Siemens SINUMERIK 840D sl Parts list manual

Valid for
Control
SINUMERIK 840D sl
SINUMERIK 840D sl (export version)
Drive
SINAMICS S120
Software version
NCU system software 1.5
NCU system software 2.5
HMI Advanced 7.5
05/08 Edition
SINUMERIK Safety Integrated
SINUMERIK 840D sl/
SINAMICS S120
Function ManualFunction ManualFunction ManualFunction ManualFunction ManualFunction ManualFunction ManualFunction ManualFunction ManualFunction ManualFunction ManualFunction ManualFunction ManualFunction Manual
Regulations and Standards 1
Brief Description 2
System Features 3
Safety Functions
Integrated in the Drive 4
Basic Information on
Safety Functions Integrated
in the System/Drive 5
Safety Functions Integrated
in the System/Drive 6
Sensor/Actuator Connection 7
Data Descriptions 8
Commissioning 9
Diagnostics 10
Interaction with
Other Functions 11
Appendix A
Index I

SINUMERIK®documentation
Printing history
Brief details of this edition and previous editions are listed below.
The status of each edition is shown by the code in the ”Remarks” column.
Status code in the ”Remarks” column:
ANew documentation.. . . . .
BUnrevised reprint with new Order No.. . . . .
CRevised edition with new status.. . . . . If factual changes have been made on the page since the last edition, this is indicated
by a new edition coding in the header on that page.
Edition Order No. Remarks
03/06 6FC5 397–4BP10–0BA0 A
03/07 6FC5 397–4BP10–1BA0 C
05/08 6FC5 397–4BP10–2BA0 C
Trademarks
All product designations may be trademarks or product names of Siemens AG or supplier
companies whose use by third parties for their own purposes could violate the rights of the
owners.
©Siemens AG 2008 All rights reserved.
We have checked that the contents of this publication agree with the
hardware and software described here. Nevertheless, differences
might exist and therefore we cannot guarantee that they are
completely identical. The data in this document is regularly checked
and the necessary corrections are included in subsequent editions.
Suggestions for improvement are also welcome.
Subject to change without prior notice.
Siemens–Aktiengesellschaft
Printed in the Federal Republic of Germany Siemens–Aktiengesellschaft
3ls

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Preface
SINUMERIK documentation
The SINUMERIK documentation is organized in 3 parts:
SGeneral documentation
SUser documentation
SManufacturer/Service documentation
An overview of publications, which is updated monthly and provides information
about the language versions available, can be found on the Internet at:
http://www.siemens.com/motioncontrol
Follow menu items -- ”Support” --> ”Technical documentation” --> ”Ordering
documentation” -- > ”Printed documentation”.
The Internet version of DOConCD (DOConWEB) is available at:
http://www.automation.siemens.com/doconweb
Information about training courses and FAQs (frequently asked questions) is avail-
able on the Internet under:
http://www.siemens.com/motioncontrol and there under the menu item ”Support”
Target group
This documentation is intended for manufacturers/end users of machine tools and
production machines who use SINUMERIK 840D sl and SINAMICS S120 and the
integrated safety functions (SINUMERIK Safety IntegratedR).
Standard scope
This documentation describes the functionality of the standard scope. 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. However, no claim can be made regarding the availability of these func-
tions when the equipment is first supplied or in the event of servicing.
For the sake of simplicity, this documentation does not contain all detailed informa-
tion about all types of the product and cannot cover every conceivable case of
installation, operation, or maintenance.

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Technical support
If you have any technical questions, please contact our hotline:
Europe/Africa
Phone +49 180 / 5050 -- 222
Fax +49 180 / 5050 -- 223
Internet http://www.siemens.com/automation/support--request
America
Phone [phone]
Fax [phone]
E--mail mailto:[e-mail]
Asia/Australia
Phone [phone]
Fax [phone]
E--mail mailto:[e-mail]
Note
National phone numbers for technical support are provided under the following
Internet address: http://www.siemens.com/automation/service&support
Calls from the German fixed line network are charged (e.g. at 0.14 €/min).
Charges of other phone services may be different and may vary.
Questions about this documentation
If you have any queries (suggestions, corrections) regarding this documentation,
please send a fax or e--mail to the following address:
Fax [phone]
E--mail mailto:[e-mail]
A fax form is available at the end of this document.
SINUMERIK Internet address
http://www.siemens.com/sinumerik

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Standard scope
The main areas covered by this description of functions are as follows:
SRegulations and Standards
SBrief Description
SSystem Features
SSafety Functions Integrated in the Drive
SBasics on the Safety Functions Integrated in the System/Drive
SSafety Functions Integrated in the System/Drive
SConnecting Sensors/Actuators
SData Description
SCommissioning
SDiagnostics
SInteraction with other Functions
Separate documents are available for the user--oriented activities. These include,
for example, the creation of part programs and operation of the control systems.
Separate information is also available for operations that the machine tool
manufacturer must carry out. These include, for example, configuring/engineering,
installation and programming the PLC.
Notes on how to use this manual
The following help functions are available with this description of functions:
SOverall table of contents
SAppendix with abbreviations and references, glossary
SIndex
If you require information about a certain term, please look for this particular term
under the chapter Index in the Appendix. Both the chapter number and the page
number, where you will find this particular information are listed there.
Documentation, 05/08 Edition
Note
The 05/08 Edition of the documentation describes the functionality for the following
products and software release:
SINUMERIK 840D sl with NCU software release 1.5/2.5, HMI Advanced 7.5

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Note
Not all of the HMI functions shown are available in all of the HMI versions (HMI
Embedded, HMI sl, HMI Advanced).
Safety instructions
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 per-
sonal safety are highlighted in the manual by a safety alert symbol, notices refer-
ring only to property damage have no safety alert symbol. Depending on the haz-
ard level, warnings are displayed in a descending order as follows:
!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 warning triangle indicates that minor personal injury can result if proper
precautions are not taken.
Caution
without warning triangle indicates that material damage can result if proper
precautions are not taken.
Notice
indicates that an unintended event or situation can occur if the corresponding
information is not taken into account.

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In the event of a number of levels of danger prevailing simultaneously, the warning
corresponding to the highest level of danger is always used. A warning with a
warning triangle indicating risk of physical injury may also include a warning of the
risk of damage to property.
Qualified personnel
The device/system may only be set up and used in conjunction with this documen-
tation. Commissioning and operation of a device/system may only be performed by
qualified personnel. Qualified persons are defined as persons who are autho-
rized to commission, to ground, and to tag circuits, equipment, and systems in ac-
cordance with established safety practices and standards.
Intended purpose
Please note the following:
!Warning
This equipment is only allowed to be used for the applications described in the
catalog and in the technical description, and only in conjunction with non--Siemens
equipment and components recommended by Siemens. Correct, reliable operation
of the product requires proper transport, storage, positioning and assembly, as
well as careful operation and maintenance.
Additional information
Note
This symbol always appears in this documentation where further, explanatory
information is provided.
Test certificates
The attachments to the following test certificates with the certified software and
hardware releases are not included in this documentation. If you require the ap-
propriate attachments, then please use the address specified on the corrections/
suggestions sheet (last page).
A list of the certified software releases and hardware versions is provided with
each ”Certificate of Licence (CoL)” of the SINUMERIK Safety Integrated options.
If you have any questions relating to current certifications, please contact your
local Siemens office.

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EC type--examination certificate of the BGIA (BG Institute for Occupational Safety &
Health) acc. to DIN EN ISO 13849--1/DIN EN 61508

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PRÜFZERT symbol
When the ”SINUMERIK Safety Integrated” option is ordered, in addition to the
Certificate of license, an adhesive label that may be used for certified software
releases and hardware versions is included in the supplementary pack.
PRÜFZERT symbol for certification acc. to DIN EN ISO 13849--1/DIN EN 61508
Symbol of the BGIA
[BG Institute for
Occupational Safety
and Health]

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Space for your notes

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Table of Contents
1 Regulations and Standards 1-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 General information 1-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1.1 Objectives 1-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1.2 Functional safety 1-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Safety of machinery in Europe 1-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.1 Machinery Directive (98/37/EC) 1-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.2 Harmonized European Standards 1-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.3 Standards to implement safety–related controls 1-21. . . . . . . . . . . . . . . . . . . . .
1.2.4 EN ISO 13849–1 (previously EN 954–1) 1-22. . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.5 EN 62061 1-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.6 Series of Standards EN 61508 (VDE 0803) 1-25. . . . . . . . . . . . . . . . . . . . . . . . .
1.2.7 Risk analysis/assessment 1-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.8 Risk reduction 1-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.9 Residual risk 1-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Machine safety in the US 1-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.1 Minimum requirements of the OSHA 1-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.2 NRTL Listing 1-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.3 NFPA 79 1-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.4 ANSI B11 1-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 Machine safety in Japan 1-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5 Equipment regulations 1-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6 Other safety–related subjects and issues 1-33. . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6.1 Information sheets from the various regulatory bodies 1-33. . . . . . . . . . . . . . . .
1.6.2 Additional references 1-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Brief Description 2-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Control/drive system 2-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 System integrated safety technology 2-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.1 Overview of the system–integrated safety functions 2-38. . . . . . . . . . . . . . . . . .
2.3 Safety technology integrated in the drive 2-40. . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.1 Overview of the safety functions integrated in the drive 2-41. . . . . . . . . . . . . . .
2.4 Comparison of the function names for SINUMERIK Safety Integrated and
acc. to EN 61800–5–2 2-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 System Features 3-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 System requirements 3-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Latest information 3-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Certification 3-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 Probability of failure 3-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5 Safety information & instructions and residual risks 3-47. . . . . . . . . . . . . . . . . .
3.5.1 General residual risks for PDS (Power Drive Systems) 3-47. . . . . . . . . . . . . . .
3.5.2 Additional safety information & instructions and residual risks for
Safety Integrated 3-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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4 Safety Functions Integrated in the Drive 4-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 General information about SINAMICS Safety Integrated 4-53. . . . . . . . . . . . . .
4.1.1 Explanations and terminology 4-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.2 Supported functions 4-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.3 Parameter, checksum, version, password 4-55. . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.4 Forced checking procedure 4-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Safe Torque Off (STO) 4-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Safe Stop 1 (SS1, time–controlled) 4-61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Safe Brake Control (SBC) 4-63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 Control via terminals on the Control Unit and the power unit 4-65. . . . . . . . . . .
4.6 Commissioning the STO, SBC and SS1 functions 4-69. . . . . . . . . . . . . . . . . . .
4.6.1 General information about commissioning safety functions 4-69. . . . . . . . . . . .
4.6.2 Procedure for commissioning STO, SBC and SS1 4-70. . . . . . . . . . . . . . . . . . .
4.6.3 Safety faults 4-74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7 Overview of parameters and function diagrams 4-77. . . . . . . . . . . . . . . . . . . . . .
4.8 Acceptance test and acceptance report 4-79. . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8.1 General information about acceptance 4-79. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8.2 Documentation 4-81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8.3 Acceptance test for Safe Torque Off (STO) 4-84. . . . . . . . . . . . . . . . . . . . . . . . .
4.8.4 Acceptance test for Safe Stop 1, time–controlled (SS1) 4-85. . . . . . . . . . . . . . .
4.8.5 Acceptance test for Safe Brake Control (SBC) 4-87. . . . . . . . . . . . . . . . . . . . . .
4.8.6 Completing the log 4-88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Basics on the Safety Functions Integrated in the System/Drive 5-91. . . . . . . . . . . .
5.1 Monitoring cycle 5-91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Crosswise data comparison 5-93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Forced checking procedure 5-94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 Actual value conditioning 5-96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.1 Encoder types 5-96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.2 Encoder adjustment, calibrating the axes 5-99. . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.3 Axis states 5-100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.4 User acknowledgement 5-103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.5 Taking into account control gears 5-105. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.6 Actual value synchronization (slip for 2–encoder systems) 5-107. . . . . . . . . . . .
5.4.7 Encoder limit frequency 5-108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5 Enabling the safety–related functions 5-109. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6 Switching the system on/off 5-111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Safety Functions Integrated in the System/Drive 6-113. . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Safe stop (SH) 6-113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1.1 Shutdown paths 6-115. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1.2 Testing the shutdown paths 6-116. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Safe operating stop (SBH) 6-118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.1 Selecting/deselecting the safe operating stop 6-119. . . . . . . . . . . . . . . . . . . . . . .
6.2.2 Effects when the limit is exceeded for SBH 6-122. . . . . . . . . . . . . . . . . . . . . . . . .

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6.3 Safe Stops A–F 6-125. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.1 General information 6-125. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.2 Description of STOP A 6-132. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.3 Description of STOP B 6-134. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.4 Description of STOP C 6-135. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.5 Description of STOP D 6-136. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.6 Description of STOP E 6-137. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.7 Description of STOP F 6-139. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.8 Forced checking procedure of the external STOPs 6-142. . . . . . . . . . . . . . . . . . .
6.4 Safe acceleration monitoring (SBR) 6-144. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5 Safely reduced speed (SG) 6-148. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5.1 Speed monitoring, encoder limit frequency 6-149. . . . . . . . . . . . . . . . . . . . . . . . . .
6.5.2 Selecting/deselecting safely reduced speed 6-150. . . . . . . . . . . . . . . . . . . . . . . . .
6.5.3 Effects when the limit value is exceeded for SG 6-153. . . . . . . . . . . . . . . . . . . . .
6.5.4 Override for safely reduced speed 6-156. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5.5 Example: Override for safely reduced speed 6-159. . . . . . . . . . . . . . . . . . . . . . . .
6.6 Safety–related output ”n<nx” 6-161. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7 Safe software limit switches (SE) 6-163. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7.1 Effects when an SE responds 6-164. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.8 Safety software cams and safety cam track (SN) 6-167. . . . . . . . . . . . . . . . . . . .
6.8.1 Safe software cams (4 cam pairs) 6-168. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.8.2 Safe cam track (SN) 6-172. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 Connecting Sensors/Actuators 7-181. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Safety–related input/output signals 7-181. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.1 Overview of the SGEs/SGAs and their structure 7-181. . . . . . . . . . . . . . . . . . . . .
7.1.2 Forced checking procedure of SPL signals 7-188. . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.3 Connecting sensors – actuators using the 3–terminal concept 7-190. . . . . . . . .
7.1.4 Sensor connection using the 4–terminal concept 7-193. . . . . . . . . . . . . . . . . . . . .
7.1.5 Multiple distribution and multiple interlocking 7-195. . . . . . . . . . . . . . . . . . . . . . . .
7.2 Connecting I/O via PROFIsafe 7-198. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.1 Description of Functions 7-198. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.2 System structure 7-200. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.3 Configuring and parameterizing the PROFIsafe I/O 7-202. . . . . . . . . . . . . . . . . .
7.2.4 Parameterizing the F master (NCK) 7-208. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.5 Parameterizing the PROFIsafe communication (NCK) 7-208. . . . . . . . . . . . . . . .
7.2.6 Parameterizing the SPL–SGE interface 7-210. . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.7 Parameterizing the SPL–SGA interface 7-214. . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.8 Module type (NCK) 7-217. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.9 Parameterizing the F master (PLC) 7-217. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.10 Response times 7-218. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.11 Functional boundary conditions 7-221. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3 Safe programmable logic (SPL) 7-223. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.1 Basic principles 7-223. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.2 Synchronized actions for Safety Integrated 7-227. . . . . . . . . . . . . . . . . . . . . . . . .
7.3.3 NCK–SPL program 7-228. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.4 Starting the SPL 7-230. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.5 Starting the NCK–SPL using the PROG_EVENT mechanism 7-231. . . . . . . . . .
7.3.6 Starting the NCK–SPL from the PLC user program 7-234. . . . . . . . . . . . . . . . . .
7.3.7 Diagnostics/commissioning 7-235. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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7.3.8 Safe software relay 7-236. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.9 System variables for SINUMERIK 840D sl 7-244. . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.10 Behavior after power on/mode change/reset 7-246. . . . . . . . . . . . . . . . . . . . . . . .
7.3.11 SPL data on the PLC side 7-247. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.12 Direct communications between NCK and PLC–SPL 7-249. . . . . . . . . . . . . . . . .
7.4 Safe brake test (SBT) 7-250. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.1 Field of application 7-250. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.2 Parameter assignment 7-250. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.3 Procedure 7-255. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.4 Limitations 7-259. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.5 Activating 7-259. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.6 Example 7-260. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 Data Description 8-261. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1 Machine data for SINUMERIK 840D sl 8-261. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1.1 Overview of the machine data 8-261. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1.2 Description of machine data 8-266. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2 Parameters for SINAMICS S120 8-313. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.1 Parameter overview 8-314. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.2 Description of parameters 8-318. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3 Interface signals 8-359. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.1 Interface signals for SINUMERIK 840D sl 8-360. . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.2 Description of the interface signal 8-361. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.3 PLC data block (DB 18) 8-370. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4 System variables 8-378. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4.1 System variable for SINUMERIK 840D sl 8-378. . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4.2 Description of the system variables 8-381. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 Commissioning 9-389. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1 HMI screens and softkeys 9-391. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2 Procedure when commissioning the drive for the first time 9-403. . . . . . . . . . . .
9.3 Series commissioning 9-409. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4 Changing data 9-410. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5 Acceptance test 9-412. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5.1 General information 9-412. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5.2 Conventional acceptance test 9-419. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5.3 Acceptance test support 9-422. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.6 Replacing a motor or encoder 9-427. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 Diagnostics 10-435. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1 Troubleshooting procedure 10-435. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1.1 Service displays 10-436. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1.2 Diagnostics support by configuring your own extended alarm text 10-443. . . . .
10.1.3 Servo trace bit graphics for Safety Integrated 10-446. . . . . . . . . . . . . . . . . . . . . .
10.1.4 Bit graphics for SI signals in the servo trace 10-449. . . . . . . . . . . . . . . . . . . . . . . .
10.1.5 Servo trace signals 10-454. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2 NCK safety alarms for SINUMERIK 840D sl 10-457. . . . . . . . . . . . . . . . . . . . . . .

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10.3 Safety messages for SINAMICS S120 10-538. . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.1 General information 10-538. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.2 List of faults and alarms 10-541. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.4 Safety PLC alarms 10-571. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.5 Reducing the number of alarms 10-572. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.5.1 Alarm suppression 10-572. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.5.2 Assigning priorities to alarms 10-573. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 Interaction with Other Functions 11-577. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.1 Limiting the speed setpoint 11-577. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2 Measuring system changeover 11-579. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.3 Gantry axes 11-579. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.4 Parking axis 11-579. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.5 OEM applications 11-580. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.6 Behavior of Safety Integrated when Profibus fails 11-581. . . . . . . . . . . . . . . . . . .
A Appendix A-583. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.1 Customer Support A-583. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.2 References A-584. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.3 Abbreviations A-587. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.4 Terms A-592. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index I-595. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Space for your notes

1-17
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Regulations and Standards
1.1 General information
1.1.1 Objectives
Manufacturers and operating companies of equipment, machines and products are
responsible for ensuring the appropriate level of safety. This results in the require-
ment that plants, machines and other equipment should be made as safe as pos-
sible according to state–of–the–art technology. In this case, companies describe in
the various Standards, state–of–the–art technology that is relevant for safety.
When the relevant Standards are complied with, it can be ensured that state–of–
the–art technology has been utilized and therefore 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 intended to play their role in keeping potential hazards for both
people and the environment as low as possible by using suitable technical equip-
ment, without restricting, more than absolutely necessary, industrial production and
the use of machines. The protection of man and environment has to be put on an
equal footing in all countries by applying rules and regulations that have been inter-
nationally harmonized. At the same time, this is also intended to avoid that safety
requirements in different countries have an impact on the competitive situation.
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 legis-
lation 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.
What is important for manufacturers of machines and companies that erect plants
and systems is that always the local legislation and regulations apply where the
machine or plant is being operated. For instance, the control system of a machine,
that is to be used in the US, must fulfill the local US requirements even if the
machine manufacturer (OEM) is based in the European Economic Area (EEA).
1

Regulations and Standards
1.2 Safety of machinery in Europe
05.08
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1.1.2 Functional safety
Safety, from the perspective of the object to be protected, cannot be split–up.
The causes of hazards and therefore also the technical measures to avoid them
can vary significantly. This is the reason that 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.
In order to achieve the functional safety of a machine or plant, it is necessary that
the safety–related parts of the protection and control devices function correctly.
And not only this, when faults develop, they must behave so that either the plant
remains in a safe state or it is brought into a safe state.
In this case, it is necessary to use specially qualified technology that fulfills the re-
quirements described in the associated Standards. The requirements to achieve
functional safety are based on the following basic goals:
SAvoiding systematic faults
SControlling systematic faults
SControlling random faults or failures
The measure for the achieved functional safety is the probability of dangerous
failures, the fault tolerance and the quality that should be guaranteed by minimizing
systematic faults. This is expressed in the Standards using different terms. In
EN 61508, EN 62061, 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 EC Directives, that apply to the implementation of products, based on Article
95 of the EU contract, that regulates the free exchange of goods. These are based
on a new global concept (”new approach”, ”global approach”):
SEC Directives only specify generally valid safety goals and define basic safety
requirements.
STechnical details can be defined in Standards by Standards Associations that
have an appropriate mandate from the European Parliament and the Council
(CEN, CENELEC). These Standards are harmonized under a specific Directive
and are listed in the Official Journal of the Commission of the European Parlia-
ment and the Council. Legislation does not specify that certain standards have
to be complied with. When the harmonized Standards are complied with, then it
can be assumed that all of the applicable safety requirements and specifica-
tions of the Directives involved are fulfilled.
The EC Directives are equal. This means that if several Directives apply for a spe-
cific piece of equipment or device, then the requirements of all of the relevant Di-
rectives apply (e.g. for a machine with electrical equipment, then the Machinery
Directive and the Low–Voltage Directive apply).

Regulations and Standards
1.2 Safety of machinery in Europe
05.08
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1.2.1 Machinery Directive (98/37/EC)
With the introduction of a European Economic Area, a decision was made that the
domestic Standards and regulations of all of the EEA Member States – that are
involved with the technical implementation of machines – would be harmonized.
This means that the Machinery Directive had to be implemented – as an internal
market Directive – as far as the content was concerned – in the domestic legisla-
tion of the individual Member States. For the Machinery Directive, this was realized
with the objective to achieve standard protective goals thus removing trade barriers
resulting from technical differences. Corresponding to its definition ”a machine is
an assembly of linked parts or components – at least one of which moves”, this
Directive is extremely extensive. The range of applications was subsequently
expanded to include ”safety–related components” and ”exchangeable equipment”
in the form of revision Directives.
The Machinery Directive involves the implementation of machines. It has 14 Articles
and 7 Annexes. The basic safety and health requirements specified in Annex I of the
Directive must be fulfilled for the safety of machines. The manufacturer must carefully
observe the following principles when it comes to integrating safety (Annex I, Para-
graph 1.1.2):
a) ”Machinery must be constructed that it is fitted for its functions, and can be
adjusted and maintained without putting persons at risk when these opera-
tions are carried out under the conditions foreseen by the manufacturer.”
”The measures must...eliminate...any risks of accidents...!”
b) ”When selecting the appropriate solutions, the manufacturer must apply the
following basic principles – and more precisely, in the specified sequence:
SEliminate or minimize hazards (by integrating the safety concept into the
development and construction of the machine);
SApply and use the necessary protective measures to protect against dan-
gers that cannot be avoided;
SInform the user about the residual dangers due to the fact that the safety
measures applied are not completely effective.”
The protective goals must be responsibly implemented in order to fulfill the require-
ments for conformity with the Directive.
The manufacturer of a machine must provide proof that his machine is in com-
pliance with the basic requirements. This proof is made more simple by applying
harmonized Standards.
1.2.2 Harmonized European Standards
The two Standards Organizations CEN (Comité Européen de Normalisation) and
CENELEC (Comité Européen de Normalisation Électrotechnique), mandated by
the EU Commission, drew–up harmonized European Standards in order to pre-
cisely specify the requirements of the EC Directives for a specific product. These
Standards (EN Standards) are published in the Official Journal of the European

Regulations and Standards
1.2 Safety of machinery in Europe
05.08
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Parliament and Council and must be included in domestic standards without any
revisions. These are used to fulfill the basic health and safety requirements and the
protective goals specified in Annex I of the Machinery Directive.
When the harmonized Standards are complied with, then there is an ”automatic
assumption” that the Directive is fulfilled. This means that the manufacturer may
then assume that he has complied with the safety aspects of the Directive under
the assumption that they are also handled in that particular Standard. However, not
every European Standard is harmonized in this sense. The listing in the Official
Journal of the European Parliament and Council is decisive.
The European Standards for Safety of Machines is hierarchically structured as
follows:
SA Standards (Basic Standards)
SB Standards (Group Standards)
SC Standards (Product Standards)
Regarding Type A Standards/Basic Standards
A Standards include basic terminology and definitions that are applicable for all
machines. This includes EN ISO 12100–1 (previously EN 292–1) ”Safety of Ma-
chines, Basic Terminology, General Design Principles.”
A Standards primarily address those bodies setting the B and C Standards. How-
ever, the techniques documented there regarding minimizing risks can also be
helpful to manufacturers if there are no applicable C Standards.
Regarding Type B Standards/Group Standards
B Standards include all Standards with safety–related statements that can involve
several machine types.
B Standards also primarily address those bodies setting C Standards. However,
they can also be helpful for manufacturers when designing and constructing a ma-
chine if no C Standards apply.
For B Standards, an additional sub–division is made – and more precisely as
follows:
–Type B1 Standards for higher–level safety aspects, e.g. basic ergonomic
principles, safety clearances from hazards, minimum clearances to avoid
crushing parts of the body.
–Type B2 Standards for protective safety devices are defined for various
machine types – e.g. Emergency Stop devices, two–hand operating circuits,
interlocking elements, contactless protective devices, safety–related parts of
controls.
Regarding Type C Standards/Product Standards
C Standards are Standards for specific products – for instance, machine tools, wood-
working machines, elevators, packaging machines, printing machines etc.
Product Standards list requirements for specific machines. The requirements can,
under certain circumstances, deviate from the Basic and Group Standards. For the
machine manufacturer, Type C Standards/Product Standards have the highest priority.
The machine manufacturer can then assume that it fulfills the basic requirements of
Attachment I of the Machinery Directive (automatic presumption of compliance).