Siemens SINAMICS G120 Parts list manual

Answers for industry.
SINAMICS
SINAMICS G120
SINAMICS G120C frequency inverter
SINAMICS G120 frequency inverter
with the Control Units CU240E-2 CU240E-2 DP
CU240E-2 F CU240E-2 DP-F
Safety Integrated Function Manual · 01 2011

Safety Integrated Function Manual,
SINAMICS G120 and G120C
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SINAMICS
SINAMICS G120
Safety Integrated Function Manual,
SINAMICS G120 and G120C
Function Manual
Edition 01/2011, Firmware V4.4
01/2011, FW 4.4
A5E03052391B AB
Change history
Introduction
1
Description
2
Interfaces
3
Commissioning
4
Servicing and maintenance
5
Alarms, faults and system
messages
6
System properties
7
Appendix
A

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
A5E03052391B AB
Ⓟ 03/2011
Copyright © Siemens AG 2010.
Technical data subject to change

Safety Integrated Function Manual, SINAMICS G120 and G120C
Function Manual, 01/2011, FW 4.4, A5E03052391B AB 3
Change history
Most essential changes to the manual, Edition 07/2010
New functions in firmware V4.4 In chapter
The SINAMICS G120C frequency inverter has been included
in the manual. •Description (Page 13)
•Servicing and maintenance
(Page 179)
New safety functions:
•SDI (Safe Direction)
•SSM (Safe Speed Monitor)
•Description (Page 13)
•Commissioning (Page 105)
Safety function SS1 (Safe Stop 1) has an additional mode:
"SS1 with delay time".
Safety function SLS (Safely Limited Speed) has an additional
mode: "SLS with delay time".
•Description (Page 13)
•Commissioning (Page 105)
From firmware V4.4, torque control is permitted in conjunction
with the safety functions SS1, SLS, SDI and SSM. •Preconditions and constraints
(Page 17)
Revised descriptions In chapter
The designations of the control words and status words in the
PROFIsafe telegram have been adapted to the PROFIsafe
specification:
•Control word 0 and status word 0 have been renamed to
be control word 1 and status word 1
•Control word 2 and status word 2 have been renamed to
be control word 5 and status word 5
•Activation via PROFIsafe
(Page 94)
In the commissioning guidelines, basic commissioning has
been added before commissioning the safety functions. •Commissioning (Page 105)
Error correction In chapter
The meaning of the "Internal Event" bit (status word 1, bit 7 in
the PROFIsafe telegram) has been corrected:
•0 ≙ fault-free operation
•1 ≙ fault
•Activation via PROFIsafe
(Page 94)

Change history
Safety Integrated Function Manual, SINAMICS G120 and G120C
4 Function Manual, 01/2011, FW 4.4, A5E03052391B AB

Safety Integrated Function Manual, SINAMICS G120 and G120C
Function Manual, 01/2011, FW 4.4, A5E03052391B AB 5
Table of contents
Change history .......................................................................................................................................... 3
1 Introduction.............................................................................................................................................. 11
1.1 About this manual ........................................................................................................................11
1.2 Guide through this manual...........................................................................................................12
2 Description............................................................................................................................................... 13
2.1 Examples of how the safety functions can be applied.................................................................16
2.2 Preconditions and constraints......................................................................................................17
2.2.1 General conditions .......................................................................................................................17
2.2.2 Permissible and prohibited applications ......................................................................................18
2.2.3 Impermissible functions ...............................................................................................................19
2.3 Safe Torque Off, STO ..................................................................................................................20
2.4 Safe Stop 1, SS1 .........................................................................................................................21
2.4.1 Basic principle of operation..........................................................................................................21
2.4.2 Monitoring modes of SS1.............................................................................................................21
2.4.3 Braking ramp monitoring..............................................................................................................22
2.4.4 Acceleration monitoring ...............................................................................................................24
2.4.5 Switching off the motor when SS1 is active.................................................................................26
2.5 Safely Limited Speed, SLS ..........................................................................................................28
2.5.1 Monitoring modes of SLS.............................................................................................................28
2.5.2 Braking ramp monitoring..............................................................................................................30
2.5.2.1 Selecting SLS when the motor is switched on.............................................................................30
2.5.2.2 Switching between monitoring thresholds ...................................................................................32
2.5.3 Acceleration monitoring ...............................................................................................................34
2.5.3.1 Selecting SLS when the motor is switched on.............................................................................34
2.5.3.2 Switching between monitoring thresholds ...................................................................................36
2.5.4 Switching off the motor when SLS is active.................................................................................38
2.5.5 Switching the motor off and on again when SLS is active...........................................................40
2.6 Safe Direction (SDI) .....................................................................................................................42
2.6.1 Selecting and deselecting SDI.....................................................................................................42
2.6.2 Switching off the motor when SDI is active..................................................................................44
2.6.3 Switching the motor off and on again when SDI is active............................................................46
2.7 Safe Speed Monitor, SSM ...........................................................................................................49
2.7.1 Switching off the motor when SSM is active................................................................................51
2.7.2 Switching the motor off and on again when SSM is active..........................................................53
2.8 Interaction of the safety functions ................................................................................................56
2.8.1 Overview ......................................................................................................................................56
2.8.2 Selecting STO when SS1 is active ..............................................................................................57
2.8.3 Selecting STO when SLS is active ..............................................................................................58
2.8.4 Selecting STO when SDI is active ...............................................................................................59
2.8.5 Selecting STO when SSM is active .............................................................................................60

Table of contents
Safety Integrated Function Manual, SINAMICS G120 and G120C
6 Function Manual, 01/2011, FW 4.4, A5E03052391B AB
2.8.6 Selecting SS1 when SLS is active .............................................................................................. 61
2.8.7 Selecting SS1 when SDI is active............................................................................................... 63
2.8.8 Selecting SS1 when SSM is active ............................................................................................. 65
2.8.9 Selecting SDI when SLS is active............................................................................................... 67
2.8.10 Selecting SLS when SDI is active............................................................................................... 68
2.8.11 Selecting SLS when SSM is active ............................................................................................. 69
2.8.12 Selecting SDI when SSM is active.............................................................................................. 70
2.9 Password..................................................................................................................................... 71
2.10 Checksum ................................................................................................................................... 71
2.11 Forced dormant error detection (test stop) ................................................................................. 72
3 Interfaces................................................................................................................................................. 75
3.1 Overview ..................................................................................................................................... 75
3.2 Activation via F-DI ....................................................................................................................... 76
3.2.1 Fail-safe digital inputs ................................................................................................................. 76
3.2.2 F-DI signal filtering ...................................................................................................................... 77
3.2.3 Wiring examples.......................................................................................................................... 80
3.2.3.1 Connecting sensors .................................................................................................................... 80
3.2.3.2 Connecting pre-processing devices............................................................................................ 85
3.3 Activation via PROFIsafe ............................................................................................................ 94
3.3.1 Communication via PROFIsafe................................................................................................... 94
3.3.2 Telegram types ........................................................................................................................... 95
3.3.3 Control word 1 and status word 1 (Basic Safety)........................................................................ 96
3.3.4 Control word 1 and status word 1 (Extended Safety) ................................................................. 97
3.3.5 Control word 5 and status word 5 ............................................................................................... 99
3.3.6 Configuring communication in STEP 7 (telegram 30)............................................................... 100
3.3.7 Configuring communication in STEP 7 (telegram 900)............................................................. 102
3.3.8 Further steps ............................................................................................................................. 102
3.3.9 Example: Interface to the S7 safety program............................................................................ 103
4 Commissioning ...................................................................................................................................... 105
4.1 Commissioning guidelines ........................................................................................................ 105
4.2 Commissioning tool................................................................................................................... 106
4.3 Resetting the safety function parameters to the factory setting................................................ 107
4.4 Selecting the commissioning method ....................................................................................... 108
4.5 Basic Safety .............................................................................................................................. 110
4.5.1 Activate STO via F-DI. .............................................................................................................. 110
4.5.1.1 Defining the commissioning method ......................................................................................... 110
4.5.1.2 Setting STO............................................................................................................................... 111
4.5.1.3 Activate settings ........................................................................................................................ 111
4.5.1.4 Multiple assignment of the DI.................................................................................................... 112
4.5.1.5 Further steps ............................................................................................................................. 113
4.5.2 Activating STO via PROFIsafe.................................................................................................. 114
4.5.2.1 Defining the commissioning method ......................................................................................... 114
4.5.2.2 Setting STO............................................................................................................................... 115
4.5.2.3 Activate settings ........................................................................................................................ 115
4.5.2.4 Further steps ............................................................................................................................. 116
4.5.3 Activating STO via PROFIsafe and F-DI................................................................................... 117

Table of contents
Safety Integrated Function Manual, SINAMICS G120 and G120C
Function Manual, 01/2011, FW 4.4, A5E03052391B AB 7
4.5.3.1 Defining the commissioning method..........................................................................................117
4.5.3.2 Setting STO................................................................................................................................118
4.5.3.3 Activate settings.........................................................................................................................118
4.5.3.4 Multiple assignment of the DI.....................................................................................................119
4.5.3.5 Further steps..............................................................................................................................120
4.6 Extended Safety.........................................................................................................................121
4.6.1 Extended Safety with activation via F-DI ...................................................................................121
4.6.1.1 Defining the commissioning method..........................................................................................121
4.6.1.2 Configuring activation via FDI....................................................................................................122
4.6.1.3 Configuring safety functions.......................................................................................................123
4.6.1.4 Setting forced dormant error detection ......................................................................................124
4.6.1.5 Setting the gear ratio and tolerance...........................................................................................124
4.6.1.6 Encoderless actual value sensing..............................................................................................126
4.6.1.7 Enabling safety functions...........................................................................................................126
4.6.1.8 Setting STO................................................................................................................................127
4.6.1.9 Setting SS1 ................................................................................................................................128
4.6.1.10 Setting SLS ................................................................................................................................130
4.6.1.11 Setting SDI.................................................................................................................................130
4.6.1.12 Activate settings.........................................................................................................................131
4.6.1.13 Multiple assignment of the DI.....................................................................................................132
4.6.1.14 Further steps..............................................................................................................................133
4.6.2 Extended Safety with activation via PROFIsafe ........................................................................134
4.6.2.1 Defining the commissioning method..........................................................................................134
4.6.2.2 Setting forced dormant error detection and the PROFIsafe address ........................................135
4.6.2.3 Setting the gear ratio and tolerance...........................................................................................136
4.6.2.4 Encoderless actual value sensing..............................................................................................137
4.6.2.5 Enabling safety functions...........................................................................................................138
4.6.2.6 Setting STO................................................................................................................................139
4.6.2.7 Setting SS1 ................................................................................................................................140
4.6.2.8 Setting SLS ................................................................................................................................142
4.6.2.9 Setting SSM ...............................................................................................................................143
4.6.2.10 Setting SDI.................................................................................................................................144
4.6.2.11 Defining the F-DI status .............................................................................................................144
4.6.2.12 Activate settings.........................................................................................................................145
4.6.2.13 Starting communication via PROFIsafe.....................................................................................146
4.6.2.14 Further steps..............................................................................................................................146
4.6.3 Extended Safety with activation via PROFIsafe and F-DI .........................................................147
4.6.3.1 Defining the commissioning method..........................................................................................147
4.6.3.2 Setting forced dormant error detection and the PROFIsafe address ........................................148
4.6.3.3 Setting the gear ratio and tolerance...........................................................................................148
4.6.3.4 Encoderless actual value sensing..............................................................................................150
4.6.3.5 Enabling safety functions...........................................................................................................151
4.6.3.6 Setting STO................................................................................................................................151
4.6.3.7 Setting SS1 ................................................................................................................................152
4.6.3.8 Setting SLS ................................................................................................................................155
4.6.3.9 Setting SSM ...............................................................................................................................156
4.6.3.10 Setting SDI.................................................................................................................................157
4.6.3.11 Defining the F-DI status .............................................................................................................157
4.6.3.12 Activate settings.........................................................................................................................158
4.6.3.13 Starting communication via PROFIsafe.....................................................................................159
4.6.3.14 Multiple assignment of the DI.....................................................................................................159
4.6.3.15 Further steps..............................................................................................................................160

Table of contents
Safety Integrated Function Manual, SINAMICS G120 and G120C
8 Function Manual, 01/2011, FW 4.4, A5E03052391B AB
4.7 Offline commissioning ............................................................................................................... 161
4.7.1 Offline parameterization............................................................................................................ 161
4.7.2 Downloading parameters .......................................................................................................... 161
4.7.3 Further steps ............................................................................................................................. 162
4.8 Series commissioning ............................................................................................................... 163
4.9 Acceptance test - Completion of commissioning ...................................................................... 164
4.9.1 Prerequisites and authorized persons ...................................................................................... 164
4.9.2 Complete acceptance test......................................................................................................... 165
4.9.3 Reduced acceptance test.......................................................................................................... 166
4.9.4 Documentation .......................................................................................................................... 167
4.9.5 Function test.............................................................................................................................. 169
4.9.5.1 Safe Torque Off, STO (Basic Safety)........................................................................................ 170
4.9.5.2 Safe Torque Off, STO (Extended Safety) .................................................................................171
4.9.5.3 Safe Stop 1, SS1....................................................................................................................... 172
4.9.5.4 Safely Limited Speed, SLS ....................................................................................................... 173
4.9.5.5 Safe Direction (SDI) .................................................................................................................. 174
4.9.5.6 Safe Speed Monitor (SSM) ....................................................................................................... 175
4.9.6 Completion of certificate............................................................................................................ 176
5 Servicing and maintenance.................................................................................................................... 179
5.1 Replacing components of the modular SINAMICS G120 inverter............................................ 179
5.1.1 Overview of replacing converter components........................................................................... 179
5.1.2 Replacing the Control Unit ........................................................................................................ 180
5.1.3 Replacing the Power Module .................................................................................................... 182
5.2 Replacing the SINAMICS G120C inverter ................................................................................ 183
5.2.1 Overview of how to replace an inverter..................................................................................... 183
5.2.2 Replacing the inverter ............................................................................................................... 184
6 Alarms, faults and system messages..................................................................................................... 187
6.1 Operating states indicated on LEDs .........................................................................................188
6.2 Reaction of the safety functions to faults .................................................................................. 190
6.2.1 Cause of fault ............................................................................................................................ 190
6.2.2 Acknowledging with a fail-safe signal or with a power on reset................................................ 191
6.2.3 STOP reactions......................................................................................................................... 192
6.2.4 Response of Safe Torque Off (STO) to faults........................................................................... 194
6.2.5 Response of Safe Stop 1 (SS1) to faults ..................................................................................197
6.2.6 Reaction of Safely Limited Speed (SLS) to faults..................................................................... 199
6.2.7 Response of Safe Direction (SDI) to faults ...............................................................................201
6.2.8 Response of Safe Speed monitoring (SSM) to faults ............................................................... 203
6.3 Alarms and faults ...................................................................................................................... 204
7 System properties.................................................................................................................................. 209
7.1 Response times ........................................................................................................................ 209
7.2 Certification ............................................................................................................................... 210
7.3 Probability of failure of the safety functions (PFH value) .......................................................... 210
A Appendix................................................................................................................................................ 211
A.1 Standards and specifications .................................................................................................... 211
A.1.1 General information................................................................................................................... 211

Table of contents
Safety Integrated Function Manual, SINAMICS G120 and G120C
Function Manual, 01/2011, FW 4.4, A5E03052391B AB 9
A.1.1.1 Aims ...........................................................................................................................................211
A.1.1.2 Functional safety........................................................................................................................212
A.1.2 Safety of machinery in Europe...................................................................................................213
A.1.2.1 Machinery Directive ...................................................................................................................213
A.1.2.2 Harmonized European Standards .............................................................................................213
A.1.2.3 Standards for implementing safety-related controllers ..............................................................215
A.1.2.4 EN ISO 13849-1 (previously EN 954-1).....................................................................................216
A.1.2.5 EN 62061 ...................................................................................................................................217
A.1.2.6 Series of standards EN 61508 (VDE 0803) ...............................................................................219
A.1.2.7 Risk analysis/assessment..........................................................................................................220
A.1.2.8 Risk reduction ............................................................................................................................222
A.1.2.9 Residual risk...............................................................................................................................222
A.1.3 Machine safety in the USA.........................................................................................................223
A.1.3.1 Minimum requirements of the OSHA .........................................................................................223
A.1.3.2 NRTL listing................................................................................................................................223
A.1.3.3 NFPA 79.....................................................................................................................................224
A.1.3.4 ANSI B11 ...................................................................................................................................225
A.1.4 Machine safety in Japan ............................................................................................................226
A.1.5 Equipment regulations ...............................................................................................................227
A.1.6 Other safety-related issues........................................................................................................228
A.1.6.1 Additional references .................................................................................................................228
A.1.6.2 Information sheets issued by the Employer's Liability Insurance Association...........................228
A.2 Additional information on the inverter ........................................................................................229
A.2.1 Manuals for your inverter ...........................................................................................................229
A.2.2 Configuring support....................................................................................................................230
A.2.3 Product Support .........................................................................................................................231
A.3 Mistakes and improvements ......................................................................................................232
Index...................................................................................................................................................... 233

Table of contents
Safety Integrated Function Manual, SINAMICS G120 and G120C
10 Function Manual, 01/2011, FW 4.4, A5E03052391B AB

Safety Integrated Function Manual, SINAMICS G120 and G120C
Function Manual, 01/2011, FW 4.4, A5E03052391B AB 11
Introduction 1
1.1 About this manual
Who requires this manual and why?
This manual is aimed primarily at machine and plant manfacturers, commissioning
engineers, and service personnel. It describes the integrated safety functions of the
SINAMICS G120 inverter and enables the target groups specified to parameterize and
commission the integrated safety functions of the inverter correctly.
What is described in this manual?
This manual covers all the information, procedures and operations required for the following
scenarios:
● Activating the safety functions via fail-safe digital inputs or PROFIsafe.
● Commissioning the safety functions.
● Performing diagnostics for the safety functions.
The appendix contains an overview of the applicable regulations and standards for using the
safety functions.
What other information do you need?
This manual alone is not sufficient for installing or commissioning the standard inverter
functions. An overview of the documentation available and the associated applications is
provided in the sectionManuals for your inverter (Page 229).

Introduction
1.2 Guide through this manual
Safety Integrated Function Manual, SINAMICS G120 and G120C
12 Function Manual, 01/2011, FW 4.4, A5E03052391B AB
1.2 Guide through this manual
Chapter In this chapter, you will find answers to the following questions:
Description (Page 13) •What safety functions does my inverter have?
•In which applications are the safety functions of my inverter not permitted?
•How must I select and deselect the safety function?
•How do the inverter and motor respond when the safety function is active?
•How do the safety functions mutually influence one another?
Interfaces (Page 75) •How many fail-safe inputs does my inverter have?
•How do I have to wire up the fail-safe inputs of my inverter?
•What do I have to observe if the wiring extends beyond the control cabinet?
•How do I configure the communication of my inverter via PROFIsafe?
•How are the control words and status words assigned in PROFIsafe?
Commissioning (Page 105) •What approach to commissioning should I take?
•What tool do I need for commissioning?
•How do I transfer the parameters of the safety functions to other inverters?
•How do I reset my inverter to the factory setting?
•How do I check the safety functions after commissioning?
•What safety function settings must I document?
Servicing and maintenance
(Page 179) •When do I have to recommission the safety functions of my inverter after I have replaced
defective components?
•What do I have to check after making a replacement?
Alarms, faults and system
messages (Page 187) •What is the meaning of the signal states of the LED on my inverter?
•How do the inverter and motor respond to faults when the safety function is active?
•How do I acknowledge safety function faults?
•What is the meaning of the alarms and faults, which are assigned to the safety
functions?
System properties
(Page 209) •How long does it take for my drive to respond when selecting a safety function?
•How long does it take for my drive to respond when the safety function is active and the
motor malfunctions?
•What are the probabilities of failure of the safety functions of my inverter?
•According to which standards are the safety functions of my inverter certified?
Appendix (Page 211) •As machine manufacturer or company operating a machine, what standards and
regulations must I observe?
•Where can I find more information on my inverter?

Safety Integrated Function Manual, SINAMICS G120 and G120C
Function Manual, 01/2011, FW 4.4, A5E03052391B AB 13
Description 2
&RQWHQWRIWKLVPDQXDO
Numeric control in
machine tools
High-performance and
motion control
applications
Applications with variable speed
Applications
with fixed speed
Integrated safety functions (to IEC 61800-5-2)
Fail-safe communication Certification
Yes
Yes
Yes
YesYes
Yes
Yes
YesYesYes
Yes Yes Yes Yes
Yes Yes
Yes Yes Yes Yes Yes Yes
Yes Yes
Yes
Yes
YesYes
Yes Yes Yes
Yes
YesYes
Yes
1
Yes Yes
Yes
YesYes
Yes
Yes, with external
components
Yes, with external
components
YesYes
2
Yes
YesYesYes
SIL 2SIL 2SIL 2SIL 3
Cat. 3 / PL dCat. 3 / PL dCat. 3 / PLd
Cat. 3Cat. 3Cat. 3Cat. 4
Cat. 4 / PL e
2
only for SINAMICS S120 Booksize
1
with certified DCC application
PROFIBUS with PROFIsafe profile PROFINET with PROFIsafe profile Safety Local via F-DI NRTL listed
Yes, external components required
in certain cases
-
-
-
-
NFPA 79 EN 61508 EN ISO 13849-1 EN 954-1
--
-
-
-----------
Safely-Limited Position SLP
-----
-- -- -- -- --
------
Safe Cam SCA
- - -- - - -
------
Safe Stop 2 SS2
------
Safe Operating Stop SOS
- -
-- --
-- --
Safe Speed Monitor SSM Safe Direction SDI
--
Safely-Limited Speed SLS
----
--
--
-
----
Safe Brake Test SBT
--
- - - - - - - - - ----
Safe Brake Control SBC
--
Safe Stop 1 SS1 Safe Torque Off STO
SINUMERIK
840D
powerline
SINUMERIK
840D sl
SINAMICS
S150
SINAMICS
S120
SINAMICS
S110
SINAMICS
G150
SINAMICS
G130
SINAMICS
G120D
SINAMICS
G120
SINAMICS
G120C
SIMATIC
ET 200pro
FC
SIMATIC
ET 200S
FC
SIMATIC
ET 200pro
Motorstarter
SIMATIC
ET 200S
Motorstarter
Figure 2-1 Overview of products for drive technology with integrated safety functions

Description
Safety Integrated Function Manual, SINAMICS G120 and G120C
14 Function Manual, 01/2011, FW 4.4, A5E03052391B AB
Safety functions in the SINAMICS G120 and SINAMICS G120C
Table 2- 1 Safety functions
Abbreviation
acc. to EN
61800-5-2
Description (de/en)
acc. to EN 61800-5-2
Function in the inverter Available for
SINAMICS G120
with Control Unit
Available with
SINAMICS
G120C
STO Sicher abgeschaltetes
Moment
Safe Torque Off
The STO function prevents the
supply of energy to the motor which
can generate a torque.
CU240E-2
CU240E-2 DP
CU240E-2 F
CU240E-2 DP-F
CU240S DP-F
1)
CU240S PN F
1)
G120C
G120C DP
G120C CAN
SS1 Sicherer Stopp 1
Safe Stop 1
The SS1 function brakes the motor,
monitors the deceleration level of the
motor within defined limits and
initiates the STO function if the motor
speed falls below a defined limit
value.
An encoder to detect the motor
speed is not required.
CU240E-2 F
CU240E-2 DP-F
CU240S DP-F
1)
CU240S PN-F
1)
-
SLS Sicher begrenzte
Geschwindigkeit
Safely-Limited Speed
The SLS function prevents the motor
exceeding the defined velocity/speed
limit.
An encoder to detect the motor
speed is not required.
CU240E-2 F
CU240E-2 DP-F
CU240S DP-F
1)
CU240S PN-F
1)
-
SSM Sichere
Geschwindigkeits-
überwachung
Safe Speed Monitor
The SSM function supplies a safe
output signal, to indicate whether the
motor speed is below a defined limit.
An encoder for measuring the motor
speed is not required.
CU240E-2 DP-F -
SDI Sichere
Bewegungsrichtung
Safe Direction
The SDI function prevents the motor
shaft from rotating in the wrong
direction.
An encoder for measuring the motor
speed is not required
CU240E-2 F
CU240E-2 DP-F
-
SBC
1)
Sichere Bremsen-
ansteuerung
1)
Safe Brake Control
1)
The SBC function supplies a safe
output signal to control an external
brake.
1)
CU240S DP-F
1)
CU240S PN-F
1)
-
1) The SBC safety function and the Control Units CU240S DP-F and CU240S PN-F are not described in this manual.

Description
Safety Integrated Function Manual, SINAMICS G120 and G120C
Function Manual, 01/2011, FW 4.4, A5E03052391B AB 15
Table 2- 2 Fail-safe communication
Communication Available for
SINAMICS G120
with Control Unit
Available with
SINAMICS
G120C
PROFIsafe via PROFIBUS CU240E-2 DP
CU240E-2 DP-F
CU240S DP-F
1)
G120C DP
PROFIsafe via PROFINET
1)
CU240S PN-F
1)
-
1) PROFIsafe communication via PROFINET and the Control Units CU240S DP-F and CU240S PN-
F are not described in this manual.
Table 2- 3 Certifications of the safety functions
Standard Available for
SINAMICS G120
with Control Unit
Available with
SINAMICS
G120C
EN 954-1
1)
Kat. 3
1)
CU240S DP-F
1)
CU240S PN-F
1)
EN ISO 13849-1 Kat. 3 / PL d CU240E-2
CU240E-2 DP
CU240E-2 F
CU240E-2 DP-F
CU240S DP-F
1)
CU240S PN-F
1)
G120C
G120C DP
G120C CAN
EN 61508 SIL 2 CU240E-2
CU240E-2 DP
CU240E-2 F
CU240E-2 DP-F
CU240S DP-F
1)
CU240S PN-F
1)
G120C
G120C DP
G120C CAN
1) The Control Units CU240S DP-F and CU240S PN-F are not described in this manual.
Information on the safety functions of the Control Units CU240S DP-F and CU240S PN-F
can be found in theFunction Manual: SINAMICS G120, SINAMICS G120D, SIMATIC
ET200S FC, SIMATIC ET200pro FC
(http://support.automation.siemens.com/WW/view/en/31676845).

Description
2.1 Examples of how the safety functions can be applied
Safety Integrated Function Manual, SINAMICS G120 and G120C
16 Function Manual, 01/2011, FW 4.4, A5E03052391B AB
2.1 Examples of how the safety functions can be applied
Safety function Application examples Solution
When the emergency stop button is pressed, a stationary motor
must not start unintentionally.
Selecting STO in the inverter via
terminal strip using an Emergency
Stop button.
STO
A central emergency stop button is designed to prevent more than
one drive from starting unintentionally.
Evaluating the Emergency Stop
button in a central control, selecting
STO in the inverter viaPROFIsafe.
After opening a protective door, the machine operator must enter
the machine and in the hazardous zone, operate a horizontal
conveyor belt running at a slow speed using a pushbutton.
Selecting SLS in the inverter via
terminal block. The inverter limits and
monitors the velocity of the horizontal
conveyor.
SLS
A spindle drive, depending on the selection of the cutting tool,
must not exceed a specific maximum speed.
Selecting SLS and the corresponding
SLS level in the inverter via
PROFIsafe.
SS1 A protective door must only be opened when a motor is at
standstill.
Selecting SS1 in the inverter; enable
the protective door via status bit
"Power removed" (PROFIsafe) of the
inverter.
SSM A centrifuge may only filled below a minimum velocity. Selecting SSM in the inverter; the
inverter safety monitors the speed of
the centrifuge and releases the
process to proceed via PROFIsafe
using the status bit "Status SSM ".
A protective door must only be opened if a drive moves in the safe
direction (away from the operator).
Selecting SDI in the inverter; enable
the protective door via status bit
(PROFIsafe) of the inverter.
When replacing the pressure cylinders of the plates, the drive
must only move in the safe direction of rotation.
After a protective device to detect a jammed door responds, a
rolling shutter gate may only start to move in one direction.
SDI
When a crane trolley is at the operating limit switch then it may
only start in the opposite direction.
Selecting SDI in the inverter.
Disabling the hazardous direction of
rotation.

Description
2.2 Preconditions and constraints
Safety Integrated Function Manual, SINAMICS G120 and G120C
Function Manual, 01/2011, FW 4.4, A5E03052391B AB 17
2.2 Preconditions and constraints
2.2.1 General conditions
Prerequisites for using fail-safe functions
1. The machine risk assessment (e.g. in compliance with EN ISO 1050, "Safety of
machinery - Principles of risk assessment") allows inverter safety functions to be used in
accordance with SIL 2 or PL d.
2. The closed-loop speed control of the inverter must function properly. Each fail-safe drive
train must be set up in such a way that all the operating procedures performed by the
driven machine can be properly monitored and that the inverter operates below its limit
values (for current, temperature, voltage, etc.). The drive train comprises an inverter,
motor, brake and driven machine. The performance and parameters of the inverter must
be compatible with both the connected motor and the application in question.
3. Once the machine has been successfully commissioned, you must review the typical
operating conditions and operate the machine close to the permissible limit values. The
fail-safe inverter must not malfunction during this test.
Permissible control modes for using fail-safe functions
When the above-mentioned conditions are fulfilled, all of the fail-safe functions can be used
for both V/f control and vector control.
Permissible motors for using fail-safe functions
When the above-mentioned conditions are fulfilled, all of the fail-safe functions can be used
for induction motors from SIEMENS and other manufacturers.
Synchronous motors are not permitted.

Description
2.2 Preconditions and constraints
Safety Integrated Function Manual, SINAMICS G120 and G120C
18 Function Manual, 01/2011, FW 4.4, A5E03052391B AB
2.2.2 Permissible and prohibited applications
The safety function STO may be used without any restrictions in all applications.
WARNING
Suspended loads
If the motor can be accelerated by the mechanical system of the connected machine part
after the motor has been switched off, encoderless safety functions SS1, SLS, SSM and
SDI must not be used.
Whether or not a mechanical brake is installed is irrelevant here.
Examples:
1. For the hoisting gear of a crane, the suspended load can accelerate the motor as soon as
the motor is switched off. In this case, encoderless safety functions SS1, SLS, SSM and
SDI are not permissible.
Even if the mechanical brake of the hoisting gear is applied after the motor has been
switched off, this is of no significance regarding the fact that safety functions SS1, SLS,
SSM and SDI are prohibited in this application.
2. A horizontal conveyor is always braked to a standstill due to friction as soon as the motor
is switched off. In this case, encoderless safety functions SS1, SLS, SSM and SDI can be
used without any restrictions.
WARNING
PM240 FSGX Power Module
Encoderless safety functions SS1, SLS, SSM and SDI must not be used in conjunction
with the PM240 FSGX Power Module.