Siemens SINAMICS S120 Parts list manual

Safety Integrated
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SINAMICS
S120
Safety Integrated
FunctionManual
Valid from: Firmware Version 4.4 SP1
(FHS), 07/2016
6SL3097
-4AR00-0BP6
Preface
Fundamental safety
instructions
1
General information about
SINAMICS Safety Integrated
2
Overview of Safety
Integrated functions
3
Description of Safety
Integrated functions
4
Control of the safety
functions
5
Commissioning
6
Acceptance test
7
System features
8
Maintenance
9
Standards and regulations
10
Appendix
A

Siemens AG
Division Digital Factory
Postfach 48 48
90026 NÜRNBERG
GERMANY
Document order number: 6SL3097-4AR00-0BP 6
Ⓟ
06/2016 Subject to change
Copyright © Siemens AG 2008 - 2016.
All rights reserved
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The noticesreferring to yourpersonal safety are highlighted in the manual bya safety alert
symbol,noticesreferring onlyto propertydamage 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 resultifproper precautions are not taken.
WARNING
indicates that death or severe personal injury mayresult ifproper precautions are not taken.
C AUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicatesthat property damage can result if proper precautions are not taken.
If more than one degree of danger is present,the warning notice representing the highestdegree of danger will
be used.A notice warning of injuryto persons with a safety alert symbol mayalso include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation maybe operated only by
personnel qualified
for the specific
task in accordance with the relevantdocumentation,in particular its warning noticesand 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 onlybe used for the applications described in the catalog and in the relevanttechnical
documentation.Ifproducts and components from other manufacturers are used,these mustbe 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
ambientconditions mustbe complied with. The information in the relevantdocumentation mustbe observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistencywith the hardware and software
described.Since variance cannotbe precluded entirely,we cannotguarantee full consistency. However,the
information in this publication is reviewed regularly and anynecessary corrections are included in subsequent
editions.

Safety Integrated
Function Manual, (FHS), 07/2016, 6SL3097-4AR00-0BP6 5
Preface
SINAMICS documentation
The SINAMICS documentation is organized in the following categories:
●General documentation/catalogs
●User documentation
●Manufacturer/service documentation
Additional information
You can find information on the following topics at the following address
(https://support.industry.siemens.com/cs/de/en/view/108993276):
●Ordering documentation/overview of documentation
●Additional links to download documents
●Using documentation online (find and search in manuals/information)
Please send any questions about the technical documentation (e.g. suggestions for
improvement, corrections) to the following e-mail address
(mailto:[e-mail]).
Siemens MySupport/Documentation
At the following address (https://support.industry.siemens.com/My/ww/en/documentation),
you can find information on how to create your own individual documentation based on
Siemens' content, and adapt it for your own machine documentation.
Training
At the following address (http://www.siemens.com/sitrain), you can find information about
SITRAIN (Siemens training on products, systems and solutions for automation and drives).
FAQs
You can find Frequently Asked Questions in the Service&Support pages under Product
Support (https://support.industry.siemens.com/cs/de/en/ps/faq).
S IN AMICS
You can find information about SINAMICS at the following address
(http://www.siemens.com/sinamics).

Preface
Safety Integrated
6Function Manual, (FHS), 07/2016, 6SL3097-4AR00-0BP6
Usage phases and their documents/tools (as an example)
Table 1 Usage phases and the available documents/tools
Usage phase
Document/tool
Orientation
SINAMICS S Sales Documentation
Planning/configuration •SIZER Engineering Tool
•Configuration Manuals,Motors
Deciding/ordering
SINAMICS S120 catalogs
•SIMOTION, SINAMICS S120 and Motors for Production Machines (Catalog PM21)
•SINAMICS and Motors for Single-axis Drives (Catalog D 31)
•SINUMERIK & SINAMICS
Equipment for Machine Tools (Catalog NC 61)
•SINUMERIK 840D sl Type 1B
Equipment for Machine Tools (Catalog NC 62)
Installation/assembly •SINAMICS S120 Manual for Control Units and Additional System Components
•SINAMICS S120 Manual for Booksize Power Units
•SINAMICS S120 Manual for Booksize Power Units C/D Type
•SINAMICS S120 Manual for Chassis Power Units, Air-cooled
•SINAMICS S120 Manual for Chassis Power Units, Liquid-cooled
•SINAMICS S120 Manual for AC Drives
•SINAMICS S120 Manual Combi
•SINAMICS S120M Manual Distributed Drive Technology
•SINAMICS HLA System Manual Hydraulic Drive
Commissioning
•STARTER Commissioning Tool
•SINAMICS S120 Getting Started with STARTER
•SINAMICS S120 Commissioning Manual with STARTER
•SINAMICS S120 CANopen Commissioning Manual
•SINAMICS S120 Function Manual Drive Functions
•SINAMICS S120 Safety Integrated Function Manual
•SINAMICS S120/S150 List Manual
•SINAMICS HLA System Manual Hydraulic Drive
•Startdrive commissioning tool1)
•SINAMICS S120 Getting Started with Startdrive1)
•SINAMICS S120 Commissioning Manual with Startdrive1)
Usage/operation •SINAMICS S120 Commissioning Manual with STARTER
•SINAMICS S120/S150 List Manual
•SINAMICS HLA System Manual Hydraulic Drive
•SINAMICS S120 Commissioning Manual with Startdrive1)

Preface
Safety Integrated
Function Manual, (FHS), 07/2016, 6SL3097-4AR00-0BP6 7
Usage phase
Document/tool
Maintenance/servicing •SINAMICS S120 Commissioning Manual with STARTER
•SINAMICS S120/S150 List Manual
•SINAMICS S120 Commissioning Manual with Startdrive1)
References
•SINAMICS S120/S150 List Manual
1) available asof Startdrive V14 release
Target group
This documentation is intended for machine manufacturers, commissioning engineers, and
service personnel who use the SINAMICS drive system.
Benefits
This manual provides all of the information, procedures and operator actions required for the
particular usage phase.
Standard scope
The scope of the functionality described in this document can differ from that 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. However, no claim can be made regarding the availability of these functions
when the equipment is first supplied or in the event of service.
●The documentation can also contain descriptions of functions 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, and 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 at the
following address (https://support.industry.siemens.com/sc/ww/en/sc/2090) in the "Contact"
area.

Preface
Safety Integrated
8Function Manual, (FHS), 07/2016, 6SL3097-4AR00-0BP6
Notation
The following notation and abbreviations are used in this documentation:
Notation forfaults and alarms(examples):
•
F12345
Fault 12345
•
A67890
Alarm 67890
•
C23456
Safety message
Notation for parameters (examples):
•
p0918
Adjustable parameter 918
•
r1024
Display parameter 1024
•
p1070[1]
Adjustable parameter 1070, index 1
•
p2098[1].3
Adjustable parameter 2098, index 1 bit 3
•
p0099[0...3]
Adjustable parameter 99, indices 0 to 3
•
r0945[2](3)
Display parameter 945, index 2 of drive object 3
•
p0795.4
Adjustable
parameter 795, bit 4

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Function Manual, (FHS), 07/2016, 6SL3097-4AR00-0BP6 9
Table of Contents
Preface................................................................................................................. 5
1 Fundamental safety instructions ...................................................................................15
1.1 Fundamental safety instructions ..................................................................................... 15
1.1.1 General safety instructions ............................................................................................. 15
1.1.2 Industrial security .......................................................................................................... 16
1.2 Fundamental safety instructions for Safety Integrated ...................................................... 17
1.3 Residual risk ................................................................................................................. 21
2 General information about SINAMICS Safety Integrated .......................................................23
2.1 Drive products with integrated safety functions ................................................................ 23
2.2 Supported functions ....................................................................................................... 24
2.3 Supported functions: HLA module................................................................................... 27
2.4 Examples of how the safety functions can be applied....................................................... 30
2.5 Drive monitoring wit h or without encoder ......................................................................... 32
3 Overview of Safety Integrated functions ..........................................................................33
3.1 Safety Integrated Basic Functions................................................................................... 33
3.1.1 Safe Torque Off (STO)................................................................................................... 34
3.1.2 Safe Stop 1 (SS1) ......................................................................................................... 35
3.1.3 Safe Brake Control (SBC) .............................................................................................. 36
3.1.3.1 Hardware required for SBC ............................................................................................ 37
3.2 Safety Integrated Extended Functions............................................................................. 39
3.2.1 Preconditions for the Safety Extended Functions ............................................................. 39
3.2.2 Control possibilities........................................................................................................ 40
3.2.3 Safe Torque Off (STO)................................................................................................... 40
3.2.4 Safe Stop 1 (SS1) ......................................................................................................... 40
3.2.5 Safe Operating Stop (SOS) ............................................................................................ 43
3.2.6 Safe Stop 2 (SS2) ......................................................................................................... 45
3.2.6.1 How does SS2 function in detail? ................................................................................... 45
3.2.7 Safely Limited Speed (SLS) ........................................................................................... 47
3.2.8 Safe Speed Monitor (SSM)............................................................................................. 53
3.2.9 Safe Direction (SDI)....................................................................................................... 55
3.2.10 Safely-Limited Position (SLP) ......................................................................................... 57
3.2.11 Safe referencing............................................................................................................ 58
3.2.12 Transferring safe position values (SP)............................................................................. 59
3.2.13 Safe Brake Test ............................................................................................................ 60
4 Description of Safety Integrated functions ........................................................................61
4.1 Safety Integrated basic functions .................................................................................... 62
4.1.1 Safe Torque Off (STO)................................................................................................... 62
4.1.1.1 Safe Torque Off (STO) for SINAMICS HLA ..................................................................... 66

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10 Function Manual, (FHS), 07/2016, 6SL3097-4AR00-0BP6
4.1.2 Safe Stop 1 (SS1, time controlled)...................................................................................68
4.1.2.1 SS1 with OFF3...............................................................................................................68
4.1.2.2 SS1 with external stop ....................................................................................................69
4.1.2.3 Function diagrams and parameters .................................................................................70
4.1.3 Safe Brake Control (SBC) ...............................................................................................71
4.1.3.1 SBC for Motor Modules in the chassis format ...................................................................73
4.1.3.2 Function diagrams and parameters .................................................................................75
4.1.4 Safety faults...................................................................................................................76
4.1.5 Forced dormant error detection (test stop) .......................................................................78
4.1.6 Function diagrams and parameters .................................................................................79
4.2 Safety Integrated Extended Functions .............................................................................80
4.2.1 License for Extended Functions ......................................................................................80
4.2.2 Differences between Extended Functions "with encoder" and "without encoder" .................80
4.2.3 Restrictions for Safety Integrated Functions "without encoder" ..........................................82
4.2.4 Safe Torque Off (STO) ...................................................................................................86
4.2.5 Safe Stop 1 (SS1) ..........................................................................................................87
4.2.5.1 Safe Stop 1 with encoder ................................................................................................87
4.2.5.2 Safe Stop 1 without encoder ...........................................................................................89
4.2.5.3 Safe Stop 1 with external stop .........................................................................................90
4.2.5.4 Function diagrams and parameters .................................................................................91
4.2.6 Safe Brake Control (SBC) ...............................................................................................91
4.2.7 Safe Operating Stop (SOS).............................................................................................92
4.2.8 Safe Stop 2 (SS2) ..........................................................................................................94
4.2.8.1 Interaction with EPOS.....................................................................................................95
4.2.8.2 SS2 with external stop (SS2E) ........................................................................................96
4.2.8.3 Overview of important parameters ...................................................................................98
4.2.9 Safely-Limited Speed (SLS) ............................................................................................99
4.2.9.1 Safely Limited Speed (SLS) ..........................................................................................100
4.2.9.2 Safely Limited Speed without encoder ...........................................................................103
4.2.9.3 Safely-Limited Speed without selection ..........................................................................105
4.2.9.4 Function diagrams and parameters ...............................................................................106
4.2.9.5 EPOS and safe setpoint velocity limitation .....................................................................107
4.2.10 Safe Speed Monitor (SSM) ...........................................................................................108
4.2.10.1 Safe Speed Monitor with encoder ..................................................................................109
4.2.10.2 Safe Speed Monitor without enc oder .............................................................................111
4.2.10.3 Function diagrams and parameters ...............................................................................114
4.2.11 Safe Direction (SDI) .....................................................................................................115
4.2.11.1 Safe Direction with encoder ..........................................................................................115
4.2.11.2 Safe Direction without encoder......................................................................................117
4.2.11.3 Safe Direction without selection.....................................................................................119
4.2.11.4 Function diagrams and parameters ...............................................................................120
4.2.12 Safely-Limited Position (SLP) ........................................................................................121
4.2.12.1 Retraction ....................................................................................................................124
4.2.12.2 Function diagrams and parameters ...............................................................................126
4.2.13 Safe referencing...........................................................................................................127
4.2.14 Transferring safe position values (SP) ...........................................................................129
4.2.15 Safe Brake Test (SBT)..................................................................................................132
4.2.15.1 Communication via SIC/SCC ........................................................................................139
4.2.15.2 Function diagrams and parameters ...............................................................................141
4.2.16 Safe Acceleration Monitor (SAM)...................................................................................142
4.2.17 Safe Brake Ramp (SBR) ...............................................................................................
144

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4.2.18 Safe actual value ac quisition .........................................................................................147
4.2.18.1 Notes regarding safe actual value sensing using an encoder system ...............................147
4.2.18.2 Notes regarding setting parameters for safe actual value sensing without encoder ...........154
4.2.19 Safe gearbox stage switchover ......................................................................................157
4.2.20 Forced dormant error detection (test stop)......................................................................160
5 Control of the safety functions ................................................................................... 167
5.1 Control possibilities.......................................................................................................167
5.2 Control signals by way of terminals on the Control Unit and Motor / Power Module ...........168
5.2.1 Simultaneity and tolerance time of the two monitoring channels .......................................171
5.2.2 Bit pattern test..............................................................................................................173
5.3 Activation via PROFIsafe ..............................................................................................174
5.3.1 Enabling of the control via PROFIsafe............................................................................175
5.3.2 Selecting a PROFIsafe telegram....................................................................................176
5.3.3 Telegram format ...........................................................................................................177
5.3.4 Process data ................................................................................................................179
5.3.4.1 S_STW1 and S_ZSW1 (Basic Functions).......................................................................179
5.3.4.2 S_STW2 and S_ZSW2 (Basic Functions).......................................................................181
5.3.4.3 S_STW1 and S_ZSW1 (Extended Functions) .................................................................183
5.3.4.4 S_STW2 and S_ZSW2 (Extended Functions) .................................................................185
5.3.4.5 Additional process data.................................................................................................188
5.3.5 Function diagrams and parameters................................................................................189
5.4 Control via TM54F ........................................................................................................190
5.4.1 Fault acknowledgment ..................................................................................................191
5.4.2 Overview of the F-DIs ...................................................................................................191
5.4.3 Overview of the F-DOs .................................................................................................193
5.5 Response for a communication failure via PROFIsafe or to the TM54F ............................196
5.5.1 STOP B as response to communication failure with PROFIsafe control ............................196
5.5.2 Initiating ESR for a communication failure ......................................................................197
5.6 Control of the Extended Functions via F-DI (for CU310-2) ...............................................199
5.6.1 Overview of the F-DIs ...................................................................................................200
5.6.2 Function of the F-DO ....................................................................................................202
5.7 Motion monitoring without selection ...............................................................................205
5.8 Safety Info Channel and Safety Control Channel ............................................................207
5.8.1 Safety Info Channel (SIC) .............................................................................................207
5.8.2 Safety Control Channel (SCC).......................................................................................207
5.8.3 Possible telegram configuration (700, 701).....................................................................207
5.8.4 Configuring ..................................................................................................................209
5.8.5 Applications .................................................................................................................210
5.8.6 Send data for SIC and SCC ..........................................................................................213
5.8.7 Receive data for SCC ...................................................................................................216
5.8.8 Overview of important parameters .................................................................................217
6 Commissioning..................................................................................................... 219
6.1 Safety Integrated firmware versions ...............................................................................219
6.2 Parameters, checksum, version.....................................................................................220
6.3 Handling the Safety password .......................................................................................222

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12 Function Manual, (FHS), 07/2016, 6SL3097-4AR00-0BP6
6.4 DRIVE-CLiQ rules for Safety Integrated Functions..........................................................224
6.5 Forced dormant error detection (test stop) .....................................................................226
6.6 Commissioning Safety Integrated functions ....................................................................229
6.6.1 General information ......................................................................................................229
6.6.2 Prerequisites for commissioning the Safety Integrated functions ......................................231
6.6.3 Default settings for commissioning Safety Integrated functions without encoder ...............232
6.6.4 Setting the sampling times ............................................................................................236
6.7 Commissioning: Basic procedure ..................................................................................238
6.7.1 Basic Functions............................................................................................................238
6.7.1.1 Commissioning via direct parameter access...................................................................238
6.7.1.2 Commissioni ng with STARTE R .....................................................................................240
6.7.2 Commissioning of the Extended Functions with STARTER .............................................246
6.7.2.1 Extended Functions with encoder ..................................................................................247
6.7.2.2 Extended Functions without encoder .............................................................................266
6.8 Commissioning CU310-2 using STARTER/SCOUT ........................................................282
6.8.1 Configuration start screen .............................................................................................283
6.8.2 F-DI/F-DO configuration................................................................................................284
6.8.3 Control interface of the drive .........................................................................................287
6.8.4 Forced dormant error detection (test stop) of the CU310-2..............................................288
6.8.4.1 Test mode 1: Evaluation of internal diagnostic signal (passive load) ................................290
6.8.4.2 Test mode 2: Read back F-DO in DI (relay circuit) ..........................................................291
6.8.4.3 Test mode 3: Read back F-DO into the DI (actuator with feedback signal) .......................292
6.8.4.4 Test stop mode parameters ..........................................................................................293
6.9 Commissioning TM54F by means of STARTER/SCOUT.................................................294
6.9.1 Basic sequence of commissioning .................................................................................294
6.9.2 Configuration start screen .............................................................................................295
6.9.3 Function diagrams and parameters ...............................................................................296
6.9.4 TM54F configuration.....................................................................................................297
6.9.5 F-DI/F-DO configuration................................................................................................300
6.9.6 Control interface of the drive group ................................................................................303
6.9.7 Forced dormant error detection (test stop) of the TM54F.................................................305
6.9.7.1 Test mode 1: Evaluation of internal diagnostic signal (passive load) ................................307
6.9.7.2 Test mode 2: Read back F-DO in DI (relay circuit) ..........................................................308
6.9.7.3 Test mode 3: Read back F-DO into the DI (actuator with feedback signal) .......................309
6.9.7.4 Parameter forced dormant error detection (test stop) ......................................................310
6.10 PROFIsafe communication ...........................................................................................311
6.10.1 PROFIsafe via PROFIBUS ...........................................................................................312
6.10.1.1 Configuring PROFIsafe via PROFIBUS .........................................................................312
6.10.2 PROFIsafe via PROFINET............................................................................................322
6.10.2.1 Assigning the IP address and the name .........................................................................322
6.10.2.2 Configuring PROFIsafe via PROFINET..........................................................................322
6.10.3 PROFIsafe configuration with STA RTER .......................................................................330
6.10.3.1 Selecting a PROFIsafe telegram ...................................................................................331
6.11 Commissioning a linear/rotary axis ................................................................................333
6.12 Modular mac hine concept Safety Integrated...................................................................335
6.13 Information pertaining to series commissioning ..............................................................336
6.14 Application examples ....................................................................................................338

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7 Acceptance test.................................................................................................... 341
7.1 General information about the acceptance test ...............................................................344
7.2 Safety logbook .............................................................................................................346
8 System features.................................................................................................... 347
8.1 Latest information .........................................................................................................347
8.2 Certification ..................................................................................................................349
8.3 Probability of failure of the safety functions (PFH value) ..................................................350
8.4 Response times ...........................................................................................................351
8.4.1 Control of Basic Functions via terminals on the Control Unit and Motor Module
(CU310-2 and CU320-2) ...............................................................................................352
8.4.2 Control of Basic Functions via PROFIsafe (CU310-2 and CU320-2).................................353
8.4.3 Control of Basic Functions via TM54F ............................................................................354
8.4.4 Control of Extended Functions with encoder via PROFIsafe (CU310-2 and CU320-2) .......355
8.4.5 Control of Extended Functions with encoder via TM54F (CU310-2 and CU320-2).............356
8.4.6 Control of Extended Functions with encoder via terminals (only CU310-2) .......................357
8.4.7 Control of Extended Functions without encoder via PROFIsafe (CU310-2 and
CU320-2).....................................................................................................................358
8.4.8 Control of Extended Functions without encoder via terminals (only CU310-2) ...................359
8.4.9 Control of Extended Functions without encoder via TM54F (CU310-2 and CU320-2) ........360
9 Maintenance........................................................................................................ 361
9.1 Information pertaining to component replacements .........................................................361
9.2 Note regarding firmware update ....................................................................................364
9.3 Safety faults .................................................................................................................365
9.3.1 Stop responses ............................................................................................................365
9.3.2 Stop response priorities ................................................................................................368
9.3.3 Acknowledging safety faults ..........................................................................................370
9.4 Message buffer ............................................................................................................371
10 Standards and regulations........................................................................................ 373
10.1 General information ......................................................................................................373
10.1.1 Aims............................................................................................................................373
10.1.2 Functional safety ..........................................................................................................374
10.2 Safety of machinery in Europe.......................................................................................375
10.2.1 Machinery Directive ......................................................................................................375
10.2.2 Harmonized European Standards ..................................................................................376
10.2.3 Standards for implementing safety-related controllers .....................................................377
10.2.4 DIN EN ISO 13849-1 (replaces EN 954-1) .....................................................................379
10.2.5 EN 62061.....................................................................................................................380
10.2.6 Series of standards IEC 61508 (VDE 0803)....................................................................381
10.2.7 Risk analysis/assessment .............................................................................................382
10.2.8 Risk reduction ..............................................................................................................384
10.2.9 Residual risk ................................................................................................................384
10.2.10 EC declaration of conformity .........................................................................................384

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10.3 Machine safety in the USA ............................................................................................385
10.3.1 Minimum requirements of the OSHA..............................................................................385
10.3.2 NRTL listing.................................................................................................................385
10.3.3 NFPA 79......................................................................................................................386
10.3.4 ANSI B11 ....................................................................................................................386
10.4 Machine safety in Japan ...............................................................................................387
10.5 Equipment regulations ..................................................................................................388
10.6 Other safety-related issues ...........................................................................................389
10.6.1 Information sheets issued by the Employer's Liability Insurance Association ....................389
10.6.2 Additional references....................................................................................................389
A Appendix ........................................................................................................... 391
A.1 List of abbreviations .....................................................................................................391
A.2 Documentation overview...............................................................................................401
A.3 Acceptance tests (recommendations) ............................................................................403
A.3.1 Contents and depth of the acceptance test ....................................................................403
A.3.1.1 Content of the complete acceptanc e test .......................................................................403
A.3.1.2 Content of the partial acceptance test............................................................................405
A.3.1.3 Test scope for specific measures ..................................................................................407
A.3.1.4 Relev ant checksums for the acceptanc e ........................................................................408
A.3.2 Acceptance reports ......................................................................................................409
A.3.2.1 Plant description - Documentation part 1........................................................................409
A.3.2.2 Description of safety functions - Documentation Part 2 ...................................................411
A.3.3 Acceptance tests..........................................................................................................420
A.3.3.1 Acceptance tests – Basic Functions...............................................................................422
A.3.3.2 Acceptance tests for Extended Functions (with encoder) ................................................426
A.3.3.3 Acceptance tests for Extended Functions (without encoder) ............................................481
A.3.3.4 Acceptance test for the transfer of F-DIs via PROFIsafe .................................................504
A.3.4 Completion of certificate ...............................................................................................505
A.4 Stop variants................................................................................................................507
Index ................................................................................................................ 509

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Function Manual, (FHS), 07/2016, 6SL3097-4AR00-0BP6 15
Fundamental safety instructions
1
1.1
Fundamental safety instructions
1.1.1
General safety instructions
WARNING
Danger to life if the safety instructions and residual risksare not observed
If the safety instructions and residual risks in the associated hardware documentation are
not observed, accidents involving severe injuries or death can occur.
•Observe the safety instructions given in the hardware documentation.
•Consider the residual risks for the risk evaluation.
WARNING
Danger to life or malfunctions of the machine as a result of incorrect or changed
parameterization
As a result of incorrect or changed parameterization, machines can malfunction, which in
turn can lead to injuries or death.
•Protect the parameterization (parameter assignments) against unauthorized access.
•Respond to possible malfunctions by applying suitable measures (e.g. EMERGENCY
STOP or EMERGENCY OFF).

Fundamental safety instructions
1.1 Fundamental safety instructions
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16 Function Manual, (FHS), 07/2016, 6SL3097-4AR00-0BP6
1.1.2
Industrial security
Note
Industrial s ecurity
Siemens provides products and solutions with industrial security functions that support the
secure operation of plants, solutions, machines, equipment and/or networks. They are
important components in a
holistic industrial security concept. With this in mind, Siemens’
products and solutions undergo continuous development. Siemens recommends strongly
that you regularly check for product updates.
For the secure operation of Siemens products and solutions, i
t is necessary to take suitable
preventive action (e.g. cell protection concept) and integrate each component into a holistic,
state
-of-the-art industrial security concept. Third-party products that may be in use should
also be considered. For more informa
tion about industrial security, visit this address
(
http://www.siemens.com/industrialsecurity).
To stay informed about product updates as they occur, sign up for a product
-specific
newsletter. For
more information, visit this address (http://support.automation.siemens.com).
WARNING
Danger as a result of unsafe operating states resulting from s oftware manipulation
Software manipulation (e.g. by viruses, Trojan horses, malware, worms) can cause unsafe
operating states to develop in your installation which can result in death, severe injuries
and/or material damage.
•Keep the software up to date.
You will find relevant information and newsletters at this address
(http://support.automation.siemens.com).
•Incorporate the automation and drive components into a holistic, state-of-the-art
industrial security concept for the installation or machine.
You will find further information at this address
(http://www.siemens.com/industrialsecurity).
•Make sure that you include all installed products into the holistic industrial security
concept.
WARNING
Danger to life due to software manipulation when using exchangeable storage media
Storing files onto exchangeable storage media amounts to an increased risk of infection,
e.g. with viruses and malware. As a result of incorrect parameterization, machines can
malfunction, which in turn can lead to injuries or death.
•Protect files stored on exchangeable storage media from malicious software by taking
suitable protection measures, e.g. virus scanners.

Fundamental safety instructions
1.2 Fundamental safety instructions for Safety Integrated
Safety Integrated
Function Manual, (FHS), 07/2016, 6SL3097-4AR00-0BP6 17
1.2
Fundamental safety instructions for Safety Integrated
Note
Malfunctions as a result of withdrawing and inserting components
Malfunctions can occur when components are withdrawn or inserted that are used for Safety
Integrated. However, this does not mean that the fail
-safe state is exited. For example,
PROFIsafe communication is not reestablished after this event.
•
Withdrawing and inserting components used for Safety Integrated (power units, Sensor
Modules, TM54F) during operation
and
in the deactivated state is
not
permissible.
Activating the components always requires a POWER ON (see section "
Modular machine
concept Safety Integrated (Page 335)").
Additional safety instructions and residual risks
Additional safety information and residual risks not specified in this section are included in
the relevant sections of this Function Manual.
DANGER
Ris k minimization through Safety Integrated
Safety Integrated can be used to minimize the level of risk associated with machines and
plants.
Machines and plants can only be operated safely in conjunction with Safety Integrated,
however, when the machine manufacturer:
•Precisely knows and observes this technical user documentation - including the
documented limitations, safety information and residual risks.
•Carefully constructs and configures the machine/plant. A careful and thorough
acceptance test must then be performed by qualified personnel and the results
documented.
•Implements and validates all the measures required in accordance with the
machine/plant risk analysis by means of the programmed and configured Safety
Integrated functions or by other means.
The use of Safety Integrated does not replace the machine/plant risk assessment carried
out by the machine manufacturer as required by the EC machinery directive.
In addition to using Safety Integrated functions, further risk reduction measures must be
implemented.
NOTICE
Danger to life as a result of inactive Safety Integrated functions after powering up
The Safety Integrated functions are only activated after the system has completely powered
up. System startup is a critical operating state with increased risk. When accidents occur,
this can result in death or severe injury.
•Make sure that the machine is safe during the system start-up.

Fundamental safety instructions
1.2 Fundamental safety instructions for Safety Integrated
Safety Integrated
18 Function Manual, (FHS), 07/2016, 6SL3097-4AR00-0BP6
WARNING
Regulations from EN 60204-1
The Emergency Stop function must bring the machine to a standstill according to stop
category 0 or 1 (STO or SS1).
The machine must not restart automatically after EMERGENCY STOP.
When individual safety functions (Extended Functions) are deactivated, an automatic
restart is permitted under certain circumstances depending on the risk analysis (except
when Emergency Stop is reset). An automatic start is permitted when a protective door is
closed, for example.
WARNING
Sy stem power-up and drive activation after c hanging or replacing hardware and/or software
After hardware and/or software components have been modified or replaced, it is only
permissible for the system to run up and the drives to be activated with the protective
devices closed. Personnel shall not be present within the danger zone.
It may be necessary to carry out a partial or complete acceptance test or a simplified
functional test after having made certain changes or replacements.
Before personnel may re-enter the hazardous area, the drives should be tested to ensure
that they exhibit stable control behavior by briefly moving them in both the plus and minus
directions (+/–).
Please note the following during switch-on:
The Safety Integrated functions are only available and can only be selected after the
system has completely powered up.
WARNING
Danger to life when the drive coastsdown for an STO or STOP A
The category 0 stop function in accordance with EN 60204-1 (STO or STOP A to Safety
Integrated) means that the drives are not decelerated but instead coast to standstill (the
time required to coast to standstill depends on the kinetic energy).
•Carefully take this response into account when designing the protective door
interlocking logic.
•For safety without encoder, you must apply other measures to ensure that the protective
door remains locked until the drive has come to a standstill.

Fundamental safety instructions
1.2 Fundamental safety instructions for Safety Integrated
Safety Integrated
Function Manual, (FHS), 07/2016, 6SL3097-4AR00-0BP6 19
WARNING
Danger to life as a result of a malfunction due to anacceptance testthat has not been
carried out after changes to parameters have been made
Safety Integrated functions cannot detect parameter changes made by the machine builder
(OEM). Incorrect parameter changes for SI functions can result in accidents leading to
death or severe injury.
•After making a change to a parameter, always carry out an acceptance test and
document the values in an acceptance report.
•Only use the system or machine after the acceptance test has been successfully
completed.
WARNING
Danger to life as a result of different responses of the Safety Integrated functions when
replacing a MotorModule or a motor
Motor Modules or the motor must be replaced with a device of the same type, as the
parameter settings will otherwise lead to an incorrect response of the Safety Integrated
functions. Functionality that has been modified can result in accidents leading to death or
severe injury.
•Always replace a component by an identical component of precisely the same type.
•Readjust the drive involved when replacing an encoder.
•Carefully test the functionality after replacement.
WARNING
Danger to life as a result of parameterized safety functions, which are only available to a
restricted extent, when an internal or external fault occurs
If an internal or external fault occurs, none or only some of the parameterized safety
functions are available during the STOP F response triggered by the fault.
•Carefully take this into account when parameterizing a delay time between STOP F and
STOP B. This is especially true for vertical axes.
WARNING
Parameterizing the encoder system
Encoder faults are detected using different hardware and software monitoring functions.
•It is not permissible to disable these monitoring functions (i.e. the encoder monitoring in
the Sensor Module) and they must be parameterized carefully. Depending on the fault
type and the responding monitoring function, stop function category 0 or 1 in
accordance with EN 60204-1 (fault response functions STOP A or STOP B to Safety
Integrated) is selected (see table "Overview of stop responses" in Section "Safety
Integrated Extended Functions", in the section "Safety faults").

Fundamental safety instructions
1.2 Fundamental safety instructions for Safety Integrated
Safety Integrated
20 Function Manual, (FHS), 07/2016, 6SL3097-4AR00-0BP6
Note
EDS s witchover for safe motion monitoring
An encoder which is used for safety functions must not be switched over when a drive data
set (DDS) is switched over.
The safety functions check the safety
-relevant encoder data for changes when data sets are
switched over. If a change is detected, fault F01670 is displayed with a fault value of 10,
which results in a non
-acknowledgeable STOP A.
•
The safety-relevant encoder data in the various data sets must therefore be identical.
WARNING
Converter operation despite active messages
With activated safety functions, there are a number of system messages that still permit the
drive to be traversed. In these cases, you must ensure that the causes of the messages are
corrected immediately. These messages include, among others, the following:
•A01774 SI Motion CU: Test stop required
A01697 SI Motion: Motion monitoring test required
Perform the required test stop.
•A13000 Insufficient license.
Purchase the license required for the operation of the Extended Functions.
•A01669 (F, N) SI Motion: Unsuitable combination of motor and power unit.
The motor / power unit combination can result in decreased robustness (incorrect
detection of errors) in the system when operating with SI Motion.