Siemens SINAMICS G130 User manual

Manual · 05/2010
Safety Integrated
SINAMICS G130 / G150 / S120 Chassis /
S120 Cabinet Modules / S150
SINAMICS
s

Safety Integrated
_
_________________
_
_
_________________
_
_
_________________
_
_
_________________
_
_
_________________
_
_
_________________
_
_
_________________
_
_
_________________
_
_
_________________
_
_
_________________
_
_
_________________
_
SINAMICS
G130, G150, S120 Chassis,
S120 Cabinet Modules, S150
Safety Integrated
Function Manual
Firmware Version 4.3 SP2
05/2010
A5E03264275A
Preface
Typicals and regulations
1
General information about
SINAMICS Safety Integrated
2
System Features
3
Supported functions
4
Safety Integrated Basic
Functions
5
Safety Integrated Extended
Functions
6
Controlling the safety
functions
7
Commissioning
8
Application examples
9
Acceptance test and
acceptance report
10

Legal information
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
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
NOTICE
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
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 for the specific task, 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 adhered to. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of the 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.
Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E03264275A
Ⓟ 10/2010
Copyright © Siemens AG 2010.
Technical data subject to change

Safety Integrated
Function Manual, 05/2010, A5E03264275A 5
Preface
Technical Support
In case of questions, please contact us through the following hotline:
Time zone Europe / Africa
Phone [phone]
Fax [phone]
Internet http://www.siemens.com/automation/support-request
Time zone Americas
Phone [phone]
Fax [phone]
E-mail [email protected]
Time zone Asia/Pacific
Phone [phone]
Fax [phone]
E-mail [email protected]
Note
Country-specific telephone numbers for technical support are provided under the following
Internet address:
http://www.automation.siemens.com/partners
Spare parts
You will find spare parts on the Internet at:
http://support.automation.siemens.com/WW/view/en/16612315.
Internet address for SINAMICS
http://www.siemens.com/sinamics.
Internet address for Safety Integrated
http://www.siemens.com/safety
This address contains detailed application examples for Safety Integrated.

Preface
Safety Integrated
6 Function Manual, 05/2010, A5E03264275A
Notation
The following notation and abbreviations are used in this documentation:
Notation for parameters (examples):
● p0918 Adjustable parameter 918
● r1024 Display parameter 1024
● p1070[1] Adjustable parameter 1070, index 1
● p2098[1].3 Adjustable parameter 2098, index 1, bit 3
● p0099[0...3] Adjustable parameter 99 indices 0 to 3
● r0945[2](3) Display parameter 945 index 2 of drive object 3
● p0795.4 Adjustable parameter 795 bit 4
Notation for faults and alarms (examples):
● F12345 Fault 12345
● A67890 Alarm 67890
ESD information
CAUTION
Electrostatic sensitive devices (ESD) are single components, integrated circuits or devices
that can be damaged by electrostatic fields or electrostatic discharges.
Regulations for the ESD handling:
During the handling of electronic components, pay attention to the grounding of the person,
workplace and packaging!
Electronic components may be touched by persons only when
•these persons are grounded using an ESD wristband, or
•these persons in ESD areas with a conducting floor wear ESD shoes or ESD grounding
straps.
Electronic components should be touched only when this is unavoidable. The touching is
permitted only on the front panel or on the circuit board edge.
Electronic components must not be brought into contact with plastics or clothing made of
artificial fibers.
Electronic components may only be placed on conducting surfaces (table with ESD coating,
conducting ESD foamed material, ESD packing bag, ESD transport container).
Electronic components may not be placed near display units, monitors or televisions
(minimum distance from the screen > 10 cm).
Measurements must only be taken on boards when the measuring instrument is grounded
(via protective conductors, for example) or the measuring probe is briefly discharged before
measurements are taken with an isolated measuring device (for example, touching a bare
metal housing).

Preface
Safety Integrated
Function Manual, 05/2010, A5E03264275A 7
Safety notices
DANGER
SINAMICS devices and AC motors must only be commissioned by suitably qualified
personnel.
The personnel must take into account the information provided in the technical customer
documentation for the product, and be familiar with and follow the specified danger and
warning notices.
When electrical equipment and motors are operated, the electrical circuits automatically
conduct a dangerous voltage.
When the machine or system is operated, hazardous axis movements can occur.
All of the work carried-out on the electrical machine or system must be carried-out with it in
a no-voltage condition.
Note
Machinery Directive (2006/42/EC)
When the European common market was launched, a decision was made that the domestic
Typicals and regulations of all of the EU Member States relating to the technical
implementation of machines would be harmonized. This meant that, as an internal market
directive, the content of the Machinery Directive had to be implemented by the individual
member states as national legislation. For the Machinery Directive, this was realized with the
objective to achieve standard protective goals thus removing trade barriers resulting from
technical differences. In accordance with the definition of a machine ("an assembly of linked
parts or components, at least one of which moves"), this directive has a very broad scope.
The revised version from 2006, which shall be binding as of Dec. 29, 2009, without
transitional period, has expanded its area of application and now includes "Logic units to
ensure safety functions".
The Machinery Directive involves the implementation of machines. It has 28 Articles and 12
Annexes. The basic safety and health requirements specified in Annex I of the Directive
must be fulfilled for the safety of machines.
The protective goals must be implemented responsibly to ensure compliance with the
Directive.
Manufacturers of a machine must verify that their machine complies with the basic
requirements. This proof is made more simple by applying harmonized Typicals.

Preface
Safety Integrated
8 Function Manual, 05/2010, A5E03264275A
DANGER
Five safety rules
When carrying out any kind of work on electrical devices, the "five safety rules" according to
EN 50110 must always be complied with:
1. Disconnect the system.
2. Protect against reconnection.
3. Make sure that the equipment is de-energized.
4. Ground and short-circuit.
5. Cover or enclose adjacent components that are still live.
WARNING
Correct and safe operation of SINAMICS units assumes correct transportation in the
transport packaging, correct long-term storage in the transport packaging, setup and
installation, as well as careful operation and maintenance.
For special versions of the drive units and motors, information and data in the Catalogs and
quotations additionally apply.
In addition to the danger and warning information provided in the technical customer
documentation, the applicable national, local, and plant-specific regulations and
requirements must be taken into account.
According to EN 61800-5-1 and UL 508, only safely isolated protective extra-low voltages
on the electronic modules may be connected to any of the terminals on the electronic
modules.
CAUTION
The motors can have surface temperatures of over +80 °C.
This is the reason that temperature-sensitive components, e.g. cables or electronic
components may neither be in contact nor be attached to the motor.
When attaching the connecting cables, you must ensure that:
•they may not be damaged,
•they may not be stressed,
•they may not be able to come into contact with any rotating parts
Note
In the configuration specified in the corresponding EC Declaration of Conformity regarding
EMC requirements and when the EMC installation guideline (order no. 6FC5297-0AD30-
0*P2) is complied with, SINAMICS devices fulfill the EMC Directive 2004/108/EC
requirements.
(*A: German; *B: English)

Preface
Safety Integrated
Function Manual, 05/2010, A5E03264275A 9
Note
When operated in dry operating areas, SINAMICS equipment with AC motors conforms to
Low-Voltage Directive 2006/95/EC.
CAUTION
Operating the equipment in the immediate vicinity (< 1.5 m) of mobile telephones with a
transmitting power of > 1 W may cause the devices to malfunction.
Safety notes on Safety Integrated
DANGER
High voltages
The drive is not disconnected from the mains by the "Safe Torque Off" function. Dangerous
voltages may be present on the motor and converter. This can result in death, serious
personal injury or severe material damage. Work on the electrical connections is not
allowed.
DANGER
Unexpected start up of the drive
If the function "Safe Torque Off" is not checked for proper function after service work, then
the drive can also start up unexpectedly after activating the "Safe Torque Off" function. This
can result in death, serious personal injury or severe material damage. Upon conclusion of
service work on all components with safety function (e.g., replacement of components), you
must verify and document proper function through a test activation.
DANGER
Restart
Drive systems, in which power supply to the motor is also possible via the load (e.g., ship's
drives, conveyors, fans, etc.) cannot be protected against restart using the "Safe Torque
Off" function. This can result in death, serious personal injury or severe material damage.
Take appropriate countermeasures such as mechanical braking.
WARNING
Only circuits that have been manufactured by I DT LD or by certified factories or that have
been installed by I DT LD Service for option K82 possess an approval. Possible plant-side
reproductions by non-certified manufacturers do not possess this approval!
An up-to-date list of authorized factories is available on request from your local Siemens
office.

Preface
Safety Integrated
10 Function Manual, 05/2010, A5E03264275A
WARNING
Unexpected start up of the drive
If the function "Safe Torque Off" is deactivated, the drive can start up unexpectedly. This
can result in death, serious personal injury or severe material damage.
To demonstrate that the function "Safe Torque Off" is deactivated, the specified switches
(e.g., "Safe Torque Off" mushroom-head pushbutton on the system) must be removed.
Note
The components must be protected against conductive pollution (e.g., using a cabinet with
IP54 protection).
Provided that conducted interference can be prevented at the installation site, the degree of
protection for the cabinet can be decreased accordingly.

Safety Integrated
Function Manual, 05/2010, A5E03264275A 11
Table of contents
Preface ...................................................................................................................................................... 5
1 Typicals and regulations .......................................................................................................................... 17
1.1 General information .....................................................................................................................17
1.1.1 Aims .............................................................................................................................................17
1.1.2 Functional safety..........................................................................................................................17
1.2 Safety of machinery in Europe.....................................................................................................18
1.2.1 Machinery Directive .....................................................................................................................18
1.2.2 Harmonized European Standards ...............................................................................................19
1.2.3 Standards for implementing safety-related controllers ................................................................21
1.2.4 EN ISO 13849-1 (previously EN 954-1).......................................................................................23
1.2.5 EN 62061 .....................................................................................................................................24
1.2.6 Series of standards EN 61508 (VDE 0803) .................................................................................26
1.2.7 Risk analysis/assessment............................................................................................................27
1.2.8 Risk reduction ..............................................................................................................................29
1.2.9 Residual risk.................................................................................................................................29
1.3 Machine safety in the USA...........................................................................................................30
1.3.1 Minimum requirements of the OSHA ...........................................................................................30
1.3.2 NRTL listing..................................................................................................................................31
1.3.3 NFPA 79.......................................................................................................................................31
1.3.4 ANSI B11 .....................................................................................................................................32
1.4 Machine safety in Japan ..............................................................................................................32
1.5 Equipment regulations .................................................................................................................32
1.6 Other safety-related issues..........................................................................................................33
1.6.1 Information sheets issued by the Employer's Liability Insurance Association.............................33
1.6.2 Additional references ...................................................................................................................33
2 General information about SINAMICS Safety Integrated .........................................................................35
2.1 Safety Integrated Functions.........................................................................................................35
2.2 Preconditions for Safety Integrated Basic Functions...................................................................36
2.3 Preconditions for Safety Integrated Extended Functions ............................................................37
2.4 Controlling the Safety Integrated functions..................................................................................37
2.5 Parameter, Checksum, Version, Password .................................................................................39
2.6 DRIVE-CLiQ rules for Safety Integrated Functions .....................................................................42
3 System Features...................................................................................................................................... 43
3.1 Latest information ........................................................................................................................43
3.2 Certification ..................................................................................................................................44
3.3 Safety instructions........................................................................................................................45
3.4 Probability of failure of the safety functions (PFH value).............................................................47
3.5 Response times ...........................................................................................................................48

Table of contents
Safety Integrated
12 Function Manual, 05/2010, A5E03264275A
3.5.1 Response times Safety Integrated Basic Functions ................................................................... 48
3.5.2 Response times, Safety Integrated Extended Functions with encoder ...................................... 49
3.5.3 Response times for Safety Integrated Extended Functions without encoder............................. 50
3.6 Residual risk................................................................................................................................ 51
4 Supported functions................................................................................................................................. 53
4.1 Content of this chapter................................................................................................................ 53
4.2 SINAMICS G130......................................................................................................................... 54
4.2.1 Basic functions ............................................................................................................................ 54
4.2.2 Extended Functions .................................................................................................................... 54
4.3 SINAMICS G150......................................................................................................................... 55
4.3.1 Basic functions ............................................................................................................................ 55
4.3.2 Extended Functions .................................................................................................................... 55
4.4 SINAMICS S120 Chassis............................................................................................................ 56
4.4.1 Basic functions ............................................................................................................................ 56
4.4.2 Extended Functions .................................................................................................................... 57
4.5 SINAMICS S120 Cabinet Modules ............................................................................................. 58
4.5.1 Booksize format Motor Module ................................................................................................... 58
4.5.1.1 Basic functions ............................................................................................................................ 58
4.5.1.2 Extended Functions .................................................................................................................... 59
4.5.2 Motor Module in chassis format .................................................................................................. 60
4.5.2.1 Basic functions ............................................................................................................................ 60
4.5.2.2 Extended Functions .................................................................................................................... 61
4.6 SINAMICS S150 ......................................................................................................................... 62
4.6.1 Basic functions ............................................................................................................................ 62
4.6.2 Extended Functions .................................................................................................................... 63
5 Safety Integrated Basic Functions ........................................................................................................... 65
5.1 Safe Torque Off (STO)................................................................................................................ 65
5.2 Safe Stop 1 (SS1, time controlled).............................................................................................. 69
5.3 Safe Brake Control (SBC)........................................................................................................... 71
5.4 Safety faults ................................................................................................................................ 73
5.5 Forced checking procedure......................................................................................................... 75
6 Safety Integrated Extended Functions..................................................................................................... 77
6.1 Safety functions "with encoder" / "without encoder" ................................................................... 77
6.2 Safety licenses for 1 to 5 axes .................................................................................................... 78
6.2.1 Safety licenses for S120 Chassis ............................................................................................... 78
6.2.1.1 Option F01 to F05 (safety licenses for 1 to 5 axes) ....................................................................78
6.2.2 Safety licenses for S120 Cabinet Modules and S150................................................................. 79
6.2.2.1 Option K01 to K05 (safety licenses for 1 to 5 axes)....................................................................79
6.3 Safe Torque Off (STO)................................................................................................................ 81
6.4 Safe Stop 1 (SS1) ....................................................................................................................... 82
6.4.1 Safe Stop 1 with encoder (time and acceleration controlled) ..................................................... 82
6.4.2 Safe Stop 1 without encoder (time and speed controlled) .......................................................... 84
6.4.3 Overview of important parameters.............................................................................................. 86
6.5 Safe Stop 2 (SS2) ....................................................................................................................... 87
6.5.1 General description..................................................................................................................... 87

Table of contents
Safety Integrated
Function Manual, 05/2010, A5E03264275A 13
6.5.2 EPOS and Safe Stop 2 ................................................................................................................89
6.6 Safe Operating Stop (SOS) .........................................................................................................90
6.7 Safely-Limited Speed (SLS).........................................................................................................92
6.7.1 General description......................................................................................................................92
6.7.2 Parking note.................................................................................................................................93
6.7.3 Safely-Limited Speed with encoder .............................................................................................93
6.7.4 Safely-Limited Speed without encoder ........................................................................................94
6.7.5 Overview of important parameters...............................................................................................97
6.7.6 EPOS and Safely-Limited Speed.................................................................................................98
6.8 Safe Speed Monitor (SSM)..........................................................................................................99
6.9 Safe Acceleration Monitor (SBR)...............................................................................................102
6.10 Safe Brake Ramp (SBR)............................................................................................................104
6.11 Safety faults ...............................................................................................................................107
6.12 Message buffer ..........................................................................................................................112
6.13 Reliable actual value acquisition with the encoder system........................................................114
6.14 Forced dormant error detection .................................................................................................119
7 Controlling the safety functions.............................................................................................................. 123
7.1 Overview of F-DI/F-DOs and of their structure ..........................................................................123
7.2 Control of "STO" and "SS1" via terminal module for option K82 ...............................................124
7.2.1 Terminal module for control of "STO" and "SS1" for SINAMICS G150 .....................................124
7.2.2 Terminal module for control of "STO" and "SS1" for SINAMICS S120 Cabinet Modules .........129
7.2.2.1 General information ...................................................................................................................129
7.2.2.2 Use of the K82 option with Control Unit CU320-2 .....................................................................133
7.2.2.3 Use of the K82 option with Control Unit CU320-2 .....................................................................133
7.2.2.4 Wiring.........................................................................................................................................133
7.2.3 Terminal module for control of "STO" and "SS1" for SINAMICS S150 .....................................134
7.3 Control of "STO" and "SS1" via terminals on the Control Unit and the Motor/Power
Module .......................................................................................................................................139
7.3.1 General information ...................................................................................................................139
7.3.1.1 Control signals by way of terminals on the Control Unit and Motor/Power Module...................139
7.3.1.2 Simultaneity and tolerance time of the two monitoring channels...............................................143
7.3.1.3 Bit pattern test............................................................................................................................144
7.3.2 Control of "STO" and "SS1" for SINAMICS G130 .....................................................................145
7.3.3 Control of "STO" and "SS1" for SINAMICS G150 .....................................................................151
7.3.4 Control of "STO" and "SS1" for SINAMICS S120 Chassis........................................................157
7.3.5 Control of "STO" and "SS1" for SINAMICS S120 Cabinet Modules..........................................163
7.3.6 Control of "STO" and "SS1" for SINAMICS S150......................................................................169
7.4 Control via TM54F / option K87 .................................................................................................175
7.4.1 General information ...................................................................................................................175
7.4.1.1 TM54F design ............................................................................................................................175
7.4.1.2 F-DI function...............................................................................................................................176
7.4.1.3 Function of the F-DO .................................................................................................................178
7.4.2 Control via TM54F for SINAMICS S120 Chassis ......................................................................180
7.4.3 Control via option K87 for SINAMICS S120 Cabinet Modules ..................................................180
7.4.4 Control via K87 for SINAMICS S150 .........................................................................................180
7.5 Control by way of PROFIsafe ....................................................................................................181
7.5.1 Safety Integrated Functions.......................................................................................................181

Table of contents
Safety Integrated
14 Function Manual, 05/2010, A5E03264275A
7.5.2 Enabling of the control via PROFIsafe...................................................................................... 181
7.5.3 Structure of telegram 30............................................................................................................ 182
7.5.3.1 Structure of telegram 30 (Basic Functions)............................................................................... 182
7.5.3.2 Structure of telegram 30 (Extended Functions) ........................................................................ 184
8 Commissioning ...................................................................................................................................... 187
8.1 General information about commissioning safety functions ..................................................... 187
8.2 Safety Integrated firmware versions ......................................................................................... 187
8.3 Commissioning of Safety Integrated functions.......................................................................... 189
8.3.1 Introduction ............................................................................................................................... 189
8.3.2 Prerequisites for commissioning the Safety Integrated functions............................................. 189
8.3.3 Default settings for commissioning Safety Integrated functions without encoder..................... 190
8.3.4 Standard commissioning of Safety Integrated functions........................................................... 192
8.3.5 Setting the sampling times........................................................................................................ 193
8.4 Commissioning of Safety Integrated Basic Functions .............................................................. 195
8.4.1 Procedure for commissioning "STO", "SS1" and "SBC"........................................................... 195
8.5 Commissioning TM54F by means of STARTER/SCOUT......................................................... 199
8.5.1 Basic sequence of commissioning............................................................................................ 199
8.5.2 Configuration start screen......................................................................................................... 200
8.5.3 TM54F configuration ................................................................................................................. 202
8.5.4 Test stop of the TM54F............................................................................................................. 203
8.5.4.1 Test stop mode 1 ...................................................................................................................... 205
8.5.4.2 Test stop mode 2 ...................................................................................................................... 206
8.5.4.3 Test stop mode 3 ...................................................................................................................... 207
8.5.4.4 Test stop mode parameters ...................................................................................................... 208
8.5.5 F-DI/F-DO configuration............................................................................................................ 209
8.5.6 Control interface of the drive group........................................................................................... 211
8.6 Procedure for configuring PROFIsafe communication ............................................................. 213
8.6.1 Configuring PROFIsafe via PROFIBUS.................................................................................... 213
8.6.2 Requirements for PROFIsafe communication .......................................................................... 213
8.6.3 Configuring PROFIsafe via PROFIBUS.................................................................................... 214
8.7 PROFIsafe via PROFINET........................................................................................................ 224
8.7.1 Configuring PROFIsafe via PROFINET.................................................................................... 224
8.7.2 Requirements for PROFIsafe communication .......................................................................... 224
8.7.3 Configuring PROFIsafe via PROFINET.................................................................................... 225
8.8 PROFIsafe configuration with STARTER (Basic Functions) .................................................... 230
8.9 Commissioning a linear/rotary axis ........................................................................................... 233
8.10 Modular machine concept Safety Integrated ............................................................................ 236
8.11 Information pertaining to component replacements.................................................................. 237
8.12 Information pertaining to series commissioning........................................................................ 239
9 Application examples............................................................................................................................. 241
9.1 Input/output interconnections for a safety switching device with TM54F.................................. 241
9.2 Application examples ................................................................................................................ 244
10 Acceptance test and acceptance report................................................................................................. 245
10.1 General information................................................................................................................... 245
10.2 Acceptance test structure.......................................................................................................... 246

Table of contents
Safety Integrated
Function Manual, 05/2010, A5E03264275A 15
10.2.1 Content of the complete acceptance test ..................................................................................248
10.2.2 Content of the partial acceptance test .......................................................................................250
10.2.3 Test scope for specific measures ..............................................................................................253
10.3 Safety logbook ...........................................................................................................................254
10.4 Acceptance report......................................................................................................................255
10.4.1 Plant description - Documentation part 1...................................................................................255
10.4.2 Description of safety functions - documentation part 2..............................................................257
10.4.2.1 Function table.............................................................................................................................257
10.4.2.2 Safety Integrated functions used ...............................................................................................257
10.4.2.3 Safety Parameter of the TM54F.................................................................................................261
10.4.2.4 Safety devices............................................................................................................................263
10.5 Acceptance tests........................................................................................................................264
10.5.1 Acceptance tests – Basic Functions ..........................................................................................265
10.5.1.1 Safe Torque Off (Basic Functions) ............................................................................................265
10.5.1.2 Safe Stop 1 (Basic Functions) ...................................................................................................267
10.5.1.3 Safe Brake Control (Basic Functions)........................................................................................269
10.5.2 Acceptance tests for Extended Functions (with encoder) .........................................................271
10.5.2.1 Acceptance test Safe Torque Off with encoder (Extended Functions)......................................271
10.5.2.2 Acceptance test for Safe Stop 1, time and acceleration controlled ...........................................273
10.5.2.3 Acceptance test for Safe Brake Control with encoder (Extended Functions)............................275
10.5.2.4 Acceptance test for Safe Stop 2 (SS2) ......................................................................................277
10.5.2.5 Acceptance test for Safe Operating Stop (SOS) .......................................................................279
10.5.2.6 Acceptance test for Safely-Limited Speed with encoder (Extended Functions)........................282
10.5.2.7 Acceptance test for Safe Speed Monitor (SSM)........................................................................293
10.5.3 Acceptance tests for Extended Functions (without encoder) ....................................................295
10.5.3.1 Acceptance test Safe Torque Off without encoder (Extended Functions).................................295
10.5.3.2 Acceptance test for Safe Stop 1 without encoder (Extended Functions) ..................................297
10.5.3.3 Acceptance test for Safe Brake Control without encoder (Extended Functions).......................299
10.5.3.4 Acceptance test for Safely Limited Speed without encoder (Extended Functions)...................301
10.6 Conclusion of the report.............................................................................................................307
Index...................................................................................................................................................... 309

Table of contents
Safety Integrated
16 Function Manual, 05/2010, A5E03264275A

Safety Integrated
Function Manual, 05/2010, A5E03264275A 17
Typicals and regulations 1
1.1 General information
1.1.1 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. To ensure this, companies describe in the various Typicals the current state
of the art covering all aspects relevant to safety. When the relevant Typicals are observed,
this ensures that state-of-the-art technology has been utilized and, in turn, the erector/builder
of a plant or a manufacturer of a machine or a piece of equipment has fulfilled his
appropriate responsibility.
Safety systems are designed to minimize potential hazards for both people and the
environment by means of suitable technical equipment, without restricting industrial
production and the use of machines more than is necessary. The protection of man and
environment must be assigned equal importance in all countries, which is it is important that
rules and regulations that have been internationally harmonized are applied. This is also
designed to avoid distortions in the competition due to different safety requirements in
different countries.
There are different concepts and requirements in the various regions and countries of the
world when it comes to ensuring the appropriate degree of safety. The legislation and the
requirements of how and when proof is to be given and whether there is an adequate level of
safety are just as different as the assignment of responsibilities.
The most important thing for manufacturers of machines and companies that set up plants
and systems is that the legislation and regulations in the country where the machine or plant
is being operated apply. For example, the control system for a machine that is to be used in
the US must fulfill local US requirements even if the machine manufacturer (OEM) is based
in the European Economic Area (EEA).
1.1.2 Functional safety
Safety, from the perspective of the object to be protected, cannot be split-up. The causes of
hazards and, in turn, the technical measures to avoid them can vary significantly. This is why
a differentiation is made between different types of safety (e.g. by specifying the cause of
possible hazards). "Functional safety" is involved if safety depends on the correct function.

Typicals and regulations
1.2 Safety of machinery in Europe
Safety Integrated
18 Function Manual, 05/2010, A5E03264275A
To ensure the functional safety of a machine or plant, the safety-related parts of the
protection and control devices must function correctly. In addition, the systems must behave
in such a way that either the plant remains in a safe state or it is brought into a safe state if a
fault occurs. In this case, it is necessary to use specially qualified technology that fulfills the
requirements described in the associated Typicals. The requirements to achieve functional
safety are based on the following basic goals:
● Avoiding systematic faults
● Controlling systematic faults
● Controlling random faults or failures
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 minimizing systematic faults. This is expressed in the Typicals using
different terms. In IEC/EN 61508, IEC/EN 62061, IEC/EN 61800-5-2 "Safety Integrity Level"
(SIL) and EN ISO 13849-1 "Categories" and "Performance Level" (PL).
1.2 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"):
● EU Directives only specify general safety goals and define basic safety requirements.
● Technical details can be defined by means of standards by Standards Associations that
have the appropriate mandate from the commission of the European Parliament and
Council (CEN, CENELEC). These standards are harmonized in line with a specific
directive and listed in the official journal of the commission of the European Parliament
and Council. Legislation does not specify that certain standards have to be observed.
When the harmonized Standards are observed, it can be assumed that the safety
requirements and specifications of the Directives involved have been fulfilled.
● EU Directives specify that the Member States must mutually recognize domestic
regulations.
The EU Directives are equal. This means that if several Directives apply for a specific piece
of equipment or device, the requirements of all of the relevant Directives apply (e.g. for a
machine with electrical equipment, the Machinery Directive and the Low-Voltage Directive
apply).
1.2.1 Machinery Directive
The basic safety and health requirements specified in Annex I of the Directive must be
fulfilled for the safety of machines.
The protective goals must be implemented responsibly to ensure compliance with the
Directive.
Manufacturers of a machine must verify that their machine complies with the basic
requirements. This verification is facilitated by means of harmonized standards.

Typicals and regulations
1.2 Safety of machinery in Europe
Safety Integrated
Function Manual, 05/2010, A5E03264275A 19
1.2.2 Harmonized European Standards
The two Typicals Organizations CEN (Comité Européen de Normalisation) and CENELEC
(Comité Européen de Normalisation Électrotechnique), mandated by the EU Commission,
drew-up harmonized European Typicals in order to precisely specify the requirements of the
EC directives for a specific product. These Typicals (EN Typicals) are published in the official
journal of the commission of the European Parliament and Council and must be included
without revision in domestic Typicals. They are designed to fulfill basic health and safety
requirements as well as the protective goals specified in Annex I of the Machinery Directive.
When the harmonized Typicals are observed, it is "automatically assumed" that the Directive
is fulfilled. As such, manufacturers can assume that they have observed the safety aspects
of the Directive under the assumption that these are also covered in this Typical. However,
not every European standardis harmonized in this sense. Key here is the listing in the official
journal of the commission of the European Parliament and Council.
The European Typicals regarding the safety of machines are structured in a hierarchical
manner as follows:
● A Typicals (basic Typicals)
● B Typicals (group Typicals)
● C Typicals (product Typicals)
Type A Typicals/basic Typicals
A Typicals include basic terminology and definitions relating to all types of machine. This
includes EN ISO 12100-1 (previously EN 292) "Safety of Machines, Basic Terminology,
General Design Principles."
A Typicals are aimed primarily at the bodies responsible for setting the B and C Typicals.
The measures specified here for minimizing risk, however, may also be useful for
manufacturers if no applicable C Typicals have been defined.
Type B Typicals/group Typicals
B Typicals cover all safety-related Typicals for various different machine types. B Typicals
are aimed primarily at the bodies responsible for setting C Typicals. They can also be useful
for manufacturers during the machine design and construction phases, however, if no
applicable C Typicals have been defined.
A further sub-division has been made for B Typicals:
● Type B1 Typicals for higher-level safety aspects (e.g. ergonomic principles, safety
clearances from sources of danger, minimum clearances to prevent parts of the body
from being crushed).
● Type B2 Typicals for protective safety devices are defined for different machine types
(e.g. EMERGENCY STOP devices, two-hand operating circuits, interlocking elements,
contactless protective devices, safety-related parts of controls).

Typicals and regulations
1.2 Safety of machinery in Europe
Safety Integrated
20 Function Manual, 05/2010, A5E03264275A
Type C Typicals/product Typicals
C Typicals are product-specific Typicals (e.g. for machine tools, woodworking machines,
elevators, packaging machines, printing machines, etc.). Product Typicals contain machine-
specific requirements. The requirements can, under certain circumstances, deviate from the
basic and group Typicals. Type C/product Typicals have the highest priority for machine
manufacturers who can assume that it fulfills the basic requirements of Annex I of the
Machinery Directive (automatic presumption of compliance). If no product standard has been
defined for a particular machine, type B Typicals can be applied when the machine is
constructed.
A complete list of the Typicals specified and the mandated draft Typicals are available on the
Internet at the following address:
http://www.newapproach.org/
Recommendation: Due to the rapid pace of technical development and the associated
changes in machine concepts, the Typicals (and C Typicals in particular) should be checked
to ensure that they are up to date. Please note that the application of a particular standard
may not be mandatory provided that all the safety requirements of the applicable EU
directives are fulfilled.