Page 3 G120, G120C, G120D and SIMATIC ET Fundamental safety ___________________ instructions 200pro FC-2 ___________________ Introduction SINAMICS ___________________ Description SINAMICS G120 ___________________ Safety Integrated - SINAMICS Installing G110M, G120, G120C, G120D and ___________________ SIMATIC ET 200pro FC-2 Commissioning Function Manual ___________________ Operation...
Page 4 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 5: Change History
(basic functions) (Page 47) Connecting an actuator without feedback signal to the safety Connecting the safety output for output of the SINAMICS G120 with CU250S-2 does not SINAMICS G120 (Page 73) comply with SIL 2. The connection example has been removed.
Page 6 Change history Supplements and revised descriptions In Chapter The probability of failure PFD has been supplemented. Probability of failure of the safety functions (PFH value) (Page 267) Error response of the SBC function has been supplemented. Response to faults in the brake control (Page 176) Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 7: Table Of Contents
Table of contents Change history ............................5 Fundamental safety instructions ......................13 General safety instructions ......................13 Industrial security ......................... 14 Introduction ............................15 About this manual ........................15 Guide through the manual ......................18 Description ............................19 About this chapter ........................19 Overview of the safety functions ....................
Page 8 Safety output ..........................71 4.4.2 Connecting the safety output for SINAMICS G120D ..............72 4.4.3 Connecting the safety output for SINAMICS G120 ..............73 Connecting a motor holding brake to a Safe Brake Relay ............74 Commissioning ............................. 77 Commissioning guidelines ......................77 Configure PROFIsafe in the higher-level control system ............
Page 9 Table of contents Series commissioning ........................ 155 5.10 Acceptance tests for the safety functions .................. 156 5.10.1 Acceptance test.......................... 156 5.10.2 Reduced acceptance test after expanding the function ............. 158 Operation ............................159 Overview and relevant inverter signals ..................159 Regularly testing the safety functions ..................
Page 10 6.13 List of alarms and faults ......................242 Corrective maintenance ........................251 Maintaining operational safety ....................251 Replacing components of the modular SINAMICS G120/G120D/G110M inverters ....253 7.2.1 Overview of replacing converter components ................253 7.2.2 Replacing a Control Unit with enabled safety function ............. 255 7.2.3...
Page 11 Table of contents A.2.1 Creating logs with the settings of the safety functions ............... 309 A.2.2 Example of machine documentation ..................311 A.2.3 Log the settings for the basic functions, firmware V4.4 ... V4.7 ..........313 A.2.4 Log the settings for the extended functions, firmware V4.4 ... V4.7 .......... 314 Standards and specifications .....................
Page 12 Table of contents Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 13: Fundamental Safety Instructions
Fundamental safety instructions General safety instructions WARNING Risk of death if the safety instructions and remaining risks are not carefully observed If the safety instructions and residual risks are not observed in the associated hardware documentation, accidents involving severe injuries or death can occur. •...
Page 14: 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 15: Introduction
Introduction About this manual Who requires this manual and why? This manual describes the safety functions integrated in the inverter for variable-speed applications. The manual is aimed primarily at machine and plant manufacturers, commissioning engineers, and service personnel. What are drive-integrated safety functions? "Safety"...
Page 16 Introduction 2.1 About this manual What inverters are described? Figure 2-1 Products with drive-integrated safety functions Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 17 Introduction 2.1 About this manual What applications are described? This manual covers all the information, procedures, and operations for the following scenarios: ● Introductory and simplified description of the inverter safety functions ● Controlling the safety functions via safety inputs or PROFIsafe ●...
Page 18: Guide Through The Manual
Introduction 2.2 Guide through the manual Guide through the manual Chapter In this chapter, you will find answers to the following questions: Description (Page 19) What safety functions does my inverter have? • How do the safety functions basically work? •...
Page 19: Description
Each of the inverters described in this manual end of the product name, e.g. Control Unit has one or several of the basic functions. CU240E-2 F. For SINAMICS G120 with a CU250S-2 Control Unit, you require a license for the extended functions.
Page 20 CU240E-2 DP-F CU240E-2 PN-F Control CU240E-2 PN-F CU250S-2 DP Units CU250S-2 CU250S-2 PN CU250S-2 DP CU250S-2 PN SINAMICS G120 CU250S-2 CAN Available Available with the following Control Units: with all CU240D-2 DP-F Control CU240D-2 PN-F Units CU240D-2 PN-F PP CU240D-2 PN-F FO...
Page 21: Overview Of The Safety-Related Inverter Interfaces
CU240M DP Telegram 30 CU240M PN SINAMICS G120C USS SINAMICS G120C CAN SINAMICS G120C DP Telegram 30 SINAMICS G120C PN SINAMICS G120 with Control Unit … CU240E-2 CU240E-2 DP Telegram 30 CU240E-2 PN CU240E-2 F CU240E-2 DP-F Telegram 30 CU240E-2 PN-F...
Page 22: Preconditions When Using The Safety Functions
Description 3.4 Preconditions when using the safety functions Preconditions when using the safety functions Risk assessment A risk analysis and assessment of the plant or machine is required before using the safety functions integrated in the drive. The risk analysis and assessment must show that the safety functions integrated in the drive are suitable as protective measure to reduce risks associated with the machine.
Page 23: Restrictions When Using Safety Functions
Description 3.5 Restrictions when using safety functions Restrictions when using safety functions Not permitted: Operation with pulling loads WARNING Death or severe injury when the motor speed is not monitored The encoderless actual value sensing does not identify all faults and errors in the closed- loop motor control.
Page 24 Description 3.5 Restrictions when using safety functions Critical applications For safety functions that have not been enabled, you can use the following applications without any restrictions. For active safety functions, several applications can result in errors in the safety-related actual value sensing. For active or enabled safety functions, faults and errors in the safety- related actual value sensing initiate a stop response: Messages C01711, C30711 with default values 1040 ff.
Page 25 Power Module Restriction PM230 The PM230 Power Modules of the SINAMICS G120 do not support any safety functions. PM240 FSGX With the PM240 Power Module frame size GX, only the STO, SBC and SS1 basic functions without speed monitoring are permitted.
Page 26: Recommendations For Stable Operation
Description 3.6 Recommendations for stable operation Recommendations for stable operation The following preconditions must be satisfied to ensure disturbance-free inverter operation with the extended functions enabled: ● Motor and inverter are adequately dimensioned for this application: – The inverter is operated below its current limit. –...
Page 27: Safe Torque Off (Sto)
Description 3.7 Safe Torque Off (STO) Safe Torque Off (STO) How does the STO safety function work? The inverter with active STO function prevents machine components from inadvertently starting. Table 3- 2 The principle of operation of STO Safe Torque Off (STO) Standard inverter functions linked with STO 1.
Page 28 Description 3.7 Safe Torque Off (STO) The distinction between Emergency Off and Emergency Stop "Emergency Off" and "Emergency Stop" are commands that minimize different risks in the machine or plant. The STO function is suitable for achieving an emergency stop but not an emergency off. Risk: Risk of electric shock: Risk of unexpected motion:...
Page 29 Description 3.7 Safe Torque Off (STO) Application examples for the STO function The STO function is suitable for applications where the motor is already at a standstill or will come to a standstill in a short, safe period of time through friction. STO does not shorten the run-on of machine components with high inertia.
Page 30: Safe Brake Control (Sbc)
Description 3.8 Safe Brake Control (SBC) Safe Brake Control (SBC) How does the SBC safety function work? An inverter equipped with the SBC function monitors the cables to an electromagnetic brake and when requested, safely shuts down the 24 V control of the brake. You must supplement the inverter with a Safe Brake Relay for the SBC function.
Page 31 Description 3.8 Safe Brake Control (SBC) The SBC safety function is standardized The SBC function is defined in IEC/EN 61800-5-2: "The SBC function supplies a safe output signal to control an external brake." The SBC inverter function complies with what is defined in the standard. Application example for the SBC function Example Possible solution...
Page 32: Safe Stop 1 (Ss1)
Description 3.9 Safe Stop 1 (SS1) Safe Stop 1 (SS1) How does SS1 function? When the SS1 function is active, the inverter reduces the kinetic energy of the machine components to the lowest possible level. The principle of operation of SS1 differs depending on whether you use SS1 with basic functions or with extended functions.
Page 33: Application Example
Description 3.9 Safe Stop 1 (SS1) SS1 of the extended functions Table 3- 5 Principle of operation of SS1, selected when the motor is rotating Safe Stop 1 (SS1) Standard inverter functions linked with SS1 The inverter recognizes the selection of SS1 via a safety input or via the PROFIsafe safe communication.
Page 34: Safely Limited Speed (Sls)
Description 3.10 Safely Limited Speed (SLS) 3.10 Safely Limited Speed (SLS) How does SLS function? An inverter with active SLS function can reduce the velocity or speed of a machine component and monitor it without having to interrupt machining operation. Table 3- 6 Principle of operation of SLS, selected when the motor is rotating Safely Limited Speed (SLS)
Page 35 Description 3.10 Safely Limited Speed (SLS) Application examples for the SLS function Examples Possible solution Setup mode: The machine operator must enter the Select SSL in the inverter via a safety input • dangerous area of a machine and manually or via PROFIsafe.
Page 36 Description 3.10 Safely Limited Speed (SLS) Application example for selecting SLS levels Examples Possible solution Depending on the diameter of the saw blade, a Select SLS and the corresponding SLS • circular saw must not exceed a specific maximum level in the inverter via PROFIsafe. speed.
Page 37: Safe Direction (Sdi)
Description 3.11 Safe Direction (SDI) 3.11 Safe Direction (SDI) How does SDI function? The inverter with active SDI function prevents that a machine component moves in the inhibited direction. Table 3- 8 Principle of operation of SDI, selected when the motor is rotating Safe Direction (SDI) Standard inverter functions linked with SDI...
Page 38: Application Examples
Description 3.11 Safe Direction (SDI) Application examples Example Possible solution When replacing the pressure cylinders of the Select SDI in the inverter via a safety input • plates, it is only permissible that the drive moves in or via PROFIsafe. the safe direction.
Page 39: Safe Speed Monitoring (Ssm)
Description 3.12 Safe Speed Monitoring (SSM) 3.12 Safe Speed Monitoring (SSM) How does SSM function? The inverter with active SSM function signals whether the velocity or speed of a machine component is above or below a limit value. Table 3- 9 The principle of operation of SSM Safe Speed Monitoring (SSM) Standard inverter...
Page 40 Description 3.12 Safe Speed Monitoring (SSM) Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 41: Installing
Installing Installing the inverter Procedure The following overview shows the procedure for installing integrated safety functions in an inverter. The step selected in gray is described in this manual. For information on the steps that are not selected, you will need to consult descriptions in other manuals. Proceed as follows: 1.
Page 42: Connection Via Profisafe
Installing 4.2 Connection via PROFIsafe Connection via PROFIsafe 4.2.1 Overview of PROFIsafe connections Communication via PROFIsafe For communication via PROFIsafe, you must connect the inverter to a central fail-safe control (F-CPU) via either PROFIBUS or PROFINET. Figure 4-1 PROFIsafe communication between an F-CPU and an inverter, e.g. via PROFINET Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 43 Manuals for your inverter (Page 334). Additional possibilities of installing the F-Switch module are listed in the Internet: FAQ (http://support.automation.siemens.com/WW/view/en/26694409). Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 44 Installing 4.2 Connection via PROFIsafe Shared Device The PROFINET "Shared Device" function allows two controls to access the same PROFINET IO device, e.g. on a SIMATIC ET 200 I/O system or on an inverter. Typical applications for "Shared Device" are systems, in which a standard CPU and a fail-safe CPU are used as separate controllers: ●...
Page 45 Installing 4.2 Connection via PROFIsafe PROFIsafe communication within the SIMATIC ET 200pro The SIMATIC-ET-200pro system allows safety-related communication, restricted to the system: ● The ET-200pro system is node on the PROFIBUS or PROFINET. ● Within the ET-200pro system, the interface module with integrated fail-safe control (IM F- CPU) controls the safety functions of the inverter via PROFIsafe.
Page 46: Profisafe Telegrams
Installing 4.2 Connection via PROFIsafe 4.2.2 PROFIsafe telegrams Two telegrams are available for the data exchange via PROFIsafe between the inverter and the higher-level controller: Table 4- 1 PROFIsafe telegrams Overview using PROFINET / PROFIsafe as Telegram Process data (PZD) example PZD1 PZD2...
Page 47: Control Word 1 And Status Word 1 (Basic Functions)
Installing 4.2 Connection via PROFIsafe 4.2.3 Control word 1 and status word 1 (basic functions) Table 4- 2 Control word 1 (bit 0 ... 15) Byte Bit Function Comment Select STO Deselect STO Select SS1 Deselect SS1 2 … 6 Not relevant Internal Event Do not acknowledge faults...
Page 48: Control Word 1 And Status Word 1 (Extended Functions)
Installing 4.2 Connection via PROFIsafe 4.2.4 Control word 1 and status word 1 (extended functions) Table 4- 4 Control word 1 (bit 0 ... 15) Byte Function Comment Select STO Deselect STO Select SS1 Deselect SS1 2, 3 Not relevant Select SLS Deselect SLS 5, 6...
Page 49 Installing 4.2 Connection via PROFIsafe Table 4- 5 Status word 1 (bit 0 ... 15) Byte Function Comment Power removed STO is not active STO is active SS1 active SS1 is not active SS1 is active 2, 3 Not relevant SLS active SLS is not active SLS is active...
Page 50: Control Word 5 And Status Word 5
Installing 4.2 Connection via PROFIsafe 4.2.5 Control word 5 and status word 5 Table 4- 6 Control word 5 (bit 0 ... 15) Byte Function Comment Reserved 0 … Assign the value 0 to the reserved bits. … Table 4- 7 Status word 5 (bit 0 ...
Page 51: Activation Via F-Di
Wiring examples are provided in the following section, also see Wiring examples (Page 54). Assignment of safety inputs Table 4- 8 Inverters (chassis units, IP20) with only one safety input SINAMICS G120C SINAMICS G120 Terminal strip Digital input Safety input with CU240E-2...
Page 52 Installing 4.3 Activation via F-DI Table 4- 9 Inverters (chassis units IP20) with several safety inputs SINAMICS G120 Terminal strip Digital input Safety inputs with Basic functions Extended CU240E-2 F functions CU240E-2 DP-F CU240E-2 PN-F CU250S-2 CU250S-2 CAN CU250S-2 DP...
Page 53 Installing 4.3 Activation via F-DI Table 4- 11 Inverters for cabinet-free installation (IP65) with several safety inputs SINAMICS G120D Connector.pin Digital input Safety inputs with Basic functions Extended CU240D-2 DP-F functions CU240D-2 PN-F CU240D-2 PN-F PP CU240D-2 PN-F FO CU250D-2 DP-F CU250D-2 PN-F CU250D-2 PN-F PP CU250D-2 PN-F FO...
Page 54: Wiring Examples
Installing 4.3 Activation via F-DI Special measures when establishing connections When routing cables over longer distances, e.g. between remote control cabinets, you have the following options to reduce the risk of damaged cables when your plant or machine is operating: ●...
Page 55 Installing 4.3 Activation via F-DI External power supply Figure 4-7 Connecting an electromechanical sensor to an external power supply Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 56 Installing 4.3 Activation via F-DI SIMATIC ET 200pro The SIMATIC ET 200pro FC converter does not have its own inputs. If you wish to directly control the safety functions of the ET 200pro FC-2 via a sensor, then you will require the F-RSM or the F-Switch module.
Page 57 Directly controlling the safety functions in the ET 200pro FC-2 converter via the F-Switch module Additional installation options for the F-Switch and F-RSM modules are listed in the following FAQ: FAQ (http://support.automation.siemens.com/WW/view/en/26694409). Series-connected electromechanical sensors You may connect Emergency Stop control devices in series if it can be ruled out that the Emergency Stop command devices are simultaneously actuated.
Page 58 Installing 4.3 Activation via F-DI The inverter provides the supply voltage Connect the 24 V supply of the inverter to the sensors and connect the reference potentials of the inputs used to GND. The 24 V supply is not required when using the G110M "24 V Power Module" option Figure 4-10 Connecting electromechanical sensors to the inverter power supply in series Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2...
Page 59 Installing 4.3 Activation via F-DI External power supply Connect the external power supply to the sensors and connect the reference potentials of the inputs used to the reference potential of the external power supply. Figure 4-11 Connecting electromechanical sensors to an external power supply in series Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 60 Installing 4.3 Activation via F-DI Activating several inverters simultaneously You may activate the safety functions of several converters simultaneously with one or several series-connected safety sensors. If there is a risk of cross-circuits or short-circuits, the cables between the sensor and the converter must be protected, for example, by routing them in a steel tube.
Page 61 Installing 4.3 Activation via F-DI External power supply Connect the external power supply to the sensors and connect the reference potentials of the inputs used to the reference potential of the external power supply. Figure 4-13 Simultaneous activation of several converters with external power supply Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 62: Connecting Pre-Processing Devices
SIRIUS 3TK28 safety relays (http://support.automation.siemens.com/WW/view/en/26414637/133300). Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 63 Installing 4.3 Activation via F-DI Components in the same control cabinet A control cabinet that has been designed and wired correctly does not contain any damaged wiring or cross circuits. Under the assumption that the preprocessing devices switch the output used twice (involves two contacts in series), within a control cabinet you can interconnect the safety relay and inverter through a single channel cable connection.
Page 64 Installing 4.3 Activation via F-DI Components in separate control cabinets If the components are located in separate control cabinets, the wiring between the safety relay and safety inputs in the inverter must be installed such that it is protected against cross and short-circuits.
Page 65 Information providing full details of how the 3RK3 Modular Safety System are wired can be found in the product-specific documentation: SIRIUS 3RK3 Modular Safety System (http://support.automation.siemens.com/WW/view/en/26412499/133300). Components in the same control cabinet A control cabinet that has been designed and wired correctly does not contain any damaged wiring or cross circuits.
Page 66 Installing 4.3 Activation via F-DI Components in separate control cabinets If the components are located in separate control cabinets, the wiring between the Modular Safety System and the F-DIs on the inverter must be installed such that it is protected against cross and short-circuits.
Page 67 S7-300 I/O modules Safety outputs that switch to P potential are required for activating the safety digital inputs of the SINAMICS G120. From the S7-300 range, the SM326 DO 10 x 24 V / 2 A PP I/O module fulfills this requirement.
Page 68 Installing 4.3 Activation via F-DI Components in separate control cabinets If the components are located in separate control cabinets, the wiring between the SM326 I/O module and the F-DIs on the inverter must be installed such that it is protected against cross and short-circuits.
Page 69 Safety outputs that switch to P potential are required for activating the safety digital inputs of the SINAMICS G120. From the ET 200 system range, only the fail-safe relay module EM 1 F-RO DC 24 V / AC 24…230 V / 5 A of the ET 200S system fulfills this requirement.
Page 70 Installing 4.3 Activation via F-DI Components in separate control cabinets If the components are located in separate control cabinets, the wiring between the I/O modules and the F-DIs on the inverter must be installed such that it is protected against cross and short-circuits.
Page 71: Evaluating Via F-Do
X5.2 DO 1 CU240D-2 PN-F PP X5.3 CU250D-2 DP-F CU250D-2 PN-F CU250D-2 PN-F PP Table 4- 13 Inverter for installation in a control cabinet (IP20) SINAMICS G120 with Control Unit Terminal Digital Safety Read back strip output output input CU250S-2...
Page 72: Connecting The Safety Output For Sinamics G120D
Installing 4.4 Evaluating via F-DO 4.4.2 Connecting the safety output for SINAMICS G120D Connecting a relay Figure 4-22 Connecting a relay at the F-DO Connecting an actuator with feedback signal Figure 4-23 Connecting an F-DO to an actuator Connecting a safety input Figure 4-24 Connecting an F-DO with an F-DI Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2...
Page 73: Connecting The Safety Output For Sinamics G120
Installing 4.4 Evaluating via F-DO 4.4.3 Connecting the safety output for SINAMICS G120 Connecting a relay Figure 4-25 Connecting a relay at the F-DO Connecting an actuator with feedback signal Figure 4-26 Connecting an F-DO to an actuator Connecting a safety input...
Page 74: Connecting A Motor Holding Brake To A Safe Brake Relay
Installing 4.5 Connecting a motor holding brake to a Safe Brake Relay Connecting a motor holding brake to a Safe Brake Relay Connecting a Safe Brake Relay and a motor holding brake The Safe Brake Relay serves as an interface between the Power Module and the motor's brake coil.
Page 75 Installing 4.5 Connecting a motor holding brake to a Safe Brake Relay Procedure To interconnect the inverter with the motor holding brake via the Safe Brake Relay, proceed as follows: 1. Connect the Safe Brake Relay to the Power Module using the cable harness provided. Power Modules FSA …...
Page 76 Installing 4.5 Connecting a motor holding brake to a Safe Brake Relay Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 77: Commissioning
Commissioning Commissioning guidelines The overview below shows the procedure for commissioning an inverter with integrated safety functions. The steps for commissioning the safety functions form part of the activities for commissioning the entire drive. ● The commissioning steps marked in gray are described → in this manual. ●...
Page 78: Configure Profisafe In The Higher-Level Control System
You can find additional information as application description or FAQ in the Internet, e.g. ● Configuring a PROFIsafe telegram with Drive ES Basic (http://support.automation.siemens.com/WW/view/en/64326460) ● Controlling SINAMICS G120 via PROFIsafe, displaying inverter messages on an HMI (http://support.automation.siemens.com/WW/view/en/61450312) 5.2.1 Configuring PROFIBUS communication with telegram 30 via GSD...
Page 79 Commissioning 5.2 Configure PROFIsafe in the higher-level control system 4. Assign standard telegram 1, for example, to the other slots of the inverter. The operating instructions contain further information on the telegrams and slot sequence. 5. Open the properties dialog by double-clicking on the PROFIsafe telegram. 6.
Page 80: Example: Interface To The S7 Safety Program
Commissioning 5.2 Configure PROFIsafe in the higher-level control system 7. In this dialog, select the "PROFIsafe" tab. ① – F_Dest_Add Note the value of this address. You require this value when commissioning the safety functions. ② – F_WD_Time Set a value which is greater than the cycle time of your safety program. If your safety program is called every 150 ms, for example, in OB35, set the value of F_WD_Time to 200.
Page 81 Commissioning 5.2 Configure PROFIsafe in the higher-level control system Table 5- 1 Control word 1 I/O address Meaning Comment A14.0 Select STO Select STO Deselect STO A14.1 Select SS1 Select SS1 Deselect SS1 A14.4 Select SLS Select SLS Deselect SLS A14.7 Internal event ACK Acknowledge with signal change 1 →...
Page 82: Configuring Profibus Communication Via Telegram 900 With The Gsdml
The communication via the Shared Device is also possible, even if both controls are configured in different projects. Firmware required: see also Support of the IO controller (http://support.automation.siemens.com/WW/view/en/44383955). Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 83 Commissioning 5.2 Configure PROFIsafe in the higher-level control system Procedure To configure communication via "Shared Device" in the higher-level control, proceed as follows: 1. Configuring your system with the standard control. 2. In HW Config, in addition to the protocol for the standard functions (for example: telegram 1), insert your communications protocol for the fail-safe functions (e.g.
Page 84: Commissioning Tools
Commissioning the safety functions with STARTER is subsequently described. A tutorial is available for Startdrive: Startdrive tutorial (http://support.automation.siemens.com/WW/view/en/73598459). Commissioning: Online or offline With STARTER, you can work offline (without a connection to the converter) as well as online. We recommend that you commission the safety functions online.
Page 85: Resetting The Safety Function Parameters To The Factory Setting
Commissioning 5.4 Resetting the safety function parameters to the factory setting Resetting the safety function parameters to the factory setting Procedure To reset the safety function settings to the factory setting without changing the standard settings, proceed as follows: 1. Go online with STARTER ①...
Page 86: Changing Settings
Commissioning 5.5 Changing settings Changing settings Procedure To start commissioning the safety functions, proceed as follows: 1. Go online with STARTER 2. In STARTER, select the fail-safe functions. 3. Select "Change settings". Parameter Description p0010 = 95 Drive commissioning parameter filter Safety Integrated commissioning p9761 Enter a password (factory setting: 0000 hex)
Page 87 Commissioning 5.5 Changing settings Parameter Description p9601 Enable functions integrated in the drive (factory setting: 0000 bin) 0 hex Safety functions integrated in the drive inhibited 1 hex Basic function STO via onboard terminals is enabled 4 hex Extended Functions via onboard terminals are enabled 8 hex Basic function STO is enabled via PROFIsafe 9 hex...
Page 88 Commissioning 5.5 Changing settings Overview of the safety functions When starting to commission the system, you already define the following: ● Which safety functions are available? ● Which interfaces are used to control the safety functions? Not all of the Control Units have a safety output, also refer to Section: Overview of the safety-related inverter interfaces (Page 21).
Page 89 Commissioning 5.5 Changing settings Your selection Outcome of commissioning See section ... Basic functions Setting basic Select STO via F-DI. • via onboard functions Acknowledge safety function faults after selecting and deselecting STO. • terminals (Page 90). Additionally, with CU250S-2: Select SS1 via F-DI.
Page 90: Setting Basic Functions
Commissioning 5.6 Setting basic functions Setting basic functions STARTER screen form for the basic functions Depending on the interface that has been selected, one of the following versions is displayed on the STARTER screen form of the basic functions: ① ●...
Page 91: Interconnecting The "Sto Active" Signal
Commissioning 5.6 Setting basic functions 5.6.1 Interconnecting the "STO active" signal If you require the feedback signal "STO active" of the inverter in your higher-level control system, then you must appropriately interconnect the signal. Procedure To interconnect the "STO active" checkback signal, proceed as follows: 1.
Page 92: Configuring Profisafe
Commissioning 5.6 Setting basic functions 5.6.2 Configuring PROFIsafe Setting the address Procedure To set the PROFIsafe address, proceed as follows: 1. In STARTER select the input field for the PROFIsafe address 2. Enter the same address as hexadecimal value, which you defined in the hardware configuration (F_Dest_Add).
Page 93 Commissioning 5.6 Setting basic functions Starting communication via PROFIsafe When you connect the converter to the higher-level control system (F-CPU) via the fieldbus for the first time, the central control system sends the PROFIsafe configuration to the converter. After the configuration data have been received in the converter, PROFIsafecommunication starts.
Page 94: Setting The Filter For Safety Inputs
Commissioning 5.6 Setting basic functions 5.6.3 Setting the filter for safety inputs You must set the input filter and the simultaneity monitoring of the safety input for all SINAMICS inverters where the safety F-DI input evaluates two redundant signals. For SIMATIC ET 200pro FC, the input signal for STO is received from the F0 rail of the backplane bus of the ET-200pro system.
Page 95 Commissioning 5.6 Setting basic functions The tolerance time does not extend the inverter response time. The inverter selects its safety function as soon as one of the two F-DI signals changes its state from high to low. Figure 5-1 Tolerance regarding discrepancy Filter to suppress short signals The inverter normally responds immediately to signal changes at its safety-related inputs.
Page 96 Commissioning 5.6 Setting basic functions Figure 5-2 Inverter response to a bit pattern test An adjustable signal filter in the inverter suppresses temporary signal changes using bit pattern test or contact bounce. The filter increases the inverter response time. The inverter only selects its safety function after the debounce time has elapsed.
Page 97 Commissioning 5.6 Setting basic functions Debounce times for standard and safety functions The debounce time p0724 for "standard" digital inputs does not influence the safety input signals. Conversely, the same applies: The F-DI debounce time does not affect the signals of the "standard"...
Page 98: Setting The Forced Checking Procedure (Test Stop)
Commissioning 5.6 Setting basic functions 5.6.4 Setting the forced checking procedure (test stop) Procedure To set the forced checking procedure (test stop) of the basic functions, proceed as follows: 1. Select the advanced settings for STO. 2. Set the monitoring time to a value to match your application. 3.
Page 99: Setting The Delay Time For Ss1
Commissioning 5.6 Setting basic functions 5.6.5 Setting the delay time for SS1 Procedure Set the delay time for SS1. The delay time must be longer than the OFF3 ramp-down time. You have set the SS1 function. Parameter Description p9652 Safe Stop 1 delay time Sets the delay time of the pulse suppression for the "Safe Stop 1"...
Page 100: Enabling Sbc
Commissioning 5.6 Setting basic functions 5.6.6 Enabling SBC Procedure Enable the SBC function. You have enabled the SBC function. Parameter Description p9602 Enable safe brake control 0: SBC is locked 1: SBC is enabled Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 101: Final Steps
Commissioning 5.6 Setting basic functions 5.6.7 Final steps Activate settings Procedure To activate the settings for the safety functions, proceed as follows: 1. Press the "Copy parameters" button, to create a redundant image of your inverter settings. 2. Press the "Activate settings" button. 3.
Page 102 Commissioning 5.6 Setting basic functions Figure 5-6 Example: Assignment of digital inputs DI 4 and DI 5 with STO Procedure In order to prevent the safety-related inputs of the safety functions unintentionally controlling "standard" functions in the inverter, proceed as follows: 1.
Page 103: Setting Extended Functions
Commissioning 5.7 Setting extended functions Setting extended functions STARTER screen form for setting the extended functions The following STARTER screen form is the starting point for all subsequent settings: Overview of the procedure To set all extended functions, proceed as follows: 1.
Page 104: Basic Settings
Commissioning 5.7 Setting extended functions 5.7.1 Basic settings 5.7.1.1 Enabling safety functions Enabling safety functions Procedure To enable the safety functions, proceed as follows: 1. Select the STARTER screen form for the extended functions. 2. Enable the safety functions. You have enabled the safety functions in the inverter. 5.7.1.2 Setting the forced dormant error detection (test stop) Procedure...
Page 105 Commissioning 5.7 Setting extended functions ① – This signal starts the forced dormant error detection and sets the remaining ③ monitoring time to the value . Interconnect this signal, for example, with a digital input or a bit in the fieldbus control word. ②...
Page 106 Commissioning 5.7 Setting extended functions Description The forced dormant error detection (test stop) of the extended functions is an inverter self test. The inverter checks its circuits to monitor the speed and to switch off the torque. Using a timer block, the inverter monitors as to whether the forced dormant error detection is regularly performed.
Page 107: Setting The Gear Ratio And Actual Value Tolerance
Commissioning 5.7 Setting extended functions 5.7.1.3 Setting the gear ratio and actual value tolerance Procedure To set the gear ratio and the actual value tolerance, proceed as follows: 1. Press the "Configuration" button. 2. Press the "Mechanical configuration" button. 3. Set the following: ①...
Page 108 Commissioning 5.7 Setting extended functions Parameter Description p9521 Number of load revolutions (factory setting: 1) Denominator for the gear ratio between the motor and load. p9522 Number of motor revolutions (factory setting: 2000 rpm) Numerator for the gear ratio between the motor and load. p9542 Actual value tolerance (Factory setting: 12 °) Tolerance for the crosswise comparison of the actual position between processor 1...
Page 109: Setting Encoderless Actual Value Sensing
Commissioning 5.7 Setting extended functions 5.7.1.4 Setting encoderless actual value sensing Procedure To set the encoderless actual value sensing, proceed as follows: 1. Press the "Configuration" button. 2. Press the "Configuration actual value sensing" button. 3. Set the following: ① –...
Page 110 Commissioning 5.7 Setting extended functions Parameter Description p9585 Fault tolerance (Factory setting: -1) Plausibility monitoring tolerance for the current and voltage angle. p9586 Delay time actual value sensing (Factory setting: 100 ms) Delay time for evaluating the encoderless actual value sensing after the motor has been switched on.
Page 111: Setting Safety Inputs
Commissioning 5.7 Setting extended functions 5.7.2 Setting safety inputs Precondition You have selected the extended functions via onboard terminals. Procedure To interconnect the safety inputs with safety functions, proceed as follows: 1. Press the "Safety inputs/outputs" button. 2. Click the "Drive" button. 3.
Page 112 Commissioning 5.7 Setting extended functions Parameter Description p10022 STO input terminal (Factory setting: 0) p10023 SS1 input terminal (Factory setting: 0) p10026 SLS input terminal (Factory setting: 0) p10030 SDI positive input terminal (Factory setting: 0) p10031 SDI negative input terminal (Factory setting: 0) 0: Static, active 1: F-DI 0 2: F-DI 1...
Page 113: Setting The Filter For Safety Inputs
Commissioning 5.7 Setting extended functions 5.7.2.1 Setting the filter for safety inputs Control via onboard terminals Precondition You have selected the extended functions via onboard terminals. Procedure To set the filters for the safety inputs, proceed as follows: 1. Press the "Safety inputs/outputs" button. 2.
Page 114 Commissioning 5.7 Setting extended functions Control via PROFIsafe and onboard terminals Precondition You have selected the extended functions via PROFIsafe and onboard terminals. Procedure To set the filters for the safety inputs, proceed as follows: 1. Press the "Safety basic functions" button. 2.
Page 115 Commissioning 5.7 Setting extended functions 3. Set the following: ③ – Discrepancy time (simultaneity monitoring) of the safety input. ④ – Input filter of the safety input. 4. Close the screen forms. You have set the filter for the safety inputs. Description of the signal filter The following are available for the signal processing of the safety-related inputs: ●...
Page 116 Commissioning 5.7 Setting extended functions A tolerance for the simultaneous monitoring The inverter checks whether the signals at both inputs always have the same signal status (high or low). With electromechanical sensors (e.g. emergency stop buttons or door switches), the two sensor contacts never switch at exactly the same time and are therefore temporarily inconsistent (discrepancy).
Page 117 Commissioning 5.7 Setting extended functions If the safety-related input signals too many signal changes within a certain time, then the inverter responds with a fault. Figure 5-10 Inverter response to a bit pattern test An adjustable signal filter in the inverter suppresses temporary signal changes using bit pattern test or contact bounce.
Page 118 Commissioning 5.7 Setting extended functions Debounce times for standard and safety functions The debounce time p0724 for "standard" digital inputs does not influence the signals of the safety inputs F-DI. Conversely, the same applies: The F-DI debounce time does not affect the signals of the "standard"...
Page 119: Interconnecting The Signal For Fail-Safe Acknowledgment
Commissioning 5.7 Setting extended functions 5.7.2.2 Interconnecting the signal for fail-safe acknowledgment Precondition You have selected the extended functions via onboard terminals. Procedure To assign the fail-safe acknowledgement signal to a safety input, proceed as follows: 1. Press the "Safety inputs/outputs" button. 2.
Page 120: Setting A Safety Output
Commissioning 5.7 Setting extended functions 5.7.3 Setting a safety output 5.7.3.1 Output signal and setting the test mode Precondition You have selected the extended functions via onboard terminals. Procedure To set the safety output, proceed as follows: 1. Press the "Safety inputs/outputs" button. 2.
Page 121 Commissioning 5.7 Setting extended functions 3. Interconnect the status signals of your choice with the fail-safe output. The following signals are available: – STO active – SS1 active – SLS active – SSM feedback active – Internal event – SDI positive active –...
Page 122 Commissioning 5.7 Setting extended functions Description: Test mode of the safety output Using its adjustable test mode, the inverter checks as to whether the safety output can be shut down. The test mode is aligned according to the interconnection of the safety output. For test modes 2 and 3, you must adapt the appropriate wait time to your particular application.
Page 123 Commissioning 5.7 Setting extended functions Test mode 3 When testing the safety output, the inverter switches off the two outputs one after the other and evaluates the feedback via a digital input. Figure 5-14 Expected response at the digital input for test mode 3 Test mode 4 When testing the safety output, the inverter switches off the two outputs one after the other.
Page 124 Commissioning 5.7 Setting extended functions Parameter Description p10039 Safe State signal selection (factory setting: 0000 0001 bin) Setting the signals for the "Safe State" signal. p10042[0…5] F-DO signal sources (Factory setting: 0) Setting the 6 signal sources for F-DO. p10046 F-DO feedback signal input activation (Factory setting: 0000 bin) Activation of the feedback input for the safety output.
Page 125: Setting The Forced Dormant Error Detection (Test Stop)
Commissioning 5.7 Setting extended functions 5.7.3.2 Setting the forced dormant error detection (test stop) Precondition You have selected the extended functions via onboard terminals. Procedure To set the forced dormant error detection (test stop) of the safety output, proceed as follows: 1.
Page 126 Commissioning 5.7 Setting extended functions Description: Forced dormant error detection of the safety output The forced dormant error detection of the safety output is the regular self-test of the inverter, in which the inverter checks whether the output can be shut down (deactivated). The inverter monitors the regular forced dormant error detection of the safety output using a timer element.
Page 127: Configuring Profisafe In The Converter
Commissioning 5.7 Setting extended functions 5.7.4 Configuring PROFIsafe in the converter Precondition You have selected PROFIsafe as interface. Procedure Proceed as follows to assign the inverter a PROFIsafe address: 1. Press the "Configuration" button. 2. Enter the same PROFIsafe address in the hexadecimal format that you defined in the hardware configuration.
Page 128 Commissioning 5.7 Setting extended functions Setting PROFIsafe telegram 900 Precondition You have selected the extended functions "via PROFIsafe" or "via PROFIsafe and onboard terminals" Procedure To set the PROFIsafe telegram 900, proceed as follows: 1. Press the "Safety inputs" button. 2.
Page 129 Commissioning 5.7 Setting extended functions Enabling Shared Device If you control the inverter safety functions via PROFINET and "Shared Device", you must enable this function in the inverter. See also Section: Configuring shared device communication via PROFINET (Page 82). Procedure To configure communication via "Shared Device"...
Page 130: Setting Ss1
Commissioning 5.7 Setting extended functions 5.7.5 Setting SS1 Monitoring modes You can select between two different monitoring modes of the SS1 function. Braking ramp monitoring Acceleration monitoring Using the SBR (Safe Brake Ramp) function, The inverter monitors the motor speed using •...
Page 131: Setting Ss1 With Braking Ramp Monitoring
Commissioning 5.7 Setting extended functions 5.7.5.1 Setting SS1 with braking ramp monitoring Procedure To set the SS1 function with braking ramp monitoring, proceed as follows: 1. Select "[1] Safety without encoder with braking ramp (SBR)". 2. Press the "Safe stop functions" button. 3.
Page 132 Commissioning 5.7 Setting extended functions A monitoring time shorter than the above calculated value does not make sense, as the inverter can reduce its monitoring curve faster than the load can be braked. The longer you set the monitoring times, the more tolerant the monitoring. ⑥...
Page 133 Commissioning 5.7 Setting extended functions Shutdown speed The inverter safely switches off the motor torque using the STO function if the speed has reached the shutdown speed. Parameter Description p9501.00 1 signal: Enable extended functions. 0 signal: Disable extended functions. p9506 Function specification: (Factory setting: 1) With braking ramp monitoring...
Page 134: Setting Ss1 With Acceleration Monitoring
Commissioning 5.7 Setting extended functions 5.7.5.2 Setting SS1 with acceleration monitoring Procedure To set the SS1 function with acceleration monitoring, proceed as follows: 1. Select "[3] Safety without encoder with accel_monitoring (SAM)/delay time". 2. Press the "Safe stop functions" button. 3.
Page 135 Commissioning 5.7 Setting extended functions Description: SS1 with acceleration monitoring Figure 5-18 SS1 with acceleration monitoring Speed tolerance As long as the speed is less, the inverter continuously adds the tolerance to the actual speed so that the monitoring tracks the speed. Shutdown speed acceleration monitoring The inverter reduces the monitoring threshold until it reaches the value of the "Shutdown speed acceleration monitoring".
Page 136 Commissioning 5.7 Setting extended functions Parameter Description p9501.00 1 signal: Enable extended functions. 0 signal: Disable extended functions. p9506 Function specification: (Factory setting: 1) With acceleration monitoring p9548 Speed tolerance (Factory setting: 300 rpm) p9556 Delay time STOP B → STO (Factory setting: 600000 ms) p9560 Shutdown speed SS1 (Factory setting: 10 rpm) p9568...
Page 137: Setting Sls
Commissioning 5.7 Setting extended functions 5.7.6 Setting SLS 5.7.6.1 Setting the monitoring functions Procedure To set the SLS function, proceed as follows: 1. In the main screen form of the extended functions, select one of the two monitoring modes: – [1] Safety without encoder with braking ramp (SBR) –...
Page 138 Commissioning 5.7 Setting extended functions 3. Set the following: ③ – The delay time only appears if you have selected acceleration monitoring (SAM). The delay time must be longer than the time, when SLS is selected, that the motor needs to brake with the maximum load from the maximum speed down to the lowest SLS level.
Page 139 Commissioning 5.7 Setting extended functions Description of the SLS function Figure 5-19 Behavior after selecting SLS. Left: with braking ramp monitoring; right: without braking ramp monitoring After selecting SLS, the inverter brakes the motor according to the OFF3 ramp-down time. Setting the braking ramp monitoring is described in Section.
Page 140 Commissioning 5.7 Setting extended functions Parameter Description p1135 OFF3 ramp-down time p9501.00 1 signal: Enable SLS and extended functions. 0 signal: Inhibit SLS and extended functions. p9506 Function specification: (Factory setting: 1) With braking ramp monitoring Without braking ramp monitoring p9531[0…3] Speed monitoring (Factory setting for all levels: 2000 rpm) p9533...
Page 141: Settings For Acceptance Test
Commissioning 5.7 Setting extended functions 5.7.6.2 Settings for acceptance test In order to be able to approach the monitoring limit of the safety function during the acceptance test, you must temporarily deactivate speed limiting in the inverter. Starter offers you the possibility to temporarily deactivating speed limiting. Procedure To prepare for acceptance, proceed as follows: 1.
Page 142: Setting Ssm
Commissioning 5.7 Setting extended functions 5.7.7 Setting SSM Procedure To set the SSM function, proceed as follows: 1. In the main screen form of the extended functions, select the SSM safety function. 2. Set the following in this screen form: ①...
Page 143 Commissioning 5.7 Setting extended functions Description: SSM without hysteresis Speed monitoring ● When the motor is switched on, the inverter compares the load speed with the speed limit. Figure 5-20 Time response of the SSM safety function without hysteresis Parameter Description p9501.00 1 signal: Enable extended functions.
Page 144 Commissioning 5.7 Setting extended functions Description: SSM with hysteresis If you wish to monitor speeds that are very close to the speed limit, you may find it useful to set the hysteresis. Speed monitoring ● When the motor is switched on, the inverter compares the load speed with the speed limit, taking the hysteresis into account.
Page 145 Commissioning 5.7 Setting extended functions Parameter Description p9501.00 1 signal: Enable extended functions. 0 signal: Disable extended functions. p9501.16 1 signal: Enable hysteresis and filtering 0 signal: Disable hysteresis and filtering p9545 Filter time (Factory setting: 0 ms) p9546 Speed limit (Factory setting: 20 rpm) p9547 Hysteresis (Factory setting: 10 rpm) r9722.15...
Page 146: Setting Sdi
Commissioning 5.7 Setting extended functions 5.7.8 Setting SDI 5.7.8.1 Setting the monitoring functions Procedure To set the SDI function, proceed as follows: 1. Select the safety function SDI. 2. Set the following in this screen form: ① – Enable the function. ②...
Page 147 Commissioning 5.7 Setting extended functions Description of the SDI function Time response If you select SDI, the inverter limits the speed or velocity setpoint to a value of zero in the inhibited direction of rotation. Figure 5-24 Delay time and tolerance Delay time The inverter monitors the direction of rotation of the motor after the delay time has expired.
Page 148 Commissioning 5.7 Setting extended functions Feedback signal SDI when the motor is switched off You can select as to whether the SDI function should remain active when the motor is switched off. ● With the motor switched off, the inverter freezes the "SDI active" signal. ●...
Page 149: Settings For Acceptance Test
Commissioning 5.7 Setting extended functions 5.7.8.2 Settings for acceptance test In order to be able to approach the monitoring limit of the safety function during the acceptance test, you must temporarily deactivate speed limiting in the inverter. Starter offers you the possibility to temporarily deactivating speed limiting. Procedure To prepare for acceptance, proceed as follows: 1.
Page 150: Final Steps
Commissioning 5.7 Setting extended functions 5.7.9 Final steps Activate settings Procedure To activate the settings for the safety functions, proceed as follows: 1. Press the "Copy parameters" button, to create a redundant image of your inverter settings. 2. Press the "Activate settings" button. 3.
Page 151 Commissioning 5.7 Setting extended functions Figure 5-26 Example: Assignment of digital inputs DI 4 and DI 5 with STO Procedure In order to prevent the safety-related inputs of the safety functions unintentionally controlling "standard" functions in the inverter, proceed as follows: 1.
Page 152 3. Remove the interconnection of the digital input that you use as feedback signal input for the safety output: – SINAMICS G120 with CU250S-2 Control Unit: Digital input DI 6 (see diagram). – SINAMICS G120D: Digital input DI 5. 4. If you use the CDS data set switchover, remove the interconnection of the feedback signal input for all CDS.
Page 153: Offline Commissioning
Commissioning 5.8 Offline commissioning Offline commissioning When you set the safety function parameters offline, you have to download them to the inverter. Once you have downloaded them, you have to finish commissioning the safety functions online. The screens for the safety functions differ from each other slightly depending on whether you work with STARTER online or offline.
Page 154 Commissioning 5.8 Offline commissioning Loading the settings into an inverter using STARTER Procedure To load the settings to the inverter, proceed as follows: 1. Go online with STARTER and start to download to the inverter using the button After the download, the inverter signals faults. Ignore these faults, as they will be automatically acknowledged by the following steps.
Page 155: Series Commissioning
Commissioning 5.9 Series commissioning Series commissioning Series commissioning is the process where you transfer the settings of one inverter to a second inverter. Procedure To transfer settings from one inverter to another, proceed as follows: 1. Using STARTER , save your project to your PC or PG. 2.
Page 156: Acceptance Tests For The Safety Functions
Commissioning 5.10 Acceptance tests for the safety functions 5.10 Acceptance tests for the safety functions 5.10.1 Acceptance test What is an acceptance? The machine manufacturer is responsible in ensuring that his plant or machine functions perfectly. As a consequence, after commissioning, the machine manufacturer must check those functions or have them checked by specialist personnel, which represent an increased risk of injury to personnel or material damage.
Page 157 Commissioning 5.10 Acceptance tests for the safety functions Documentation of the inverter The following must be documented for the inverter: ● The results of the acceptance test. ● The settings of the integrated drive safety functions. The commissioning tool STARTER logs the settings of the integrated drive functions, if necessary.
Page 158: Reduced Acceptance Test After Expanding The Function
Commissioning 5.10 Acceptance tests for the safety functions 5.10.2 Reduced acceptance test after expanding the function A full acceptance test is necessary only after first commissioning. A reduced acceptance test is sufficient when safety functions are expanded. Table 5- 4 Reduced acceptance test after expanding the function Measure Acceptance test...
Page 159: Operation
Operation Overview and relevant inverter signals About this chapter This chapter answers the following questions: ● How must you regularly test the drive in order to maintain the assured probability of failure of the safety functions? ● How does the drive respond when you select and deselect one of the safety functions? ●...
Page 160 Operation 6.1 Overview and relevant inverter signals Inverter signals Most of the inverter signals in this chapter are contained in the PROFIsafe telegram, can be connected with a safety input or output – and are assigned the following parameters: Inverter signals PROFIsafe F-DI F-DO...
Page 161: Regularly Testing The Safety Functions
Operation 6.2 Regularly testing the safety functions Regularly testing the safety functions 6.2.1 Overview Overview You must initiate the following function tests as a minimum once per year in order to maintain the assured failure probability of the safety functions: ●...
Page 162: Testing The Basic Functions
Operation 6.2 Regularly testing the safety functions 6.2.3 Testing the basic functions Time The inverter monitors as to whether the self test (= forced dormant error detection, test stop) is regularly started. Figure 6-1 Starting and monitoring the forced dormant error detection (test stop) In the case of alarm A01699, you must initiate a self test at the next opportunity, e.g.: ●...
Page 163: Testing The Extended Functions
Operation 6.2 Regularly testing the safety functions 6.2.4 Testing the extended functions Time The inverter monitors as to whether the self test (= forced dormant error detection, test stop) is regularly started. Figure 6-2 Starting and monitoring the forced dormant error detection (test stop) If the inverter outputs alarm A01699 or A01697, you must initiate a forced dormant error detection at the next opportunity, e.g.: ●...
Page 164 Operation 6.2 Regularly testing the safety functions Performing a forced dormant error detection (test stop) When testing the extended functions, the inverter switches the motor into a no-torque condition. Preconditions ● STO is not active. If you start the forced dormant error detection with STO active, then the inverter responds with a fault.
Page 165: Testing A Safety Output
Operation 6.2 Regularly testing the safety functions 6.2.5 Testing a safety output Time of the test The inverter monitors that the test is regularly performed using a time block. Figure 6-3 Start and monitoring of the forced dormant error detection (test stop) of the safety output If the inverter outputs alarm A01774, you must initiate the test at the next opportunity, e.g.: ●...
Page 166 Operation 6.2 Regularly testing the safety functions The response of the safety output depends on the test stop mode that has been selected. Figure 6-4 Test stop mode 2 Figure 6-5 Test stop mode 3 Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 167 Operation 6.2 Regularly testing the safety functions Figure 6-6 Test stop mode 4 Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 168: Safe Torque Off (Sto)
Operation 6.3 Safe Torque Off (STO) Safe Torque Off (STO) 6.3.1 Overview What can you find in this Chapter? The relevant operating cases for the STO function are described in this chapter. Table 6- 1 Operating cases for the STO function when the motor is switched on (ON/OFF1 = 1) Selecting and deselecting STO →...
Page 169: Selecting And Deselecting Sto When The Motor Is Switched On
Operation 6.3 Safe Torque Off (STO) 6.3.2 Selecting and deselecting STO when the motor is switched on Select STO Function 1. The machine control selects the STO safety function via a safety input or via PROFIsafe (safety-related bus communication). 2. The inverter then safely switches off the motor torque. Figure 6-7 Time response of the STO safety function (Safe Torque Off) Switching on the motor once STO is active...
Page 170: Response To A Discrepancy When Sto Is Active
Operation 6.3 Safe Torque Off (STO) 6.3.3 Response to a discrepancy when STO is active The inverter responds to a discrepancy at the safety input by activating safety function STO. The inverter response depends on the setting of the inverter: ●...
Page 171 Operation 6.3 Safe Torque Off (STO) Independent of the voltage levels available, the inverter sets the evaluation of the discrepant F-DI into the safe state (=zero) until you acknowledge the inverter using a fail-safe signal or using a power-on reset. Case 1: Switching on the motor after a discrepancy Procedure To switch the motor on again, proceed as follows:...
Page 172 Operation 6.3 Safe Torque Off (STO) Case 2: Response of the drive for STO of the extended functions You have selected the extended functions via onboard terminals. Figure 6-9 Response of safety function STO in the event of a discrepancy The inverter does not set the error bit of the safety functions (= internal event).
Page 173: Safe Brake Control (Sbc)
Operation 6.4 Safe Brake Control (SBC) Safe Brake Control (SBC) 6.4.1 Selecting and deselecting SBC when the motor is switched on If you have connected the motor holding brake to the inverter via the Safe Brake Relay, then the SBC function is active under the following conditions: 1.
Page 174 Operation 6.4 Safe Brake Control (SBC) Selecting SS1 when the motor is rotating Function 1. The higher-level control selects the SS1 function 2. The inverter brakes the motor with the OFF3 ramp-down time. 3. The inverter closes the motor holding brake once the motor is at a standstill. 4.
Page 175 Operation 6.4 Safe Brake Control (SBC) Selecting STO when the motor is rotating Function 1. The higher-level control selects the STO function. 2. The inverter closes the brake without taking the current speed into consideration. Figure 6-12 The motor holding brake closes after selecting STO Before you can switch on the motor again, you must deselect the STO function.
Page 176: Response To Faults In The Brake Control
Operation 6.4 Safe Brake Control (SBC) 6.4.2 Response to faults in the brake control Faults in the brake control When opening or closing the brake, the inverter identifies faults in the brake cable and in the brake winding. ① Control cable from the inverter to the Safe Brake Relay is interrupted ②...
Page 177: Safe Stop 1 (Ss1)
Operation 6.5 Safe Stop 1 (SS1) Safe Stop 1 (SS1) 6.5.1 Overview What can you find in this Chapter? The relevant operating cases for the SS1 function are described in this chapter. Table 6- 3 Response of the SS1 function when the motor is switched on (ON/OFF1 = 1) Select and deselect SS1 →...
Page 178: Selecting And Deselecting Ss1 When The Motor Is Switched On
Operation 6.5 Safe Stop 1 (SS1) 6.5.2 Selecting and deselecting SS1 when the motor is switched on 6.5.2.1 SS1 without monitoring Select SS1 Function 1. The higher-level control selects the SS1 function via a safety input or via the PROFIsafe safe communication.
Page 179: Ss1 With Braking Ramp Monitoring
Operation 6.5 Safe Stop 1 (SS1) 6.5.2.2 SS1 with braking ramp monitoring Select SS1 Function 1. The higher-level control selects the SS1 safety function via a safety input or via the PROFIsafe safe communication. 2. If the motor has already been switched off when selecting SS1, then the inverter safely switches off the motor torque with the safety function STO.
Page 180: Ss1 With Acceleration Monitoring
Operation 6.5 Safe Stop 1 (SS1) 6.5.2.3 SS1 with acceleration monitoring Select SS1 Function 1. The higher-level control selects the SS1 safety function via a safety input or via the PROFIsafe safe communication. 2. If the motor has already been switched off when selecting SS1, then the inverter safely switches off the motor torque with the safety function STO.
Page 181 Operation 6.5 Safe Stop 1 (SS1) Switching on the motor once SS1 is active Procedure To switch on the motor again once SS1 is active, proceed as follows: 1. Deselect SS1. 2. Switch on the motor: ON/OFF1 = 1. You have switched on the motor. Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 182: Switching Off The Motor When Ss1 Is Active
Operation 6.5 Safe Stop 1 (SS1) 6.5.3 Switching off the motor when SS1 is active Description If you switch the motor off with the OFF1 or OFF3 command while the SS1 safety function is active, for example when limit switches are reached, this does not affect how the motor behaves.
Page 183: Response To A Discrepancy When Ss1 Is Active
Operation 6.5 Safe Stop 1 (SS1) 6.5.4 Response to a discrepancy when SS1 is active The inverter responds with the active safety function SS1 to a discrepancy at the safety input. The behavior of the drive depends on the setting of the inverter. 1.
Page 184 Operation 6.5 Safe Stop 1 (SS1) Independent of the voltage levels available, the inverter sets the evaluation of the discrepant F-DI into the safe state (=zero) until you acknowledge the inverter using a fail-safe signal or using a power-on reset. Switching on the motor after a discrepancy Procedure To switch the motor on again, proceed as follows:...
Page 185 Operation 6.5 Safe Stop 1 (SS1) 2. case: Response of the drive for SS1 of the extended functions You have selected the extended functions via onboard terminals. Figure 6-19 Inverter response for discrepancy of the input signal for SS1 (as example: SS1 with braking ramp monitoring) The inverter does not set the error bit of the safety functions (= internal event).
Page 186 Operation 6.5 Safe Stop 1 (SS1) Switching on the motor after a discrepancy Procedure To switch the motor on again, proceed as follows: 1. Remove the discrepancy. 2. Acknowledge the discrepancy message with the fail-safe acknowledge signal via a safety input: F-DI = 0 →...
Page 187: Limit Value Violation When Ss1 Is Active
Operation 6.5 Safe Stop 1 (SS1) 6.5.5 Limit value violation when SS1 is active Drive response If motion monitoring detects a fault when SS1 is active, the inverter safely switches off the motor torque (STOP A). Figure 6-20 General fault response of safety function SS1 (as an example: SS1 with acceleration monitoring) Switching the motor on after an internal event Procedure...
Page 188: Safely Limited Speed (Sls)
Operation 6.6 Safely Limited Speed (SLS) Safely Limited Speed (SLS) 6.6.1 Overview What can you find in this Chapter? The relevant operating cases for the SLS function are described in this chapter. Table 6- 5 Response of the SLS function when the motor is switched on (ON/OFF1 = 1) Selecting and deselecting SLS →...
Page 189: Selecting And Deselecting Sls When The Motor Is Switched On
Operation 6.6 Safely Limited Speed (SLS) 6.6.2 Selecting and deselecting SLS when the motor is switched on Selecting SLS when the motor is switched on As soon as the inverter detects the selection of SLS via a safety input or via the PROFIsafe safe communication, the following happens: ●...
Page 190 Operation 6.6 Safely Limited Speed (SLS) Selecting SLS at low motor speeds If the motor speed when selecting SLS is less than the SLS limit, then the drive responds as follows: With braking ramp monitoring Without braking ramp monitoring The inverter monitors the speed after the "delay The inverter monitors the load speed after an time for the braking ramp".
Page 191: Sls With Braking Ramp Monitoring
Operation 6.6 Safely Limited Speed (SLS) 6.6.2.1 SLS with braking ramp monitoring Selecting and deselecting SLS If the machine control selects the SLS safety function via a safety input or via the PROFIsafe safe communication , then the motor behaves differently depending on the absolute value of the load speed.
Page 192 Operation 6.6 Safely Limited Speed (SLS) Scenario 2: The absolute value of the load speed is higher than the setpoint speed limit. Function 1. The inverter brakes the motor. 2. The inverter monitors the speed after the delay time has expired. 3.
Page 193: Sls Without Braking Ramp Monitoring
Operation 6.6 Safely Limited Speed (SLS) 6.6.2.2 SLS without braking ramp monitoring Selecting and deselecting SLS If the machine control selects the SLS safety function via a safety input or via the PROFIsafe safe communication , then the motor behaves differently depending on the absolute value of the load speed.
Page 194 Operation 6.6 Safely Limited Speed (SLS) Scenario 2: The absolute value of the load speed is higher than the monitoring threshold. Function 1. The inverter brakes the motor. 2. The inverter monitors the speed after the delay time has expired. 3.
Page 195: Switching Over Sls Levels
Operation 6.6 Safely Limited Speed (SLS) 6.6.3 Switching over SLS levels Overview When SLS is active, you can switch between four different speed levels via PROFIsafe. The drive response when switching over to a lower SLS level depends on whether you have selected SLS with or without braking ramp monitoring.
Page 196: Sls With Braking Ramp Monitoring
Operation 6.6 Safely Limited Speed (SLS) 6.6.3.1 SLS with braking ramp monitoring Switching over SLS levels When is SLS is active, you can switch between four different speed monitoring levels (SLS levels). Note Switching over SLS levels is only possible via PROFIsafe with control word 1. See also Section: Control word 1 and status word 1 (extended functions) (Page 48).
Page 197 Operation 6.6 Safely Limited Speed (SLS) Figure 6-25 Switching between different monitoring thresholds The inverter signals the active SLS level via PROFIsafe to the higher-level control. See also Section: Control word 1 and status word 1 (extended functions) (Page 48). Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 198: Sls Without Braking Ramp Monitoring
Operation 6.6 Safely Limited Speed (SLS) 6.6.3.2 SLS without braking ramp monitoring Switching over SLS levels When is SLS is active, you can switch between four different speed monitoring levels (SLS levels). Note Switching over SLS levels is only possible via PROFIsafe with control word 1. See also Section: Control word 1 and status word 1 (extended functions) (Page 48).
Page 199: Switching Off The Motor When Sls Is Active
Operation 6.6 Safely Limited Speed (SLS) 6.6.4 Switching off the motor when SLS is active Description If you switch off the motor with the SLS function active using the OFF1 or OFF3 command, e.g. when reaching limit switches, the following happens: 1.
Page 200 Operation 6.6 Safely Limited Speed (SLS) If you switch off the motor using the OFF2 command, then the inverter immediately safely switches off the motor torque using the STO safety function. Figure 6-28 OFF2 command when the SLS safety function is active Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 201: Switching On The Motor When Sls Is Active
Operation 6.6 Safely Limited Speed (SLS) 6.6.5 Switching on the motor when SLS is active Switch on motor Procedure To switch the motor on with SLS active, proceed as follows: 1. Select STO (or SS1). 2. Deselect STO (or SS1). 3.
Page 202: Response To A Discrepancy When Sls Is Active
Operation 6.6 Safely Limited Speed (SLS) 6.6.6 Response to a discrepancy when SLS is active Drive response The inverter responds with the active SLS safety function to a discrepancy at the safety input. Figure 6-30 Behavior of the inverter for discrepancy of the input signal for SLS The inverter does not set the error bit of the safety functions (= internal event).
Page 203 Operation 6.6 Safely Limited Speed (SLS) Deselecting SLS after a discrepancy Procedure To deselect SLS, proceed as follows: 1. Remove the discrepancy. 2. Acknowledge the discrepancy message with the fail-safe acknowledge signal via a safety input: F-DI = 0 → 1 → 0. Alternatively, you can acknowledge the message in one of the following ways.
Page 204: Limit Value Violation When Sls Is Active
Operation 6.6 Safely Limited Speed (SLS) 6.6.7 Limit value violation when SLS is active Drive response When motion monitoring detects a fault when SLS is active, the inverter responds by triggering a STOP A or STOP B. The inverter response is parameterized during commissioning.
Page 205 Operation 6.6 Safely Limited Speed (SLS) Switching the motor on after an internal event Procedure To switch the motor on after an internal event while SLS is active, proceed as follows: 1. Deselect the SLS function. 2. Issue an OFF1 command (ON/OFF1 = 0). 3.
Page 206: Safe Speed Monitor (Ssm)
Operation 6.7 Safe Speed Monitor (SSM) Safe Speed Monitor (SSM) 6.7.1 Overview What can you find in this Chapter? The relevant operating cases for the SSM function are described in this chapter. Table 6- 7 Response of the SSM function when the motor is switched on (ON/OFF1 = 1) Feedback signal The SSM function signals as to whether the motor speed is above or below the set SSM limit value.
Page 207: Selecting Ssm When The Motor Is Switched On
Operation 6.7 Safe Speed Monitor (SSM) 6.7.2 Selecting SSM when the motor is switched on Description The safety function SSM cannot be selected or deselected using external control signals. SSM is active if all of the following conditions are met: ●...
Page 208: Switching Off The Motor When Ssm Is Active
Operation 6.7 Safe Speed Monitor (SSM) 6.7.3 Switching off the motor when SSM is active Description If you switch off the motor with the SSM function active using the OFF1 or OFF3 command, e.g. when reaching limit switches, the following happens: 1.
Page 209 Operation 6.7 Safe Speed Monitor (SSM) The inverter brakes the motor down to a standstill using the OFF1 or OFF3 command and then switches it off. If the "SSM active" feedback signal should remain active when the pulses are inhibited, then the inverter safely switches off the motor torque using the safety function STO.
Page 210 Operation 6.7 Safe Speed Monitor (SSM) The inverter immediately switches off the motor with the OFF2 command. If the "SSM active" feedback signal should remain active when the pulses are inhibited, then the inverter safely switches off the motor torque using the safety function STO. Figure 6-34 OFF2 command when the SSM safety function is active Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2...
Page 211 Operation 6.7 Safe Speed Monitor (SSM) When switching off, the speed is higher than the SSM limit value The inverter brakes the motor down to a standstill using the OFF1 or OFF3 command and then switches it off. If the "SSM active" feedback signal should remain active when the pulses are inhibited, then the inverter safely switches off the motor torque using the safety function STO.
Page 212 Operation 6.7 Safe Speed Monitor (SSM) The inverter immediately switches off the motor with the OFF2 command. If the "SSM active" feedback signal should remain active when the pulses are inhibited, then the inverter safely switches off the motor torque using the safety function STO. The feedback signal "SSM active"...
Page 213: Switching On The Motor When Ssm Is Active
Operation 6.7 Safe Speed Monitor (SSM) 6.7.4 Switching on the motor when SSM is active The procedure for switching on the motor depends on how you have set the SSM function. The feedback signal "SSM active" for pulse inhibit becomes inactive With this setting, the SSM function does not influence switching on the motor.
Page 214 Operation 6.7 Safe Speed Monitor (SSM) The feedback signal "SSM active" for pulse inhibit remains active With this setting, you must maintain a certain sequence before switching on the motor. Procedure To switch the motor on, proceed as follows: 1. Select STO (or SS1) after the motor has been switched off. 2.
Page 215: Safe Direction (Sdi)
Operation 6.8 Safe Direction (SDI) Safe Direction (SDI) 6.8.1 Overview What can you find in this Chapter? The relevant operating cases for the SDI function are described in this chapter. Table 6- 9 Response of the SDI function when the motor is switched on (ON/OFF1 = 1) Selecting and deselecting →...
Page 216: Selecting And Deselecting Sdi When The Motor Is Switched On
Operation 6.8 Safe Direction (SDI) 6.8.2 Selecting and deselecting SDI when the motor is switched on Select SDI Function 1. The higher-level control selects the SDI safety function via a safety input or via the PROFIsafe safe communication. 2. The inverter limits the speed to the permitted direction of rotation. When SDI is selected, if the motor rotates in the impermissible direction, then the inverter brakes the motor down to standstill.
Page 217: Switching Off The Motor When Sdi Is Active
Operation 6.8 Safe Direction (SDI) 6.8.3 Switching off the motor when SDI is active Description If you switch off the motor with the SDI function active using the OFF1 or OFF3 command, e.g. when reaching limit switches, the following happens: 1.
Page 218 Operation 6.8 Safe Direction (SDI) If you switch the motor off with the OFF2 command when the SDI safety function is active, the inverter immediately switches off the motor. Depending on the selected setting, the inverter immediately switches off the motor torque with the STO safety function. Figure 6-41 OFF2 command when the SDI safety function is active Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2...
Page 219: Switching On The Motor When Sdi Is Active
Operation 6.8 Safe Direction (SDI) 6.8.4 Switching on the motor when SDI is active The procedure for switching on the motor depends on how you have set the SDI function. The feedback signal "SDI active" for pulse inhibit becomes inactive With this setting, the SDI function does not influence switching on the motor.
Page 220 Operation 6.8 Safe Direction (SDI) The feedback signal "SDI active" for pulse inhibit remains active Procedure To switch the motor on, proceed as follows: 1. Select STO (or SS1). 2. Deselect STO (or SS1) again. 3. After deselecting STO, wait until the inverter is "ready to switch on". Alternatively: After deselecting STO, wait a certain time before switching on.
Page 221: Response To A Discrepancy When Safe Direction Is Active (Sdi)
Operation 6.8 Safe Direction (SDI) 6.8.5 Response to a discrepancy when Safe Direction is active (SDI) Drive response The inverter responds with the active SDI safety function to a discrepancy at the safety input. Figure 6-44 Behavior of the inverter for discrepancy of the input signal for SDI (SDI - as example ) The inverter does not set the error bit of the safety functions (= internal event).
Page 222 Operation 6.8 Safe Direction (SDI) Deselecting SDI after a discrepancy Procedure To deselect SDI, proceed as follows: 1. Remove the discrepancy. 2. Acknowledge the discrepancy message with the fail-safe acknowledge signal via a safety input: F-DI = 0 → 1 → 0. Alternatively, you can acknowledge the message in one of the following ways.
Page 223: Limit Value Violation When Safe Direction (Sdi) Is Active
Operation 6.8 Safe Direction (SDI) 6.8.6 Limit value violation when Safe Direction (SDI) is active Drive response When motion monitoring detects a fault when SDI is active, the inverter responds by triggering a STOP A or STOP B. The inverter response is parameterized during commissioning.
Page 224 Operation 6.8 Safe Direction (SDI) Switching the motor on after an internal event Procedure To switch the motor on after an internal event while SDI is active, proceed as follows: 1. Deselect the SDI function. 2. Issue an OFF1 command (ON/OFF1 = 0). 3.
Page 225: Response To A Discrepancy In The Signals Transferred Via Profisafe
Operation 6.9 Response to a discrepancy in the signals transferred via PROFIsafe Response to a discrepancy in the signals transferred via PROFIsafe Drive response Figure 6-46 Behavior of the inverter in the event of a discrepancy in a safety input in PROFIsafe telegram 900 The inverter does not set the error bit of the safety functions (= internal event).
Page 226 Operation 6.9 Response to a discrepancy in the signals transferred via PROFIsafe Acknowledging a discrepancy message Procedure To acknowledge the discrepancy message, proceed as follows: 1. Remove the discrepancy. 2. Acknowledge the discrepancy message in one of the following ways: Selected setting How can the internal event be acknowledged? F-DI...
Page 227: Stop Responses
Operation 6.10 Stop responses 6.10 Stop responses Internal event An "internal event" is a major fault that causes the inverter to bring the motor to a standstill as quickly as possible by triggering a STOP reaction. For example, an "internal event" can be caused by one of the following: ●...
Page 228 Operation 6.10 Stop responses STOP F If a safety function is active , a STOP F initiates a STOP A or STOP B: ● Fault F01611 immediately initiates a STOP A. ● For message C01711, the inverter response depends on the active safety function: –...
Page 229: Example 1: Internal Event With Sto Active
Operation 6.10 Stop responses 6.10.1 Example 1: Internal event with STO active Drive response Figure 6-48 Internal event when the STO safety function is active The inverter signals an internal event. Switching the motor on after an internal event Procedure To switch the motor on after an internal event, proceed as follows: 1.
Page 230: Example 2: Internal Event With Ssm Active
Operation 6.10 Stop responses 6.10.2 Example 2: Internal event with SSM active Internal event when the motion monitoring function is active If an active safety function with motion monitoring (SS1, SSL, SDI or SSM) is interrupted with an internal event, the inverter responds with a STOP F. A STOP F does not necessarily mean that the motor is stopped.
Page 231 Operation 6.10 Stop responses Switching the motor on after an internal event Procedure To switch the motor in the example above on again, proceed as follows: 1. Issue an OFF1 command (ON/OFF1 = 0). 2. Acknowledge the internal event in one of the following ways: –...
Page 232: Fail-Safe Acknowledgment Signal
Operation 6.11 Fail-safe acknowledgment signal 6.11 Fail-safe acknowledgment signal 6.11.1 Acknowledging using a fail-safe signal You must acknowledge the majority of safety function faults using a fail-safe signal. The following options are available. ● Acknowledging using a safety input F-DI ●...
Page 233: Response To A Discrepancy Of The Fail-Safe Acknowledge Signal
Operation 6.11 Fail-safe acknowledgment signal Acknowledging by switching the power supply on and off You can acknowledge faults by temporarily switching off the power supply to the inverter and then switching it on again (power on reset). 6.11.2 Response to a discrepancy of the fail-safe acknowledge signal Drive response Figure 6-50 Behavior of the inverter for discrepancy of the input signal for fail-safe acknowledgment...
Page 234: Selecting Safety Function When A Safety Function Is Active
Operation 6.12 Selecting safety function when a safety function is active 6.12 Selecting safety function when a safety function is active The table below lists the notes regarding the behavior of your drive if you select more than one safety function at the same time. Some cases do not affect the behavior of your drive.
Page 235 Operation 6.12 Selecting safety function when a safety function is active Select STO SLS is active Select STO SDI is active Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 236 Operation 6.12 Selecting safety function when a safety function is active Select STO SSM is active Example for speed < SSM monitoring speed Example for speed > SSM monitoring speed Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 237 Operation 6.12 Selecting safety function when a safety function is active Select SS1 SLS is active Example: SS1 with braking ramp monitoring Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 238 Operation 6.12 Selecting safety function when a safety function is active Select SS1 SDI is active Example: SS1 with acceleration monitoring SAM Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 239 Operation 6.12 Selecting safety function when a safety function is active Select SS1 SSM is Example: SS1 with brake ramp monitoring < SSM monitoring speed active Example: SS1 with brake ramp monitoring, speed < SSM monitoring speed Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 240 Operation 6.12 Selecting safety function when a safety function is active Select SLS SDI is active Select SLS SSM is active Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 241 Operation 6.12 Selecting safety function when a safety function is active Select SDI SLS is active Select SDI SSM is active Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 242: List Of Alarms And Faults
Operation 6.13 List of alarms and faults 6.13 List of alarms and faults Syntax for faults and alarms F12345 Fault 12345 A67890 Alarm 67890 C01700 Message 1700 for safety functions These messages are either alarms or faults, see the following table. The table in this manual only contains the alarms and faults of the safety functions.
Page 243 Operation 6.13 List of alarms and faults Signal Cause Remedy Complete information on the messages is available in the List Manual. Remedy: Check the F-DI wiring (contact problems). • Resolve the contact problems or faults at the PROFIBUS • master/PROFINET controller. The inverter terminates the monitoring and does not signal any faults if the signal state remains stable before the time 5 ×...
Page 244 Operation 6.13 List of alarms and faults Signal Cause Remedy Complete information on the messages is available in the List Manual. 6165: Fault in reception of the PROFIsafe telegram. This fault can also arise if the inverter has received an inconsistent or out-of-date PROFIsafe telegram after a power on reset or after the PROFIBUS/PROFINET line has been connected.
Page 245 Operation 6.13 List of alarms and faults Signal Cause Remedy Complete information on the messages is available in the List Manual. A01654 PROFIBUS configuration differs Check the PROFIsafe configuring in the higher-level control. Alarm value r2124 = 1: • In the higher-level F control, remove the PROFIsafe configuring, or enable PROFIsafe in the drive.
Page 246 Operation 6.13 List of alarms and faults Signal Cause Remedy Complete information on the messages is available in the List Manual. F01681 Incorrect parameter value Correct the parameter value: Fault value (r0949) yyyyxxxx decimal, yyyy = supplementary information, xxxx = parameter F01682 Monitoring function not supported Deselect the monitoring function involved (p9501, p9601, p9801).
Page 247 Operation 6.13 List of alarms and faults Signal Cause Remedy Complete information on the messages is available in the List Manual. C01711 Defect in a monitoring channel The complete list of the r2124 fault values is provided in the List (alarm) Manual.
Page 248 Operation 6.13 List of alarms and faults Signal Cause Remedy Complete information on the messages is available in the List Manual. C01712 Defect when processing F-IO 1. Check the F-DI wiring. (alarm) 2. Check the setting of the safety functions. 3.
Page 249 Operation 6.13 List of alarms and faults Signal Cause Remedy Complete information on the messages is available in the List Manual. F30630 Brake control defective 1. Check the following: – p1278 = 0. – Motor holding brake connection – Motor holding brake function –...
Page 250 Operation 6.13 List of alarms and faults Signal Cause Remedy Complete information on the messages is available in the List Manual. F30692 Parameter value incorrect for Correct the parameter value. encoderless A30693, Safety parameter settings changed, 1. Save the settings so that they are protected against power failure F30693 warm restart/POWER ON required.
Page 251: Corrective Maintenance
Procedure Proceed as follows to register to receive a newsletter for inverters with integrated safety technology: 1. In the Internet, open the following page: Siemens automation technology (www.automation.siemens.com). 2. On this page, open the "Support" folder. 3. In the "Support" folder, select the "Newsletter" link.
Page 252 Corrective maintenance 7.1 Maintaining operational safety 7. As a minimum, select the "Drive technology" Newsletter. 8. You can select additional Newsletters if you so desire. 9. Save your settings by pressing the appropriate button. You have registered to receive the Newsletter for inverters with integrated safety technology. Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 253: Replacing Components Of The Modular Sinamics G120/G120D/G110M Inverters
Corrective maintenance 7.2 Replacing components of the modular SINAMICS G120/G120D/G110M inverters Replacing components of the modular SINAMICS G120/G120D/G110M inverters 7.2.1 Overview of replacing converter components Permissible replacement of components In the event of a long-term function fault, you must replace the Power Module or Control Unit.
Page 254 Corrective maintenance 7.2 Replacing components of the modular SINAMICS G120/G120D/G110M inverters Special issue relating to communication via PROFINET: Device replacement without removable data storage medium The inverter supports the PROFINET functionality, replacing the device without data storage medium. Precondition The topology of the PROFINET IO system with the IO device involved is configured in your higher-level control system.
Page 255: Replacing A Control Unit With Enabled Safety Function
Corrective maintenance 7.2 Replacing components of the modular SINAMICS G120/G120D/G110M inverters 7.2.2 Replacing a Control Unit with enabled safety function Replacing a Control Unit with data backup on a memory card Precondition You have a memory card with the actual settings of the Control unit to be replaced.
Page 256 Corrective maintenance 7.2 Replacing components of the modular SINAMICS G120/G120D/G110M inverters Replacing a Control Unit with data backup in the PC Precondition You have backed up the actual settings of the Control Unit to be replaced to a PC using STARTER.
Page 257 Corrective maintenance 7.2 Replacing components of the modular SINAMICS G120/G120D/G110M inverters Replacing the Control Unit with data backup in the operator Panel Precondition You have backed up the actual settings of the Control Unit to be replaced to an operator panel.
Page 258: Replacing The Control Unit Without Data Backup
Corrective maintenance 7.2 Replacing components of the modular SINAMICS G120/G120D/G110M inverters 21.Switch on the inverter power supply again (power on reset). 22.Perform a reduced acceptance test, see the section Reduced acceptance test after component replacement (Page 266). You have replaced the Control Unit and transferred the safety function settings from the operator panel to the new Control Unit.
Page 259: Replacing A Power Module With Enabled Safety Function
Corrective maintenance 7.2 Replacing components of the modular SINAMICS G120/G120D/G110M inverters 7.2.4 Replacing a Power Module with enabled safety function DANGER Danger from touching energized Power Module connections After switching off the mains voltage, it will take up to 5 minutes until the capacitors in the Power Module are sufficiently discharged for the residual voltage to be safe.
Page 260: 7.3 Replacing Sinamics G120C Inverters Or Simatic Et 200Pro Fc-2 Converters
Corrective maintenance 7.3 Replacing SINAMICS G120C inverters or SIMATIC ET 200pro FC-2 converters Replacing SINAMICS G120C inverters or SIMATIC ET 200pro FC-2 converters 7.3.1 Overview of how to replace an inverter You must replace the inverter if it continually malfunctions. Overview In the following cases you will need to replace the inverter: Replacement:...
Page 261: Replacing A Converter With Enabled Safety Function
– or having to reassign the device names with a PG. Details of the device replacement without removable storage medium can be found in the PROFINET system description (http://support.automation.siemens.com/WW/view/en/19292127). 7.3.2 Replacing a converter with enabled safety function DANGER Risk of fatal injury when touching energized Power Module connections After the power supply has been switched off, it takes up to 5 min.
Page 262 Corrective maintenance 7.3 Replacing SINAMICS G120C inverters or SIMATIC ET 200pro FC-2 converters Replacing an inverter with data backup on a memory card Procedure To replace the inverter, proceed as follows: 1. Disconnect the line voltage to the inverter and (if installed) the external 24 V supply or the voltage for the digital outputs of the inverter.
Page 263 Corrective maintenance 7.3 Replacing SINAMICS G120C inverters or SIMATIC ET 200pro FC-2 converters Replacing an inverter with data backup in the PC Procedure To replace the inverter, proceed as follows: 1. Disconnect the line voltage to the inverter and (if installed) the external 24 V supply or the voltage for the digital outputs of the inverter.
Page 264 Corrective maintenance 7.3 Replacing SINAMICS G120C inverters or SIMATIC ET 200pro FC-2 converters Replacing the inverter with data backup in the operator panel (BOP-2 or IOP) Procedure To replace the inverter, proceed as follows: 1. Disconnect the line voltage to the inverter and (if installed) the external 24 V supply or the voltage for the digital outputs of the inverter.
Page 265: Replacing A Converter Without Data Backup
Corrective maintenance 7.3 Replacing SINAMICS G120C inverters or SIMATIC ET 200pro FC-2 converters 7.3.3 Replacing a converter without data backup If the settings have not been backed up, after replacing the inverter, you must recommission the drive. Procedure To replace the inverter, proceed as follows: 1.
Page 266: Reduced Acceptance Test After Component Replacement
Corrective maintenance 7.4 Reduced acceptance test after component replacement Reduced acceptance test after component replacement After a component has been replaced or the firmware updated, a reduced acceptance test of the safety functions must be performed. Table 7- 1 Reduced acceptance test after component replacement Measure Acceptance test Documentation...
Page 267: System Properties
System properties Probability of failure of the safety functions (PFH value) The specified probability of failure values apply under the following preconditions: ● The service life of the inverter has not expired. ● The test interval has not expired. Service life You may not operate inverters with integrated safety functions for longer than 20 years.
Page 268 We provide a free tool in the Internet to calculate the PFH value of a complete machine: Safety Evaluation Tool (www.siemens.com/safety-evaluation-tool). Application examples for the probability of failure PFH and PFD are available in the Internet: Application example (http://support.automation.siemens.com/WW/view/en/76254308).
Page 269: Response Times
System properties 8.2 Response times Response times Response times after selection When selecting the Safe Torque Off (STO) function, the motor is safely in a no-torque condition after the response time. If, at the instant that STO is selected, the motor is stationary, then after the response time, the motor is also in a safe state.
Page 270 System properties 8.2 Response times Response times of the STO function after selection. The response times depend on the following conditions: ● Safety function setting – Basic function – Extended function ● PROFIBUS or PROFINET ● Selected via safety input or PROFIsafe The response times in the tables below apply from the point at which the safety input signal changes or the PROFIsafe telegram is received.
Page 271 System properties 8.2 Response times Response times of the STO function when selected via a safety input Table 8- 4 STO response times Worst case for a fault-free inverter Worst case for an inverter fault STO basic function 4 ms + t_E 6 ms + t_E STO extended function 50 ms + t_E...
Page 272 System properties 8.2 Response times Signal change into the "Status SSM" Function Response Worst case for a fault-free Worst case when a fault drive system exists Signal change into the 67 ms 113 ms "Status SSM" If you switch on the motor when a safety function is active, the inverter signals the correct status at the earliest after the "Delay time actual value acquisition"...
Page 273: Certification
Proceed as follows, to load the certificates relevant for Safety Integrated from the Internet: 1. In the Internet, open the following page: Certificates (http://support.automation.siemens.com/WW/view/en/36426537/134200) 2. Filter according to Certificate type "Functional safety/machine safety". 3. Select the certificate according to the inverter order number.
Page 274 The current EC Declarations of Conformity for the inverter are available in the Internet: EC Declaration of Conformity (http://support.automation.siemens.com/WW/view/en/67385845) Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 275: Safe Brake Relay
System properties 8.4 Safe Brake Relay Safe Brake Relay Technical data of the Safe Brake Relay Technical data Property Supply voltage 20.4 to 28.8 V DC We recommend that you use a power supply with a minimum rated voltage of 26 V in order to compensate for voltage drops along the brake cable.
Page 276 System properties 8.4 Safe Brake Relay Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 277: Appendix
The "Safety Acceptance Test" application guides you semi-automatically through the acceptance test of the safety functions. The application logs its settings as an Excel file. Application acceptance test (http://support.automation.siemens.com/WW/view/en/73102423). Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 278: Acceptance Test Sto (Basic Functions)
Appendix A.1 Examples of acceptance tests A.1.1 Acceptance test STO (basic functions) Figure A-1 Acceptance test for STO (basic functions) Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 279 Appendix A.1 Examples of acceptance tests Procedure To perform an acceptance test of the STO function as part of the basic functions, proceed as follows: Status The inverter is ready The inverter signals neither faults nor alarms of the safety functions (r0945[0…7], •...
Page 280: Acceptance Test Sto (Extended Functions)
Appendix A.1 Examples of acceptance tests A.1.2 Acceptance test STO (extended functions) Figure A-2 Acceptance test for STO (Extended functions) Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 281 Appendix A.1 Examples of acceptance tests Procedure To perform an acceptance test of the STO function as part of the extended functions, proceed as follows: Status The inverter is ready The inverter signals neither faults nor alarms of the safety functions •...
Page 282: Ss1 Acceptance Test (Basic Functions)
Appendix A.1 Examples of acceptance tests A.1.3 SS1 acceptance test (basic functions) Figure A-3 SS1 acceptance test for basic functions Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 283 Appendix A.1 Examples of acceptance tests Procedure To perform the acceptance test of the SS1 function, proceed as follows: Status 1. The inverter is ready Check the following: The inverter signals neither faults nor alarms of the safety functions • (r0945[0…7], r2122[0…7]).
Page 284: Ss1 Acceptance Test (Extended Functions)
Appendix A.1 Examples of acceptance tests A.1.4 SS1 acceptance test (extended functions) The two diagrams show the recommended steps to take during the acceptance test. The behavior of the drive differs according to the settings you have made for SS1: ●...
Page 285 Appendix A.1 Examples of acceptance tests Figure A-5 Diagram 2 - acceptance test for SS1 with acceleration monitoring Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 286 Appendix A.1 Examples of acceptance tests Procedure To perform the acceptance test of the SS1 function, proceed as follows: Status The inverter is ready The inverter signals neither faults nor alarms of the safety functions • (r0945[0…7], r2122[0…7]). SS1 is not active (r9722.1 = 0). •...
Page 287 Appendix A.1 Examples of acceptance tests Example of a trace ① SS1 is selected ② SS1 is active ③ Speed: The motor brakes on the OFF3 ramp. ④ Monitoring the speed when braking ⑤ STO is active Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 288: Sbc Acceptance Test
Appendix A.1 Examples of acceptance tests A.1.5 SBC acceptance test Figure A-6 Acceptance test for SBC Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 289 Appendix A.1 Examples of acceptance tests Procedure To perform the acceptance test of the SBC function, proceed as follows: Status The inverter is ready The inverter signals neither faults nor alarms of the safety functions • (r0945[0…7], r2122[0…7]). SBC is not active (r9773.4 = 0). •...
Page 290: Acceptance Test Sls
Appendix A.1 Examples of acceptance tests A.1.6 Acceptance test SLS The two diagrams show the recommended steps to take during the acceptance test. The behavior of the drive differs according to the settings you have made for SLS : ● Diagram 1: If the speed is excessively high, the drive responds with a STOP A. ●...
Page 291 Appendix A.1 Examples of acceptance tests Figure A-8 Diagram 2 - acceptance test SLS with stop reaction STOP B Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 292 Appendix A.1 Examples of acceptance tests Procedure To perform the acceptance test of the SLS function, proceed as follows: Status If you are using multiple SLS levels, repeat the test for each of the SLS levels. The inverter is ready Check the following: The inverter signals neither faults nor alarms of the safety functions (r0945[0…7], •...
Page 293 Appendix A.1 Examples of acceptance tests Status 2.5. Check that the correct motor is running. The following tests depend on how you have set the SLS function during commissioning: First diagram: Second diagram: The inverter responds with STOP A in The inverter responds with STOP B in the event of a limit violation.
Page 294 Appendix A.1 Examples of acceptance tests Example of a trace (STOP B in the event of a limit violation) ① SLS is active ② Speed: The motor accelerates to the active SLS level ③ The speed exceeds the active SLS level ④...
Page 295: Ssm Acceptance Test
Appendix A.1 Examples of acceptance tests A.1.7 SSM acceptance test The two diagrams show the recommended steps to take during the acceptance test. It differs depending on the settings you have made for SSM: ● Diagram 1: The "speed below limit value" checkback signal remains active when the motor is switched off.
Page 296 Appendix A.1 Examples of acceptance tests Figure A-10 Diagram 2 - acceptance test SSM with inactive feedback signal when the motor is switched off Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 297 Appendix A.1 Examples of acceptance tests Procedure To perform the acceptance test of the SSM function, proceed as follows: Status The inverter is ready Check: The inverter signals neither faults nor alarms of the safety functions • (r0945[0…7], r2122[0…7]). Go online with the STARTER and configure the following trace: Trigger on variable - bit pattern (r9722.15 = 0) •...
Page 298 Appendix A.1 Examples of acceptance tests Example of a trace ① Speed: The motor accelerates ② Speed above the limit value ③ Speed below the limit value Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 299: Acceptance Test Sdi
Appendix A.1 Examples of acceptance tests A.1.8 Acceptance test SDI The acceptance test for SDI+ and SDI- is separately described in the following. If you use the SDI function in both directions of rotation, you must carry out both acceptance tests. SDI can be set with the STOP A and STOP B stop responses.
Page 300 Appendix A.1 Examples of acceptance tests Figure A-12 Diagram 2 - acceptance for SDI+, "SDI active" becomes inactive when the motor is switched off Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 301 Appendix A.1 Examples of acceptance tests Procedure To perform the acceptance test of the SDI function for the positive direction of rotation, proceed as follows: Status The inverter is ready Check the following: The inverter signals neither faults nor alarms of the safety functions (r0945[0…7], •...
Page 302 Appendix A.1 Examples of acceptance tests Status Test the set limit value 4.1. Enter a negative speed setpoint. The following test depends on how you have set the SDI function during 4.2. commissioning: STOP A in the event of a limit value STOP B in the event of a limit value violation violation...
Page 303 Appendix A.1 Examples of acceptance tests Acceptance test for SDI negative The two diagrams show the recommended steps to take during the acceptance test. The acceptance test differs depending on how you have set SDI: ● Diagram 1: The "SDI active" feedback signal remains active when the motor is switched off.
Page 304 Appendix A.1 Examples of acceptance tests Figure A-14 Diagram 2 - acceptance for SDI-, "SDI active" becomes inactive when the motor is switched off Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 305 Appendix A.1 Examples of acceptance tests Procedure To perform the acceptance test of the SDI function for the negative direction of rotation, proceed as follows: Status The inverter is ready Check the following: SDI- is not active (r9722.13 = 0). •...
Page 306 Appendix A.1 Examples of acceptance tests Status Test the set limit value 4.1. Enter a positive speed setpoint. The following test depends on how you have set the SDI function during 4.2. commissioning: STOP A in the event of a limit value STOP B in the event of a limit value violation violation...
Page 307 Appendix A.1 Examples of acceptance tests Example of a trace (STOP B in the event of a limit violation) ① SDI is selected ② Position actual value: The motor starts to rotate ③ The position actual value of the drive deviates from the permissible tolerance ④...
Page 308: Acceptance Test For F-Di Status In Profisafe Telegram 900
Appendix A.1 Examples of acceptance tests A.1.9 Acceptance test for F-DI status in PROFIsafe telegram 900 Figure A-15 Acceptance test for the status of the safety inputs using the example of a SINAMICS G120D Procedure To perform the acceptance test of the F-DI status, proceed as follows: Status The inverter is ready The inverter signals neither faults nor alarms of the safety functions (r0945[0…7],...
Page 309: Documentation For Acceptance
Appendix A.2 Documentation for acceptance Documentation for acceptance A.2.1 Creating logs with the settings of the safety functions STARTER creates a log of the settings of the safety functions, which you can use for your machine documentation. Procedure Proceed as follows to create the acceptance documentation for the drive using STARTER: 1.
Page 310 Appendix A.2 Documentation for acceptance 3. You load the created reports for archiving and the machine documentation for further processing: 4. Archive the protocols and the machine documentation. You have generated the documents to accept the safety functions. You can find the logs and the machine documentation in the following sections. Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 311: Example Of Machine Documentation
Appendix A.2 Documentation for acceptance A.2.2 Example of machine documentation Machine or system description Designation … Type … Serial number … Manufacturer … End user … Block diagram of the machine and/or plant: … … … … … … … Inverter data Table A- 1 Hardware version of the safety-related inverter...
Page 312 Appendix A.2 Documentation for acceptance Logging the settings File name of the log: … … Data backup Data Storage medium Holding area Archiving type Designation Date Log of the settings … … … … Acceptance tests … … … … STARTER traces …...
Page 313: Log The Settings For The Basic Functions, Firmware V4.4
Appendix A.2 Documentation for acceptance A.2.3 Log the settings for the basic functions, firmware V4.4 ... V4.7 Drive = <pDO-NAME_v> Table A- 3 Firmware version Name Number Value Control Unit firmware version <r18_v> SI version, safety functions integrated in the drive (processor 1) r9770 <r9770_v>...
Page 314: Log The Settings For The Extended Functions, Firmware V4.4
Appendix A.2 Documentation for acceptance A.2.4 Log the settings for the extended functions, firmware V4.4 ... V4.7 Drive = <pDO-NAME_v> Table A- 8 Firmware version Name Number Value Control Unit firmware version <r18_v> SI motion, version safe motion monitoring functions r9590 <r9590_v>...
Page 315 Appendix A.2 Documentation for acceptance Name Number Value SI Motion SSM filter time p9545 <p9545_v> SI Motion SSM speed limit p9546 <p9546_v> SI Motion SSM speed hysteresis p9547 <p9547_v> SI Motion SAM actual speed tolerance p9548 <p9548_v> SI Motion SLS changeover delay time p9551 <p9551_v>...
Page 316 SI F-DI monitoring status r10049 <r10049_v> SI PROFIsafe F-DI transfer p10050 <p10050_v> Table A- 12 Fail-safe output in SINAMICS G120D with CU240/250D-2 DP/PN F and in SINAMICS G120 with CU250S-2 Name Number Value SI wait time for test stop at DO p10001 <p10001_v>...
Page 317: Standards And Specifications
Appendix A.3 Standards and specifications Standards and specifications A.3.1 General information A.3.1.1 Aims Manufacturers and operating companies of equipment, machines, and products are responsible for ensuring the required level of safety. This means that plants, machines, and other equipment must be designed to be as safe as possible in accordance with the current state of the art.
Page 318 Appendix A.3 Standards and specifications Benchmarks for establishing whether or not a sufficient level of functional safety has been achieved include the probability of hazardous failures, the fault tolerance, and the quality that is to be ensured by avoiding systematic faults. This is expressed in the standards using specific classification.
Page 319: Safety Of Machinery In Europe
Appendix A.3 Standards and specifications A.3.2 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 320 Appendix A.3 Standards and specifications The European Safety of Machines standard is hierarchically structured. It is divided into: ● A standards (basic standards) ● B standards (group standards) ● C standards (product standards) Type A standards/basic standards A standards include basic terminology and definitions relating to all types of machine. This includes EN ISO 12100 (previously EN 292-1) "Safety of Machines, Basic Terminology, General Design Principles".
Page 321: Standards For Implementing Safety-Related Controllers
Appendix A.3 Standards and specifications A.3.2.3 Standards for implementing safety-related controllers If the functional safety of a machine depends on various control functions, the controller must be implemented in such a way that the probability of safety functions failing in a dangerous fashion is sufficiently minimized.
Page 322: Din En Iso 13849-1 (Replaces En 954-1)
Appendix A.3 Standards and specifications Systems for executing safety-related control EN ISO 13849-1 EN 62061 functions Non-electrical (e.g. hydraulic, pneumatic) Not covered Electromechanical (e.g. relay and/or basic Restricted to the designated All architectures and max. up to electronics) architectures (see comment 1) SIL 3 and max.
Page 323: A.3.2.5 En 62061
Appendix A.3 Standards and specifications DIN EN ISO 13849-1 is based on the known categories of EN 954-1. It now also takes into account complete safety functions and all the devices required to execute these. With DIN EN ISO 13849-1, safety functions are investigated from a quantitative perspective going beyond the qualitative basis of EN 954-1.
Page 324 Appendix A.3 Standards and specifications Safety-related characteristic quantities for subsystems: ● SIL CL: SIL claim limit ● PFH Probability of dangerous failures per hour ● T1: Lifetime Simple sub-systems (e.g. sensors and actuators) in electromechanical components can, in turn, comprise sub-system elements (devices) interconnected in different ways with the characteristic quantities required for determining the relevant PFH value of the sub-system.
Page 325: Series Of Standards Iec 61508 (Vde 0803)
Appendix A.3 Standards and specifications EN 62061 does not include information about non-electric systems. The standard provides detailed information on implementing safety-related electrical, electronic, and programmable electronic control systems. DIN EN ISO 13849-1 must be applied for non-electric systems. Note Function examples Details of simple sub-systems that have been implemented and integrated are now available as "functional examples".
Page 326: Risk Analysis/Assessment
Appendix A.3 Standards and specifications A.3.2.7 Risk analysis/assessment Risks are intrinsic in machines due to their design and functionality. For this reason, the Machinery Directive requires that a risk assessment be performed for each machine and, if necessary, the level of risk reduced until the residual risk is less than the tolerable risk. To assess these risks, the following standards must be applied: ●...
Page 327: Risk Reduction
Appendix A.3 Standards and specifications Figure A-17 Iterative process for achieving safety Risks must be reduced by designing and implementing the machine accordingly (e.g. by means of controllers or protective measures suitable for the safety-related functions). If the protective measures involve the use of interlocking or control functions, these must be designed according to EN ISO 13849-1.
Page 328: Residual Risk
Appendix A.3 Standards and specifications 1050). Annex A of the standard describes a method for determining the required Safety Integrity Level (SIL). Regardless of which standard is applied, steps must be taken to ensure that all the machine controller components required for executing the safety-related functions fulfill these requirements.
Page 329: Machine Safety In The Usa
Appendix A.3 Standards and specifications A.3.3 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 330: Nfpa 79
Appendix A.3 Standards and specifications A.3.3.3 NFPA 79 Standard NFPA 79 (Electrical Standard for Industrial Machinery) applies to electrical equipment on industrial machines with rated voltages of less than 600 V. A group of machines that operate together in a coordinated fashion is also considered to be one machine.
Page 331: Machine Safety In Japan
Appendix A.3 Standards and specifications A.3.4 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 332: Equipment Regulations
Appendix A.3 Standards and specifications A.3.5 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 333: Other Safety-Related Issues
Appendix A.3 Standards and specifications A.3.6 Other safety-related issues A.3.6.1 Additional references ● Safety Integrated: The Safety System for Industry (5th Edition and supplement), order no. 6ZB5 000-0AA01-0BA1 ● Safety Integrated - Terms and Standards - Machine Safety Terminology (Edition 04/2007), order no.
Page 334: Manuals And Technical Support
Function Manual for Safety (this manual) English, Integrated German, Chinese Fieldbus Function Manual Configuring fieldbuses. for the SINAMICS G120, G120C and G120D inverters Safety Integrated - SINAMICS G110M, G120, G120C, G120D and SIMATIC ET 200pro FC-2 Function Manual, 04/2014, FW V4.7, A5E34261271B AA...
Page 335 CU250D-2 SINAMICS G110M • SIMATIC ET 200pro FC-2 • Getting Started Guide Installing the Power Module English for the following SINAMICS G120 Power Modules: PM240, PM250 and PM260 • PM240-2 • Installation Instructions Installing components for reactors, filters and braking...
Page 336: Configuring Support
Support when configuring and selecting the inverter Manual or tool Contents Available Download or order number languages Catalog D 31 Ordering data and technical English, Everything about SINAMICS G120 information for the standard German, (www.siemens.en/sinamics-g120) SINAMICS G inverters Italian, French, Spanish Online catalog (Industry...
Page 337: Product Support
Product Support You can find additional information on the product and more in the Internet under: Product support (http://www.siemens.com/automation/service&support). In addition to our documentation, under this address we offer our complete knowledge base online: You can find the following information: ●...
Page 338: Mistakes And Improvements
If you come across any mistakes when reading this manual or if you have any suggestions for how it can be improved, then please send your suggestions to the following address or by E-mail: Siemens AG Drive Technologies Motion Control Systems...
Page 339: Index
Index Circuit diagram, 312 Commissioning, 77 Offline, 84 Online, 84 3RK3 (modular safety system), 65 Overview, 88 3TK28 (safety relay), 62 Commissioning engineer, 15 Compound braking, 24 Configuring support, 336 Consistency, 94, 116 Acceleration voltage tolerance, 109 Consistent signals, 94, 116 Acceptance mode, 141, 149, 292, 301 Contact bounce, 95, 116 Acceptance test, 77, 156, 312...
Page 340 Index SS1, 184, 185 Extended functions, 105 STO, 170 Performing, 162 Tolerance time, 94, 116 Safety output, 125 DO (digital output), 71 setting, 98 Download, 153 F-RSM, 56 F-Switch, 43, 56 Function table, 311 Functional expansions, 158 EC Declaration of Conformity, 274 EC type-examination certificate, 273 Electromechanical sensor, 54, 58, 60 Emergency Stop button, 29...
Page 341 Index Download, 334 Configure, 78 Function Manual for Safety Integrated, 334 Control word 1, 47, 48 Inverter accessories, 334 Control word 5, 50 Overview, 334 Start communication, 93, 129 Manufacturer, 311 Status word 1, 47, 49, 169, 229 Manufacturer declaration, 273 Status word 5, 50 Minimum current, 109 Telegram 30, 46...
Page 342 Shutdown speed, 130, 131, 133, 134 SIMATIC ET 200pro FC-2, 20, 21, 51 Speed tolerance, 134 Standstill monitoring, 130, 131, 179, 180 SINAMICS G110M, 20, 21 SINAMICS G120 Switch off the motor, 182 CU230P-2, 20, 21 Tolerance, 130, 135 CU240B-2, 20, 21...
Page 343 Index active, 160 Discrepancy, 170 Winders, 23 Fault response, 229 Wire breakage, 94, 116 select, 169 Selecting, 27 Selection, 160 Stop Category 1, 227 STOP A, 187, 204, 223, 227 STOP B, 204, 223, 227 STOP F, 228, 230 Suggestions for improvement manual, 338 Support, 337 Switch-off signal paths, 98 Switch-off signal paths (forced dormant error...

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Sinamics g110m Sinamics g120c Sinamics g120d Simatic et 200pro fc-2

Siemens SINAMICS G120 Function Manual

1 Fundamental Safety Instructions

2 Introduction

3 Description

4 Installing

5 Commissioning

6 Operation

7 Corrective Maintenance

8 System Properties

Appendix

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Summary of Contents for Siemens SINAMICS G120