Siemens SINUMERIK 828D Turning Parts list manual

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Safety Integrated
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SINUMERIK
SINUMERIK 828D,
SINAMICS S120
Safety Integrated
Function Manual
Valid for:
SINUMERIK
CNC software Version 4.5 SP1
07/2012
6FC5397-3EP40-3BA0
Preface
General information about
SINAMICS Safety Integrated
1
Description of Safety
Integrated Basic Functions
2
Description of the Safety
Integrated Extended
Functions
3
Commissioning the functions
4
Example of commissioning
with SINUMERIK 828D
5
Acceptance tests and
acceptance reports
6
Service graphics for
SI diagnostics
7
System Features
8
Standards and specifications
9
Appendix
A

Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
Order number: 6FC5397-3EP40-3BA0
Ⓟ 10/2012 Technical data subject to change
Copyright © Siemens AG 2012.
All rights reserved
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
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. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.

Safety Integrated
Function Manual, 07/2012, 6FC5397-3EP40-3BA0 3
Preface
SINUMERIK documentation
The SINUMERIK documentation is organized in the following categories:
● General documentation
● User documentation
● Manufacturer/service documentation
Additional information
You can find information on the following topics under the link
(www.siemens.com/motioncontrol/docu):
● Ordering documentation/overview of documentation
● Additional links to download documents
● Using documentation online (find and search in manuals/information)
Please send any questions about the technical documentation (e.g. suggestions for
improvement, corrections) to the following address:
(mailto:[e-mail])
My Documentation Manager (MDM)
Under the following link you will find information to individually compile OEM-specific
machine documentation based on the Siemens content: MDM (www.siemens.com/mdm)
Training
For information about the range of training courses, refer under:
● SITRAIN (www.siemens.com/sitrain) - training courses from Siemens for automation
products, systems and solutions
● SinuTrain (www.siemens.com/sinutrain) - training software for SINUMERIK
FAQs
You can find Frequently Asked Questions in the Service&Support pages under Product
Support (www.siemens.com/automation/service&support).
SINUMERIK
You can find information on SINUMERIK under the following link:
(www.siemens.com/sinumerik)

Preface
Safety Integrated
4 Function Manual, 07/2012, 6FC5397-3EP40-3BA0
Target group
Project engineers, technologists (of the machine manufacturers), commissioning engineers
(for systems or machines), and programmers.
Benefits
The function manual describes the functions so that the target group knows them and can
select them. It provides the target group with the information required to implement the
functions.
Planning and configuration phase, implementation phase, setup and commissioning phase.
Standard version
This documentation only describes the functionality of the standard version. Extensions or
changes made by the machine manufacturer are documented by the machine manufacturer.
Other functions not described in this documentation might be executable in the control. This
does not, however, represent an obligation to supply such functions with a new control or
when servicing.
Further, for the sake of simplicity, this documentation does not contain all detailed
information about all types of the product and cannot cover every conceivable case of
installation, operation or maintenance.
Technical Support
Country-specific telephone numbers for technical support are provided in the Internet under
"Contact" (www.siemens.com/automation/service&support).
EC Declaration of Conformity
The EC declaration of conformity for the EMC directive can be found in the Internet
(www.siemens.com/automation/service&support).
There, as search term, enter the number 15257461 or contact your local Siemens office.

Safety Integrated
Function Manual, 07/2012, 6FC5397-3EP40-3BA0 5
Table of contents
Preface ...................................................................................................................................................... 3
1 General information about SINAMICS Safety Integrated ........................................................................... 7
1.1 Supported functions .......................................................................................................................7
1.2 Examples of how the safety functions can be applied...................................................................9
1.3 Drive monitoring with encoder .....................................................................................................10
2 Description of Safety Integrated Basic Functions..................................................................................... 11
2.1 Safe Torque Off (STO).................................................................................................................12
2.2 Safe Stop 1 (SS1) ........................................................................................................................13
2.3 Safe Brake Control (SBC)............................................................................................................14
3 Description of the Safety Integrated Extended Functions ........................................................................ 17
3.1 Safe Torque Off (STO).................................................................................................................18
3.2 Safe Stop 1 (SS1) ........................................................................................................................19
3.3 Safe Brake Control (SBC)............................................................................................................21
3.4 Safe Stop 2 (SS2) ........................................................................................................................22
3.5 Safe Operating Stop (SOS) .........................................................................................................24
3.6 Safely Limited Speed (SLS).........................................................................................................25
3.7 Safe Speed Monitor (SSM)..........................................................................................................29
3.8 Safe Direction (SDI) .....................................................................................................................31
4 Commissioning the functions................................................................................................................... 33
5 Example of commissioning with SINUMERIK 828D.................................................................................35
5.1 Planning .......................................................................................................................................35
5.1.1 Creating a function table ..............................................................................................................35
5.1.2 From the function table to the logic diagram................................................................................37
5.2 Preconditions for commissioning .................................................................................................39
5.3 Programming of the TM54F.........................................................................................................41
5.3.1 Configuring the drive groups........................................................................................................41
5.3.2 Connecting safe outputs ..............................................................................................................45
5.3.3 TM54F terminal description .........................................................................................................46
5.4 Control with SIRIUS 3TK or with SIRIUS 3RK relays..................................................................48
5.4.1 Control of the TM54F with SIRIUS 3TK.......................................................................................48
5.4.2 Control of the TM54F with SIRIUS 3RK ......................................................................................53
5.5 Configuration of the SI functions for the drive..............................................................................56
5.5.1 Activating Safety Integrated.........................................................................................................56
5.5.2 Encoder parameterization............................................................................................................59

Table of contents
Safety Integrated
6 Function Manual, 07/2012, 6FC5397-3EP40-3BA0
5.5.3 Setting parameters SLS1-4, SBC, SS1, SS2.............................................................................. 60
5.6 SINUMERIK 828D control system ..............................................................................................62
5.6.1 Signals between SINUMERIK and SINAMICS Safety Integrated............................................... 62
5.6.2 Selecting SLS speeds................................................................................................................. 63
5.6.3 Wiring the terminals to the NCK inputs....................................................................................... 64
6 Acceptance tests and acceptance reports ............................................................................................... 67
6.1 General requirements ................................................................................................................. 67
6.2 Acceptance test structure............................................................................................................ 68
7 Service graphics for SI diagnostics.......................................................................................................... 71
7.1 This is how you display the status for SI diagnostics.................................................................. 71
7.2 This is how you confirm the replacement of SI hardware........................................................... 75
7.3 Safety Integrated alarms............................................................................................................. 76
8 System Features...................................................................................................................................... 77
8.1 Latest information........................................................................................................................ 77
8.2 Certification ................................................................................................................................. 79
8.3 Safety instructions....................................................................................................................... 80
8.4 Probability of failure of the safety functions (PFH value)............................................................ 83
8.5 Residual risk................................................................................................................................ 84
9 Standards and specifications................................................................................................................... 87
9.1 General........................................................................................................................................ 87
9.2 Safety of machinery in Europe.................................................................................................... 89
9.2.1 Safety of machinery in Europe.................................................................................................... 89
9.2.2 Harmonized European Standards............................................................................................... 89
9.3 Machine safety in the USA.......................................................................................................... 91
9.3.1 Machine safety in the USA.......................................................................................................... 91
9.3.2 Minimum requirements of the OSHA .......................................................................................... 91
9.3.3 NRTL listing................................................................................................................................. 92
9.3.4 NFPA 79...................................................................................................................................... 92
9.3.5 ANSI B11..................................................................................................................................... 93
9.4 Machine safety in Japan ............................................................................................................. 94
9.4.1 Machine safety in Japan ............................................................................................................. 94
9.5 Equipment regulations ................................................................................................................ 95
9.5.1 Equipment regulations ................................................................................................................ 95
9.6 Other safety-related issues ......................................................................................................... 96
9.6.1 Information sheets issued by the Employer's Liability Insurance Association............................ 96
9.6.2 Additional references .................................................................................................................. 96
A Appendix.................................................................................................................................................. 97
A.1 Abbreviations .............................................................................................................................. 97
A.2 Documentation overview SINUMERIK 828D............................................................................ 106
Index...................................................................................................................................................... 107

Safety Integrated
Function Manual, 07/2012, 6FC5397-3EP40-3BA0 7
General information about SINAMICS Safety
Integrated 1
1.1 Supported functions
All of the Safety Integrated functions available under SINUMERIK 828D/SINAMICS S120 are
listed in this chapter. SINAMICS makes a distinction between Safety Integrated Basic
Functions and Safety Integrated Extended Functions.
The safety functions listed here conform to:
● Safety Integrity Level (SIL) 2 according to DIN EN 61508
● Category 3 according to DIN EN ISO 13849-1
● Performance level (PL) d according to DIN EN ISO 13849-1
The safety functions correspond to the functions according to DIN EN 61800-5-2.
The following Safety Integrated functions (SI functions) are available:
● Safety Integrated Basic Functions
These functions are part of the standard scope of the drive and can be used without
requiring an additional license. These functions are always available. These functions do
not require an encoder and/or do not place any special requirements on the encoder
used.
– Safe Torque Off (STO)
Safe Torque Off is a safety function that prevents the drive from restarting
unexpectedly, in accordance with EN 60204-1. STO prevents the supply of energy to
the motor which can generate a torque and corresponds to Stop Category 0.
– Safe Stop 1 (SS1, time controlled)
Safe Stop 1 is based on the "Safe Torque Off" function. This means that a Category 1
stop in accordance with EN 60204-1 can be implemented.
– Safe Brake Control (SBC)
Safe Brake Control is used to safely control a holding brake.1) 2)

General information about SINAMICS Safety Integrated
1.1 Supported functions
Safety Integrated
8 Function Manual, 07/2012, 6FC5397-3EP40-3BA0
● Safety Integrated Extended Functions
These functions require an additional Safety license: Extended Functions with encoder
require an encoder with Safety capability (see section "Reliable actual value acquisition
with encoder system").
– Safe Torque Off (STO)
Safe Torque Off is a safety function that prevents the drive from restarting
unexpectedly in accordance with EN- 60204-1.
– Safe Stop 1 (SS1, time and acceleration controlled)
Safe Stop 1 is based on the "Safe Torque Off" function. This means that a Category 1
stop in accordance with EN 60204-1 can be implemented.
– Safe Brake Control (SBC)
Safe Brake Control is used to safely control a holding brake. 1) 2)
– Safe Stop 2 (SS2)
Safe Stop 2 is used to safely brake the motor with a subsequent transition into the
"Safe Operating Stop" state (SOS). This means that a Category 2 stop in accordance
with EN 60204-1 can be implemented.
– Safe Operating Stop (SOS)
Safe Operating Stop is used to protect against unintentional movements. The drive is
in closed-loop control mode and is not disconnected from the power supply.
– Safely Limited Speed (SLS)
Safely Limited Speed ensures that the drive does not exceed a preset speed
limit/velocity.
– Safe Speed Monitor (SSM)
Safe Speed Monitor is used for safely identifying when a speed limit is fallen below in
both directions of motion, e.g. to identify zero speed. A fail-safe output signal is
available for further processing.
– Safe Acceleration Monitor (SAM)
Safe Acceleration Monitor (SAM) is used to safely monitor drive acceleration.
– Safe Direction (SDI):
Safe Direction is used to safely monitor the direction of motion.
1) Note regarding Power/Motor Modules in chassis format:
For the chassis format, SBC is only supported by Power/Motor Modules with order number
...3 or higher. A Safe Brake Adapter is needed in addition for this design.
2) Note regarding Power/Motor Modules in blocksize format:
blocksize Power Modules additionally require a Safe Brake Relay for this function.

General information about SINAMICS Safety Integrated
1.2 Examples of how the safety functions can be applied
Safety Integrated
Function Manual, 07/2012, 6FC5397-3EP40-3BA0 9
1.2 Examples of how the safety functions can be applied
Safety function Application examples Possible solution
When an Emergency Stop button is pressed, the drive must be
braked as quickly as possible and transitioned into STO
Selecting STO in the inverter via
terminal strip using an Emergency
Stop button.
STO
A central Emergency Stop button ensures that several drives
cannot unintentionally start.
Evaluating the Emergency Stop
button in a central control, selecting
STO in the inverter viaPROFIsafe.
SS1 It is only permissible to open a protective door if the motor torque
has been switched off.
Select SS1 in the inverter via a fail-
safe input or via PROFIsafe.
After pressing the Emergency Stop
button, the drive is braked along the
braking ramp and then brought into a
torque-free condition.
After opening a protective door, the machine operator must enter
the machine and in the hazardous zone, operate a horizontal
conveyor belt running at a slow speed using an acknowledgment
button.
Selecting SLS in the inverter via
terminal block. The inverter limits and
monitors the velocity of the horizontal
conveyor.
SLS
A spindle drive must not exceed a specific maximum speed,
depending on the selection of the cutting tool.
Selecting SLS and the corresponding
SLS level in the inverter via
PROFIsafe.
SSM It is only permissible to open a protective door when a motor is at
standstill.
Selecting SSM in the inverter; the
inverter safety monitors the speed
and releases the process to proceed
via PROFIsafe using the status bit
"Status SSM".
It is only permissible to open a protective door if a drive moves in
the safe direction (away from the operator).
Selecting SDIin the inverter; enable
the protective door via status bit
(PROFIsafe) of the inverter.
When replacing the plates of the pressure cylinders, the drive
must only move in the safe direction of rotation.
After a protective device to detect a jammed door responds, a
rolling shutter gate may only start to move in one direction.
SDI
When a crane trolley is at the operating limit switch then it may
only start in the opposite direction.
Selecting SDI in the inverter.
Disabling the hazardous direction of
rotation.
NOTICE
PROFIsafe function
The PROFIsafe function for the SINUMERIK 828D has not been released.

General information about SINAMICS Safety Integrated
1.3 Drive monitoring with encoder
Safety Integrated
10 Function Manual, 07/2012, 6FC5397-3EP40-3BA0
1.3 Drive monitoring with encoder
Overview of the Safety Integrated functions
Functions Abbreviation Brief description
Safe Torque Off STO Safe torque off
Safe Stop 1 SS1 Safe stopping process in accordance with
stop category 1
Basic
Functions
Safe Brake Control SBC Safe brake control
Safe Torque Off STO Safe torque off
Safe Stop 1 SS1 Safe stop in accordance with stop category
1
Safe Brake Control SBC Safe brake control
Safe Stop 2 SS2 Safe stop in accordance with stop category
2
Safe Operating Stop SOS Safe monitoring of the standstill position
Safely-Limited Speed SLS Safe monitoring of the maximum speed
Safe Speed Monitor SSM Safe monitoring of the minimum speed
Safe Acceleration
Monitor
SAM Safe monitoring of drive acceleration
Extended
Functions
Safe Direction SDI Safe monitoring of the direction of motion
The STARTER or SCOUT tools are used to configure the Safety Integrated functions and to
select the encoder-based monitoring.

Safety Integrated
Function Manual, 07/2012, 6FC5397-3EP40-3BA0 11
Description of Safety Integrated Basic Functions 2
Overview
This chapter should provide first-time users with a quick overview of the principle mode of
operation of safety functions.
The entry into the description of the safety functions is based on the definition according to
standard EN 61800-5-2 and some simple examples for using the function.
The description of the functions is simplified, as far as possible, to clearly show essential
properties and setting options.
Note
The Safety Integrated Basic Functions are functions for safely stopping the drive. You do not
require an encoder.
References
More information about commissioning the functions can be found in:
SINAMICS S120 Safety Integrated Function Manual, Chapter: "Commissioning the
functions"

Description of Safety Integrated Basic Functions
2.1 Safe Torque Off (STO)
Safety Integrated
12 Function Manual, 07/2012, 6FC5397-3EP40-3BA0
2.1 Safe Torque Off (STO)
Definition
Definition according to EN 61800-5-2:
"The STO function prevents energy from being supplied to the motor, which can generate a
torque."
Select STO
STO
Y
W
Examples of how the function can be used
Example Possible solution
After an Emergency Stop button has been
pressed, the drive must be braked as quickly
as possible and transitioned into STO.
•Wire the Emergency Stop button with a fail-safe
input.
•Select STO via the fail-safe input.
A central Emergency Stop button ensures that
several drives are braked as quickly as
possible and transitioned into the STO state.
•Evaluating an emergency stop pushbutton in a
central control.
How does STO function in detail?
The inverter detects the selection of STO using a fail-safe input. The inverter then safely
switches off the torque of the connected motor.
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Description of Safety Integrated Basic Functions
2.2 Safe Stop 1 (SS1)
Safety Integrated
Function Manual, 07/2012, 6FC5397-3EP40-3BA0 13
2.2 Safe Stop 1 (SS1)
Definition
Definition according to EN 61800-5-2:
"The function SS1 brakes the motor and trips the function STO after a delay time."
STO
Y
W
Select SS1
Example of how the function can be used
Example Possible solution
It is only permissible to open a protective door if the
motor torque has been switched off. •Select SS1 in the inverter using a terminal.
•The motor is braked and the inverter then
goes into the STO state.
How does SS1 function in detail?
The drive decelerates once "Safe Stop 1" has been selected, and goes into the "Safe Torque
Off" state once the delay time has expired.
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As soon as the inverter detects the selection of SS1 via a terminal, the following happens:
● If the motor has already been switched off when selecting SS1 , then the inverter safely
switches off the motor torque (STO).
● If the motor is switched on when SS1 is selected, the inverter brakes the motor with the
AUS3 ramp-down time.

Description of Safety Integrated Basic Functions
2.3 Safe Brake Control (SBC)
Safety Integrated
14 Function Manual, 07/2012, 6FC5397-3EP40-3BA0
2.3 Safe Brake Control (SBC)
Overview
The "Safe Brake Control" function (SBC) is used to control holding brakes that function
according to the closed-circuit principle (e.g. motor holding brake).
SBC is (if configured) initiated together with STO. he Motor Module/Safe Brake Relay then
carries out the action and activates the outputs for the brake.
Brake activation via the brake connection on the Motor Module/Safe Brake Relay involves a
safe, two-channel method.
Features of the "Safe brake control" function
Supplementary conditions:
● SBC is executed when "Safe Torque Off" (STO) is selected.
● Unlike conventional brake control, SBC is executed via p1215 through two channels.
● SBC is executed regardless of the brake control or mode set in p1215. However, for
p1215 = 0 or 3, then SBC is not recommended.
● When the state changes, electrical faults, such as e.g. a short-circuit in the brake winding
or wire breakage can be detected.
Two-channel brake control
The brake is essentially controlled from the Control Unit. Two signal paths are available for
applying the brake:
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Description of Safety Integrated Basic Functions
2.3 Safe Brake Control (SBC)
Safety Integrated
Function Manual, 07/2012, 6FC5397-3EP40-3BA0 15
For the "Safe Brake Control" function, the Motor/Power Module assumes a monitoring
function to ensure that when the Control Unit fails or malfunctions the brake current is
interrupted therefore closing the brake.
The brake diagnostics can only reliably detect a malfunction in either of the switches (TB+,
TB–) when the status changes, i.e. when the brake is released or applied.
If the Motor Module or Control Unit detects a fault, the brake current is switched off and the
safe status is reached.

Description of Safety Integrated Basic Functions
2.3 Safe Brake Control (SBC)
Safety Integrated
16 Function Manual, 07/2012, 6FC5397-3EP40-3BA0

Safety Integrated
Function Manual, 07/2012, 6FC5397-3EP40-3BA0 17
Description of the Safety Integrated Extended
Functions 3
Overview
This chapter should provide first-time users with a quick overview of the principle mode of
operation of safety functions.
The entry into the description of the safety functions is based on the definition according to
standard EN 61800-5-2 and some simple examples for using the function.
The description of the functions is simplified, as far as possible, to clearly show essential
properties and setting options.
References
More information about commissioning the functions can be found in:
SINAMICS S120 Safety Integrated Function Manual, Chapter: "Commissioning the
functions"
Prerequisite
A license is required to use the Safety Integrated Extended Functions.
Software option
You require the following software option in order to use this function:
"drive based SI-axis/spindle additional 1 axis/spindle"
(MLFB: 6FC5800-0AC50-0YB0).
Enter the associated license key via the operating software SINUMERIK Operate.
References
SINUMERIK 828D Turning and Milling Commissioning Manual, Chapter "Checking and
entering licenses"

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

Description of the Safety Integrated Extended Functions
3.2 Safe Stop 1 (SS1)
Safety Integrated
Function Manual, 07/2012, 6FC5397-3EP40-3BA0 19
3.2 Safe Stop 1 (SS1)
Definition
Definition according to EN 61800-5-2:
"The function SS1 brakes the motor, monitors the magnitude of the motor deceleration, and
after a delay time, initiates the STO function."
STO
Y
W
Select SS1
Example of how the function can be used
Example Possible solution
It is only permissible to open a protective door if
the motor torque has been switched off. •Select SS1 in the inverter using a terminal.
How does SS1 function in detail?
Using the SS1 function, the inverter brakes the motor and monitors the absolute speed. If the
motor speed is low enough or the delay time has expired, the inverter safely switches off the
motor torque using STO .
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As soon as the inverter detects the selection of SS1 via a fail-safe input, the following
happens:
● If the motor has already been switched off when selecting SS1 , then the inverter safely
switches off the motor torque (STO).
● If the motor is switched on when SS1 is selected, the inverter brakes the motor with the
AUS3 ramp-down time.

Description of the Safety Integrated Extended Functions
3.2 Safe Stop 1 (SS1)
Safety Integrated
20 Function Manual, 07/2012, 6FC5397-3EP40-3BA0
Acceleration monitoring with encoder
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For Extended Functions with encoder, there is only the "acceleration monitoring" mode:
● The inverter monitors the motor speed using the function SAM (Safe Acceleration
Monitor).
● The inverter prevents the motor from re-accelerating by continuously adjusting the
monitoring threshold to the decreasing speed.
● The inverter reduces the monitoring threshold until the "Shutdown speed" has been
reached.
● The inverter safely switches off the motor torque (STO) if one of the following conditions
is fulfilled:
– The inverter detects that the motor is stationary.
– The maximum time until the torque is switched off has expired.
Note
SS1 without OFF3
If you use "SS1 without OFF3", neither of the two monitoring functions (SBR, SAM) is active.