A.2 840D sl / 828D documentation overview 840D sl / 828D documentation overview SINUMERIK Operate acceptance test Function Manual, 08/2018, A5E39460574B AC...

  • Page 94: Abbreviations

    Appendix A.3 Abbreviations Abbreviations The most important abbreviations are listed alphabetically. Abbreviation Derivation of the abbreviation Meaning 1 von 1 Auswertung Encoder signal is available through one channel, is read once 2 von 2 Auswertung Encoder signal is available through one channel, is read twice and compared A...
  • Page 95 Appendix A.3 Abbreviations Abbreviation Derivation of the abbreviation Meaning Digital Input Digital input Digital Output Digital output DKE-AK Deutsche elektrotechnische Kommission-Ar‐ German Electrotechnical Working Committee beitskreis Datum Links Data left Direct Measure System Direct measuring system Dezentrale Peripherie Distributed I/O DP-Master Central component in the PROFIBUS DP data bus Dual Port RAM...
  • Page 96 Appendix A.3 Abbreviations Abbreviation Derivation of the abbreviation Meaning Inbetriebnahme Commissioning Industrial Ethernet Industrial Ethernet International Electrotechnical Commision International Electrotechnical Commission Institut für Arbeitssicherheit Institute for work safety Impulssperre Pulse inhibit Indirect Measure System Indirect measuring system INSE Eingangsdaten der Sicheren programmierba‐ Input data of the safe programmable logic (SPL) from the ren Logik (SPL) von der Peripherie INSI...
  • Page 97 Safely reduced speed Sicherheitsgerichteter Ausgang Safety-related output Sicherheitsgerichteter Eingang Safety-related input Sicherer Halt Safe standstill Safety Integrated Integrated safety technology from SIEMENS. ® Safety Info Channel Safety Information Channel Safety Integrity Level Safety Integrity Level SILCL SIL claim limit Name of a Safety Integrity Level...
  • Page 98 Appendix A.3 Abbreviations Abbreviation Derivation of the abbreviation Meaning Safe Motion Monitoring Safe motion monitoring Zusammenfassung für SMI, SMC und SME Common term for SMI, SMC and SME Sicherer Software-Nocken, Sichere Nockens‐ Safe software cam, Safe Cam Track Safe Operating Stop Safe Operating Stop Limits the stop position of the motor.

  • Page 99: Index

    Index Acceptance test Gantry axes, 26, 47 Authorized person, 17 Effects with SINUMERIK 828D, (Safety Integrated) Effects with SINUMERIK 840D sl, (Safety Integrated (system-integrated)), (Safety Inputs Integrated plus) Customizing templates, 68 Example, (Safety Integrated), (Safety Integrated (system-integrated), (Safety Integrated plus)
  • Page 100 Index Template editor SINUMERIK Operate, 67 Test instances, 71 Test types, 25, 46, 71 Text marks, 73 SINUMERIK Operate acceptance test Function Manual, 08/2018, A5E39460574B AC...

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