Siemens SINAMICS S110 Parts list manual

SINAMICS
Function Manual · 01/2011
SINAMICS S110
s

Function Manual
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SINAMICS
S110
Function Manual
Function Manual
Valid for: Firmware version 4.4
01/2011
6SL3097-4AB10-0BP3
Preface
General information for
commissioning
1
Commissioning preparations
for PROFIBUS
2
Commissioning with
PROFIBUS
3
Commissioning with
CANopen
4
Diagnostics
5
Parameterization using the
Basic Operator Panel 20
6
Drive functions
7
Safety Integrated Functions
8
Communication
9
Basic information about the
drive system
10
Appendix
11

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
order number: 6SL3097-4AB10-0BP3
Ⓟ 12/2010
Copyright © Siemens AG 2008,
2009, 2010, 2011.
Technical data subject to change

Function Manual
Function Manual, 01/2011, 6SL3097-4AB10-0BP3 3
Preface
SINAMICS Documentation
The SINAMICS documentation is organized in the following categories:
● General documentation / catalogs
● User documentation
● Manufacturer/Service documentation
More information
Using the following link, you can find information on the topics:
● Ordering documentation/overview of documentation
● Additional links to download documents
● Using documentation online (find and search in manuals/information)
http://www.siemens.com/motioncontrol/docu
Please send any questions about the technical documentation (e.g. suggestions for
improvement, corrections) to the following e-mail address:
[e-mail]
My Documentation Manager
Using the following link, you can find information on how to create your own individual
documentation based on Siemens' content, and adapt it for your own machine
documentation:
http://www.siemens.com/mdm
Training
Using the following link, you can find information on SITRAIN - training from Siemens for
products, systems and automation engineering solutions:
http://www.siemens.com/sitrain
FAQs
You can find Frequently Asked Questions in the Service&Support pages under Product
Support:
http://support.automation.siemens.com

Preface
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4 Function Manual, 01/2011, 6SL3097-4AB10-0BP3
SINAMICS
You can find information on SINAMICS at:
http://www.siemens.com/sinamics.
Usage phases and the available tools/documents
Table 1 Usage phase and the available tools / documents
Usage phase Tools/documents
Orientation SINAMICS S Sales Documentation
Planning/configuration SIZER configuration tool
Configuration Manuals, Motors
Decision making /
ordering
SINAMICS S Catalogs
Installation / assembly SINAMICS S110 Equipment Manual
Commissioning STARTER commissioning tool
SINAMICS S110 Getting Started
SINAMICS S110 Function Manual Drive Functions
SINAMICS S110 List Manual
Usage / operation SINAMICS S110 Function Manual Drive Functions
SINAMICS S110 List Manual
Maintenance / service SINAMICS S110 Function Manual Drive Functions
SINAMICS S110 List Manual
SINAMICS S110 Equipment Manual
Target group
This documentation is aimed at machine manufacturers, commissioning engineers, and
service personnel who use SINAMICS.
Benefits
This manual describes all the information, procedures and operational instructions required
for commissioning and servicing SINAMICS S110.

Preface
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Function Manual, 01/2011, 6SL3097-4AB10-0BP3 5
Standard scope
The scope of the functionality described in this document can differ from the scope of the
functionality of the drive system that is actually supplied.
● Other functions not described in this documentation might be able to be executed in the
drive system. This does not, however, represent an obligation to supply such functions
with a new control or when servicing.
● Functions can be described in the documentation that are not available in a particular
product version of the drive system. The functionality of the supplied drive system should
only be taken from the ordering documentation.
● Extensions or changes made by the machine manufacturer must be documented by the
machine manufacturer.
For reasons of clarity, this documentation does not contain all of the detailed information on
all of the product types. This documentation cannot take into consideration every
conceivable type of installation, operation and service/maintenance.
Technical Support
Country-specific telephone numbers for technical support are provided in the Internet under
Contact:
http://www.siemens.com/automation/service&support
EC Declaration of Conformity
The EC Declaration of Conformity for the EMC Directive can be found on the Internet at:
http://support.automation.siemens.com
There – as a search term – enter the number 15257461 or contact your local Siemens office.
The EC Declaration of Conformity for the Low Voltage Directive can be found on the Internet
at:
http://support.automation.siemens.com
There – as a search term – enter the number 22383669 .
Note
When operated in dry areas, SINAMICS S devices conform to the Low Voltage Directive
73/23/EEC or 2006/95/EEC.
Note
SINAMICS S devices fulfill EMC Directive 89/336/EEC or 2004/108/EEC in the configuration
specified in the associated EC Declaration of Conformity for EMC and when the EMC
installation guideline is implemented, Order No. 6FC5297-0AD30-0P.

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6 Function Manual, 01/2011, 6SL3097-4AB10-0BP3
Note
The Equipment Manual describes a desired state which, if maintained, ensures the required
level of operational reliability and compliance with EMC limit values.
Should there be any deviation from the requirements in the Equipment Manual, appropriate
actions (e.g. measurements) must be taken to check/prove that the required level of
operational reliability and compliance with EMC limit values are ensured.
Spare parts
You can find spare parts on the Internet at:
http://support.automation.siemens.com/WW/view/de/16612315
Test certificates
The Safety Integrated functions of SINAMICS components are generally certified by
independent institutes. An up-to-date list of certified components is available on request from
your local Siemens office. If you have any questions relating to certifications that have not
been completed, please ask your Siemens contact.

Preface
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Function Manual, 01/2011, 6SL3097-4AB10-0BP3 7
ESD information
CAUTION
Electrostatic sensitive devices (ESD) are single components, integrated circuits or devices
that can be damaged by electrostatic fields or electrostatic discharges.
Regulations for handling ESD components:
When handling components, make sure that personnel, workplaces, and packaging are
well grounded.
Personnel may only come into contact with electronic components, if
They are grounded with an ESD wrist band, or
They are in ESD areas with conductive flooring, ESD shoes or ESD grounding straps.
Electronic boards should only be touched if absolutely necessary. They must only be
handled on the front panel or, in the case of printed circuit boards, at the edge.
Electronic boards must not come into contact with plastics or items of clothing containing
synthetic fibers.
Boards must only be placed on conductive surfaces (work surfaces with ESD surface,
conductive ESD foam, ESD packing bag, ESD transport container).
Electronic boards may not be placed near display units, monitors, or televisions (minimum
distance from the screen > 10 cm).
Measurements must only be taken on boards when the measuring instrument is grounded
(via protective conductors, for example) or the measuring probe is briefly discharged before
measurements are taken with an isolated measuring device (for example, touching a bare
metal housing).
DANGER
Electrical, magnetic and electromagnetic fields (EMF) that occur during operation can pose
a danger to persons who are present in the direct vicinity of the product - especially
persons with pacemakers, implants, or similar devices.
The relevant directives and standards must be observed by the machine/plant operators
and people present in the vicinity of the product. These are, for example, EMF Directive
2004/40/EEC and standards EN 12198-1 to -3 in the European Economic Area (EEA) and,
in Germany, the accident prevention regulation BGV 11 and the associated rule BGR 11
"Electromagnetic fields" from the German Employer's Liability Insurance Association.
These state that a hazard analysis must drawn up for every workplace, from which
measures for reducing dangers and their impact on persons are derived and applied, and
exposure and danger zones are defined and observed.
The relevant safety notes in each chapter must be observed.

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8 Function Manual, 01/2011, 6SL3097-4AB10-0BP3
General safety guidelines
DANGER
Commissioning is absolutely prohibited until it has been completely ensured that the
machine in which the components described here are to be installed is in full compliance
with the provisions of the EC Machinery Directive.
Only appropriately qualified personnel may install, commission, and maintain SINAMICS S
devices.
The personnel must take into account the information provided in the technical customer
documentation for the product, and be familiar with and observe the specified danger and
warning notices.
Operational electrical equipment and motors have parts and components which are at
hazardous voltage levels, that if touched, can result in severe bodily injury or death.
All work on the electrical system must be carried out when the system has been
disconnected from the power supply.
In combination with the drive system, the motors are generally approved for operation on
TN and TT systems with grounded neutral and on IT systems.
In operation on IT systems, the occurrence of a first fault between an active part and
ground must be signaled by a monitoring device. In accordance with IEC 60364-4-41 it is
recommended that the first fault should be eliminated as quickly as practically possible.
In networks with a grounded external conductor, an isolating transformer with grounded
neutral (secondary side) must be connected between the supply and the drive system to
protect the motor insulation from excessive stress. The majority of TT systems have a
grounded external conductor, so in this case an isolating transformer must be used.
DANGER
Correct and safe operation of SINAMICS S drive units assumes correct transportation in
the transportation packaging, correct long-term storage in the transport packaging, setup
and installation, as well as careful operation and maintenance.
The details in the Catalogs and proposals also apply to the design of special equipment
versions.
In addition to the danger and warning information provided in the technical customer
documentation, the applicable national, local, and system-specific regulations and
requirements must be taken into account.
According to EN 61800-5-1 and UL 508, only safely isolated protective extra low voltages
may be connected to any of the connections or terminals on the electronics modules.
DANGER
Using protection against direct contact via DVC A (PELV) is only permissible in areas with
equipotential bonding and in dry rooms indoors. If these conditions are not met, other
protective measures with regard to electric shock must be taken, e.g. touch protection.

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DANGER
As part of routine tests, SINAMICS S components will undergo a voltage test in accordance
with EN 61800-5-1. Before the voltage test is performed on the electrical equipment of
machines acc. to EN 60204-1, Section 18.4, all connectors of SINAMICS S equipment must
be disconnected/unplugged to prevent the equipment from being damaged.
Motors should be connected up in accordance with the circuit diagram supplied with the
motor (refer to the connection examples for Power Modules). They must not be connected
directly to the three-phase supply because this will damage them.
WARNING
Operating the equipment in the immediate vicinity (< 1.8 m) of cell phones with a
transmitter power of > 1 W may cause the equipment to malfunction.
Explanation of symbols
The symbols are in accordance with IEC 617-2.
Table 2 Symbols
Symbol Meaning
Protective earth (PE)
Ground (e.g. M 24 V)
Functional ground
Equipotential bonding

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Table of contents
Preface ...................................................................................................................................................... 3
1 General information for commissioning.................................................................................................... 21
1.1 Explanations regarding the STARTER user interface .................................................................21
1.2 BICO interconnection procedure in STARTER............................................................................23
1.3 DRIVE-CLiQ interface for CU305 ................................................................................................32
1.4 Notes on the commissioning of a 2-pole resolver as absolute encoder ......................................32
1.5 Temperature sensors for SINAMICS components ......................................................................33
2 Commissioning preparations for PROFIBUS ........................................................................................... 37
2.1 Requirements for commissioning.................................................................................................37
2.2 PROFIBUS components..............................................................................................................38
2.3 Connection via serial interface.....................................................................................................40
2.4 Powering-up/powering-down the drive system............................................................................42
3 Commissioning with PROFIBUS.............................................................................................................. 45
3.1 Sequence of operations during commissioning...........................................................................45
3.1.1 Safety guidelines..........................................................................................................................46
3.2 STARTER commissioning tool.....................................................................................................46
3.2.1 Important STARTER functions.....................................................................................................47
3.2.2 Activating online operation: STARTER via PROFIBUS...............................................................50
3.3 Basic Operator Panel 20 (BOP20)...............................................................................................51
3.3.1 Important functions via BOP20 ....................................................................................................52
3.4 Creating a project in STARTER...................................................................................................53
3.4.1 Creating a project offline..............................................................................................................53
3.4.2 Searching for a drive unit online ..................................................................................................55
3.4.3 Searching for nodes that can be accessed..................................................................................57
3.5 Example of first commissioning with STARTER ..........................................................................58
3.5.1 Task .............................................................................................................................................58
3.5.2 Commissioning with STARTER (example) ..................................................................................59
3.6 Initial commissioning using servo AC DRIVE with BOP20 as an example..................................60
3.6.1 Task .............................................................................................................................................60
3.6.2 Component wiring (example).......................................................................................................61
3.6.3 Quick commissioning using the BOP (example)..........................................................................62
4 Commissioning with CANopen ................................................................................................................ 65
4.1 Requirements for commissioning.................................................................................................65
4.1.1 Previous knowledge.....................................................................................................................65
4.1.2 Prerequisites for commissioning CU305 with CANopen .............................................................66
4.1.3 CAN bus on the CU305 ...............................................................................................................67

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4.1.4 CAN bus interface X126.............................................................................................................. 68
4.1.5 CANopen functionality CU305 CAN............................................................................................ 69
4.1.6 Diagnostics LED "COM".............................................................................................................. 70
4.2 Commissioning............................................................................................................................ 70
4.2.1 Procedure when commissioning the drive for the first time ........................................................ 70
4.2.2 CANopen object directory ........................................................................................................... 71
4.2.3 Commissioning options............................................................................................................... 72
4.2.4 Configuring the drive unit with STARTER (overview) ................................................................. 72
4.2.5 Searching for the drive unit ONLINE........................................................................................... 74
4.2.6 Configuring a drive unit ............................................................................................................... 75
4.2.7 Monitoring.................................................................................................................................... 81
4.2.8 Loading the project to the drive unit............................................................................................ 83
4.3 Configuring COB-IDs and process data objects ......................................................................... 84
4.3.1 Configuring COB-IDs and process data...................................................................................... 84
4.4 Interconnecting process data...................................................................................................... 84
4.4.1 Interconnecting process data...................................................................................................... 84
4.5 Loading and managing projects ONLINE ................................................................................... 85
4.5.1 In ONLINE mode, load the projects from the drive unit to the PC/PG and save. ....................... 85
5 Diagnostics .............................................................................................................................................. 87
5.1 Diagnostics via LEDs .................................................................................................................. 87
5.1.1 LEDs when the Control Unit is booted........................................................................................ 87
5.1.2 LEDs after the Control Unit CU305 has booted.......................................................................... 89
5.1.3 Sensor Module Cabinet SMC10 / SMC20 .................................................................................. 91
5.1.4 Meaning of LEDs on the Sensor Module Cabinet-Mounted SMC30 .......................................... 92
5.2 Diagnostics via STARTER .......................................................................................................... 93
5.2.1 Function generator ...................................................................................................................... 93
5.2.2 Trace function ............................................................................................................................. 97
5.2.3 Measuring function...................................................................................................................... 98
5.2.4 Measuring sockets .................................................................................................................... 101
5.3 Fault and alarm messages........................................................................................................ 105
5.3.1 General information about faults and alarms............................................................................ 105
5.3.2 Buffer for faults and alarms....................................................................................................... 107
5.3.3 Configuring messages .............................................................................................................. 110
5.3.4 Parameters and function diagrams for faults and alarms ......................................................... 112
5.3.5 Forwarding of faults and alarms................................................................................................ 113
6 Parameterization using the Basic Operator Panel 20 ............................................................................ 115
6.1 General information about the BOP20...................................................................................... 115
6.2 Displays and using the BOP20 ................................................................................................. 117
6.3 Fault and alarm displays ........................................................................................................... 121
6.4 Controlling the drive using the BOP20......................................................................................122
7 Drive functions....................................................................................................................................... 123
7.1 Servo control ............................................................................................................................. 123
7.1.1 Speed controller ........................................................................................................................ 123
7.1.2 Speed setpoint filter .................................................................................................................. 124
7.1.3 Speed controller adaptation ...................................................................................................... 125

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7.1.4 Torque-controlled operation.......................................................................................................127
7.1.5 Torque setpoint limitation...........................................................................................................129
7.1.6 Current controller .......................................................................................................................134
7.1.7 Current setpoint filter..................................................................................................................137
7.1.7.1 Integration ..................................................................................................................................143
7.1.8 Note about the electronic motor model......................................................................................143
7.1.9 V/f control for diagnostics...........................................................................................................144
7.1.10 Optimizing the current and speed controller..............................................................................147
7.1.11 Operation without an encoder....................................................................................................150
7.1.12 Motor data identification.............................................................................................................154
7.1.12.1 Motor data identification - induction motor.................................................................................157
7.1.12.2 Motor data identification - synchronous motor...........................................................................159
7.1.13 Pole position identification .........................................................................................................162
7.1.14 Vdc control .................................................................................................................................166
7.1.15 Travel to fixed stop.....................................................................................................................170
7.1.16 Vertical axes...............................................................................................................................175
7.1.17 Variable signaling function.........................................................................................................176
7.1.18 Central probe evaluation............................................................................................................178
7.1.19 Pulse/direction interface.............................................................................................................181
7.1.19.1 Commissioning the pulse/direction interface .............................................................................182
7.2 Basic functions...........................................................................................................................187
7.2.1 Changing over units ...................................................................................................................187
7.2.2 Reference parameters/normalizations.......................................................................................189
7.2.3 Automatic restart........................................................................................................................191
7.2.4 Armature short-circuit brake, DC brake .....................................................................................193
7.2.5 OFF3 torque limits .....................................................................................................................196
7.2.6 Simple brake control ..................................................................................................................197
7.2.7 Parking axis and parking encoder .............................................................................................200
7.2.8 Runtime (operating hours counter) ............................................................................................202
7.2.9 Changing the direction of rotation without changing the setpoint..............................................203
7.3 Function modules.......................................................................................................................204
7.3.1 Function modules - Definition and commissioning ....................................................................204
7.3.2 Technology controller.................................................................................................................205
7.3.2.1 Features.....................................................................................................................................205
7.3.2.2 Description .................................................................................................................................205
7.3.2.3 Integration ..................................................................................................................................208
7.3.2.4 Commissioning with STARTER .................................................................................................209
7.3.3 Extended monitoring functions...................................................................................................210
7.3.3.1 Description .................................................................................................................................210
7.3.3.2 Commissioning...........................................................................................................................211
7.3.4 Extended brake control..............................................................................................................212
7.3.4.1 Features.....................................................................................................................................212
7.3.4.2 Integration ..................................................................................................................................212
7.3.4.3 Description .................................................................................................................................214
7.3.4.4 Examples ...................................................................................................................................214
7.3.4.5 Commissioning...........................................................................................................................216
7.3.5 Closed-loop position control.......................................................................................................217
7.3.5.1 General features ........................................................................................................................217
7.3.5.2 Position actual value conditioning..............................................................................................217
7.3.5.3 Position controller ......................................................................................................................227
7.3.5.4 Monitoring functions...................................................................................................................228

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7.3.5.5 Measuring probe evaluation and reference mark search ......................................................... 231
7.3.5.6 Integration ................................................................................................................................. 232
7.3.6 Basic Positioner ........................................................................................................................ 233
7.3.6.1 Mechanical system.................................................................................................................... 235
7.3.6.2 Limits......................................................................................................................................... 237
7.3.6.3 Referencing............................................................................................................................... 241
7.3.6.4 Referencing with more than one zero mark per revolution....................................................... 249
7.3.6.5 Traversing blocks ...................................................................................................................... 252
7.3.6.6 Travel to fixed stop.................................................................................................................... 258
7.3.6.7 Direct setpoint input (MDI) ........................................................................................................ 262
7.3.6.8 Jog............................................................................................................................................. 265
7.3.6.9 Status signals............................................................................................................................ 266
7.3.7 Extended setpoint channel........................................................................................................ 269
7.3.7.1 Activation of the "extended setpoint channel" function module ................................................ 269
7.3.7.2 Description ................................................................................................................................ 269
7.3.7.3 Jog............................................................................................................................................. 271
7.3.7.4 Fixed speed setpoints ............................................................................................................... 275
7.3.7.5 Motorized potentiometer ........................................................................................................... 276
7.3.7.6 Main/supplementary setpoint and setpoint modification ........................................................... 278
7.3.7.7 Direction limitation and setpoint inversion................................................................................. 280
7.3.7.8 Suppression bandwidths and setpoint limits.............................................................................281
7.3.7.9 Ramp-function generator .......................................................................................................... 283
7.3.8 Free function blocks.................................................................................................................. 287
7.3.8.1 Overview ................................................................................................................................... 287
7.3.8.2 Commissioning.......................................................................................................................... 298
7.3.8.3 AND........................................................................................................................................... 302
7.3.8.4 OR............................................................................................................................................. 303
7.3.8.5 XOR (exclusive OR).................................................................................................................. 303
7.3.8.6 NOT (inverter) ........................................................................................................................... 303
7.3.8.7 ADD (adder) .............................................................................................................................. 304
7.3.8.8 SUB (subtracter) ....................................................................................................................... 304
7.3.8.9 MUL (multiplier)......................................................................................................................... 304
7.3.8.10 DIV (divider) .............................................................................................................................. 305
7.3.8.11 AVA (absolute value generator with sign evaluation) ............................................................... 305
7.3.8.12 MFP (pulse generator) .............................................................................................................. 306
7.3.8.13 PCL (pulse shortener)............................................................................................................... 306
7.3.8.14 PDE (ON delay) ........................................................................................................................ 307
7.3.8.15 PDF (OFF delay)....................................................................................................................... 308
7.3.8.16 PST (pulse stretcher) ................................................................................................................ 309
7.3.8.17 RSR (RS flip-flop, reset dominant)............................................................................................ 309
7.3.8.18 DFR (D flip-flop, reset dominant) .............................................................................................. 310
7.3.8.19 BSW (binary change-over switch)............................................................................................. 310
7.3.8.20 NSW (numeric change-over switch) ......................................................................................... 311
7.3.8.21 LIM (limiter) ............................................................................................................................... 311
7.3.8.22 PT1 (smoothing element).......................................................................................................... 312
7.3.8.23 INT (integrator).......................................................................................................................... 313
7.3.8.24 DIF (derivative action element) ................................................................................................. 314
7.3.8.25 LVM (double-sided limit monitor with hysteresis)......................................................................315
8 Safety Integrated Functions................................................................................................................... 317
8.1 Standards and regulations ........................................................................................................ 317
8.1.1 General information................................................................................................................... 317

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8.1.1.1 Aims ...........................................................................................................................................317
8.1.1.2 Functional safety........................................................................................................................318
8.1.2 Safety of machinery in Europe...................................................................................................318
8.1.2.1 Machinery Directive ...................................................................................................................319
8.1.2.2 Harmonized European Standards .............................................................................................319
8.1.2.3 Standards for implementing safety-related controllers ..............................................................321
8.1.2.4 EN ISO 13849-1 (previously EN 954-1).....................................................................................322
8.1.2.5 EN 62061 ...................................................................................................................................323
8.1.2.6 Series of standards EN 61508 (VDE 0803) ...............................................................................325
8.1.2.7 Risk analysis/assessment..........................................................................................................326
8.1.2.8 Risk reduction ............................................................................................................................328
8.1.2.9 Residual risk...............................................................................................................................328
8.1.3 Machine safety in the USA.........................................................................................................328
8.1.3.1 Minimum requirements of the OSHA .........................................................................................329
8.1.3.2 NRTL listing................................................................................................................................329
8.1.3.3 NFPA 79.....................................................................................................................................330
8.1.3.4 ANSI B11 ...................................................................................................................................330
8.1.4 Machine safety in Japan ............................................................................................................331
8.1.5 Equipment regulations ...............................................................................................................331
8.1.6 Other safety-related issues........................................................................................................332
8.1.6.1 Information sheets issued by the Employer's Liability Insurance Association...........................332
8.1.6.2 Additional references .................................................................................................................332
8.2 General information about SINAMICS Safety Integrated ..........................................................333
8.2.1 Supported functions ...................................................................................................................333
8.2.2 Control of Safety Integrated functions .......................................................................................335
8.2.3 Drive monitoring with or without encoder...................................................................................336
8.2.4 Parameter, Checksum, Version, Password ...............................................................................337
8.3 System features .........................................................................................................................340
8.3.1 Latest information ......................................................................................................................340
8.3.2 Certification ................................................................................................................................341
8.3.3 Safety instructions......................................................................................................................342
8.3.4 Probability of failure for safety functions....................................................................................345
8.3.5 Response times .........................................................................................................................345
8.3.6 Residual risk...............................................................................................................................350
8.4 Safety Integrated Basic Functions .............................................................................................352
8.4.1 Safe Torque Off (STO)...............................................................................................................352
8.4.2 Safe Stop 1 (SS1, time controlled) ............................................................................................355
8.4.3 Safe Brake Control (SBC)..........................................................................................................357
8.4.4 Safety faults ...............................................................................................................................359
8.4.5 Forced dormant error detection .................................................................................................361
8.5 Safety Integrated Extended Functions.......................................................................................362
8.5.1 Safety functions "with encoder" / "without encoder" ..................................................................362
8.5.2 Safe Torque Off .........................................................................................................................364
8.5.3 Safe Stop 1 (SS1) ......................................................................................................................365
8.5.3.1 Safe Stop 1 (SS1, time and acceleration controlled).................................................................365
8.5.3.2 Safe Stop 1 without encoder (time and speed controlled).........................................................367
8.5.3.3 Safe Stop 1 - Parameter ............................................................................................................369
8.5.4 Safe Stop 2 (SS2) ......................................................................................................................370
8.5.4.1 EPOS and Safe Stop 2 ..............................................................................................................372
8.5.5 Safe Operating Stop (SOS) .......................................................................................................373

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8.5.6 Safely Limited Speed (SLS)...................................................................................................... 375
8.5.6.1 Safely Limited Speed (SLS)...................................................................................................... 375
8.5.6.2 Safely Limited Speed without encoder...................................................................................... 377
8.5.6.3 Safely Limited Speed - Parameter ............................................................................................ 380
8.5.6.4 EPOS and Safely-Limited Speed.............................................................................................. 381
8.5.7 Safe Speed Monitor (SSM) ....................................................................................................... 382
8.5.7.1 Safe Speed Monitor with encoder............................................................................................. 382
8.5.7.2 Safe Speed Monitor without encoder........................................................................................ 385
8.5.7.3 Safe Speed Monitor restart ....................................................................................................... 387
8.5.7.4 Overview of important parameters............................................................................................ 388
8.5.8 Safe Acceleration Monitor (SAM).............................................................................................. 389
8.5.9 Safe Brake Ramp (SBR)........................................................................................................... 391
8.5.10 Safe Direction (SDI) .................................................................................................................. 394
8.5.10.1 Safe Direction with encoder ...................................................................................................... 394
8.5.10.2 Safe Direction without encoder ................................................................................................. 396
8.5.10.3 Overview of parameters and function diagrams ....................................................................... 398
8.5.11 Safety faults .............................................................................................................................. 399
8.5.12 Message buffer ......................................................................................................................... 403
8.5.13 Safe actual value acquisition .................................................................................................... 405
8.5.13.1 Reliable actual value acquisition with the encoder system....................................................... 405
8.5.13.2 Safe current actual value acquisition without encoder.............................................................. 408
8.5.14 Forced dormant error detection ................................................................................................ 409
8.5.15 Safety Info Channel................................................................................................................... 411
8.6 Controlling the safety functions................................................................................................. 413
8.6.1 Control of the Basic Functions via a safe input terminal pair.................................................... 414
8.6.2 Control of the Extended Functions using safe input terminals.................................................. 415
8.6.3 Note on F-DIs............................................................................................................................ 419
8.6.4 Overview of the F-DOs.............................................................................................................. 420
8.6.5 Control by way of PROFIsafe.................................................................................................... 422
8.6.5.1 Enabling of the control via PROFIsafe...................................................................................... 422
8.6.5.2 Structure of telegram 30............................................................................................................ 423
8.7 Commissioning.......................................................................................................................... 427
8.7.1 Safety Integrated firmware versions ......................................................................................... 427
8.7.2 Commissioning of Safety Integrated functions.......................................................................... 428
8.7.2.1 General information................................................................................................................... 428
8.7.2.2 Prerequisites for commissioning the Safety Integrated functions............................................. 430
8.7.2.3 Default settings for commissioning Safety Integrated functions without encoder..................... 430
8.7.2.4 Information pertaining to series commissioning........................................................................ 434
8.7.2.5 Setting the sampling times........................................................................................................ 435
8.7.3 Commissioning the safety terminals by means of STARTER/SCOUT..................................... 436
8.7.3.1 Basic sequence of commissioning............................................................................................ 436
8.7.3.2 Configuration start screen......................................................................................................... 437
8.7.3.3 Configuration of the Safety terminals (Extended Functions) .................................................... 439
8.7.3.4 Test stop.................................................................................................................................... 441
8.7.3.5 F-DI/F-DO configuration............................................................................................................ 445
8.7.3.6 Control interface........................................................................................................................ 447
8.7.4 PROFIsafe configuration with STARTER ................................................................................. 448
8.7.5 Procedure for configuring PROFIsafe communication ............................................................. 449
8.7.6 Information pertaining to component replacements.................................................................. 453
8.8 Application examples ................................................................................................................ 454
8.8.1 Input/output interconnections for a safety switching device with CU305.................................. 454

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8.9 Acceptance test and acceptance report ....................................................................................458
8.9.1 General information ...................................................................................................................458
8.9.2 Acceptance test structure ..........................................................................................................459
8.9.2.1 Content of the complete acceptance test ..................................................................................460
8.9.2.2 Content of the partial acceptance test .......................................................................................463
8.9.2.3 Test scope for specific measures ..............................................................................................466
8.9.3 Safety logbook ...........................................................................................................................467
8.9.4 Acceptance reports....................................................................................................................468
8.9.4.1 Plant description - Documentation part 1...................................................................................468
8.9.4.2 Description of safety functions - Documentation Part 2.............................................................469
8.9.5 Acceptance tests........................................................................................................................474
8.9.5.1 Acceptance tests – Basic Functions ..........................................................................................475
8.9.5.2 Acceptance tests for Extended Functions (with encoder) .........................................................481
8.9.5.3 Acceptance tests for Extended Functions (without encoder) ....................................................509
8.9.6 Completion of certificate ............................................................................................................520
9 Communication...................................................................................................................................... 521
9.1 Fieldbus configuration................................................................................................................521
9.2 Communication according to PROFIdrive .................................................................................522
9.2.1 General information about PROFIdrive for SINAMICS..............................................................522
9.2.2 Application classes ....................................................................................................................523
9.2.3 Cyclic communication ................................................................................................................528
9.2.3.1 Telegrams and process data .....................................................................................................528
9.2.3.2 Description of control words and setpoints ................................................................................532
9.2.3.3 Description of status words and actual values...........................................................................544
9.2.3.4 Control and status words for encoder........................................................................................558
9.2.3.5 Central control and status words ...............................................................................................568
9.2.3.6 Motion Control with PROFIdrive ................................................................................................574
9.2.4 Acyclic communication...............................................................................................................577
9.2.4.1 General information about acyclic communication ....................................................................577
9.2.4.2 Structure of orders and responses.............................................................................................578
9.2.4.3 Determining the drive object numbers .......................................................................................583
9.2.4.4 Example 1: read parameters......................................................................................................584
9.2.4.5 Example 2: write parameters (multi-parameter request) ...........................................................586
9.3 Communication via PROFIBUS DP...........................................................................................589
9.3.1 General information about PROFIBUS......................................................................................589
9.3.2 Commissioning PROFIBUS.......................................................................................................591
9.3.2.1 General information about commissioning ................................................................................591
9.3.2.2 Commissioning procedure .........................................................................................................594
9.3.2.3 Diagnostics options....................................................................................................................594
9.3.2.4 SIMATIC HMI addressing ..........................................................................................................595
9.3.2.5 Monitoring: telegram failure .......................................................................................................596
9.3.3 Motion Control with PROFIBUS.................................................................................................597
9.3.4 Slave-to-slave communication ...................................................................................................602
9.3.4.1 General information ...................................................................................................................602
9.3.4.2 Setpoint assignment in the subscriber.......................................................................................604
9.3.4.3 Activating/parameterizing slave-to-slave communications........................................................604
9.3.4.4 Commissioning of the PROFIBUS slave-to-slave communication ............................................606
9.3.4.5 GSD file......................................................................................................................................615
9.3.4.6 Diagnosing the PROFIBUS slave-to-slave communication in STARTER .................................616
9.4 Communication via PROFINET IO ............................................................................................617

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9.4.1 General information about PROFINET IO ................................................................................ 617
9.4.1.1 Real-time (RT) and isochronous real-time (IRT) communication ............................................. 617
9.4.1.2 Data transfer ............................................................................................................................. 618
9.4.1.3 General information about PROFINET IO for SINAMICS......................................................... 618
9.4.1.4 Addresses ................................................................................................................................. 620
9.4.1.5 PROFINET: Address parameters ............................................................................................. 622
9.4.2 Hardware setup......................................................................................................................... 622
9.4.2.1 Structuring CU305 with PROFINET.......................................................................................... 622
9.4.3 RT classes for PROFINET IO ................................................................................................... 624
9.4.4 Selection of the PROFINET variant .......................................................................................... 629
9.4.5 PROFINET GSD ....................................................................................................................... 630
9.4.6 Motion Control with PROFINET ................................................................................................ 632
9.4.7 PROFINET with 2 controllers.................................................................................................... 635
9.4.7.1 Settings for SINAMICS S .......................................................................................................... 635
9.4.7.2 Configuring the controls ............................................................................................................ 638
9.4.7.3 Overview of important parameters............................................................................................ 639
9.5 Communication using USS ....................................................................................................... 640
9.5.1 Configuring the USS interface .................................................................................................. 640
9.5.2 Transferring PZD....................................................................................................................... 641
9.5.3 General information about communication with USS over RS485 ........................................... 642
9.5.4 Structure of a USS telegram ..................................................................................................... 642
9.5.5 User data range of the USS telegram....................................................................................... 644
9.5.6 Data structure of the USS parameter channel.......................................................................... 645
9.5.7 Time-out and other errors ......................................................................................................... 651
9.5.8 USS process data channel (PZD)............................................................................................. 653
10 Basic information about the drive system .............................................................................................. 655
10.1 Parameter.................................................................................................................................. 655
10.2 Data sets ................................................................................................................................... 658
10.2.1 CDS: Command Data Set......................................................................................................... 658
10.2.2 DDS: Drive Data Set ................................................................................................................. 660
10.2.3 EDS: Encoder Data Set ............................................................................................................ 661
10.2.4 MDS: Motor Data Set................................................................................................................ 662
10.2.5 Integration ................................................................................................................................. 662
10.2.6 Using data sets ......................................................................................................................... 663
10.3 Working with the memory card.................................................................................................. 665
10.3.1 Using parameter data sets........................................................................................................ 666
10.3.2 Working with firmware versions ................................................................................................ 669
10.3.3 Replacing the device................................................................................................................. 671
10.3.4 Removing the memory card safely ........................................................................................... 673
10.3.5 Integration ................................................................................................................................. 673
10.4 BICO technology: Interconnecting signals................................................................................ 674
10.4.1 Description ................................................................................................................................ 674
10.4.2 Binectors, connectors................................................................................................................ 675
10.4.3 Interconnecting signals using BICO technology ....................................................................... 676
10.4.4 Internal encoding of the binector/connector output parameters ............................................... 677
10.4.5 Sample interconnections........................................................................................................... 677
10.4.6 BICO technology: ...................................................................................................................... 678
10.4.7 Scaling....................................................................................................................................... 679
10.5 Inputs/outputs............................................................................................................................ 680