Siemens SINAMICS S120 User manual

Functional Example MC-FE-I-005-V11-EN
SINAMICS S120
Safety Integrated Extended Functions
Fail-Safe Drives
Controlling the CU320 from a TM54F and F-CPU

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Preliminary remark
The Functional Examples dealing with “Safety Integrated” are fully
functional and tested automation configurations based on I IA&DT
standard products for simple, fast and inexpensive implementation of
automation tasks in safety engineering. Each of these Functional Ex-
amples covers a frequently occurring subtask of a typical customer
problem in safety engineering.
Aside from a list of all required software and hardware components
and a description of the way they are connected to each other, the
Functional Examples include the tested and commented code. This
ensures that the functionalities described here can be reset in a short
period of time and thus also be used as a basis for individual expan-
sions.
Important note
The Safety Functional Examples are not binding and do not claim to
be complete regarding the circuits shown, equipping and any eventu-
ality. The Safety Functional Examples do not represent customer-
specific solutions. They are only intended to provide support for typi-
cal applications. You are responsible for ensuring that the described
products are used correctly.
These Safety Functional Examples do not relieve you of the responsi-
bility of safely and professionally using, installing, operating and ser-
vicing equipment. When using these Safety Functional Examples, you
recognize that Siemens cannot be made liable for any damage/claims
beyond the liability clause described. We reserve the right to make
changes to these Safety Functional Examples at any time without pri-
or notice. If there are any deviations between the recommendations
provided in these Safety Function Examples and other Siemens publi-
cations – e.g. Catalogs – the contents of the other documents have
priority.

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Table of Contents
1Warranty, Liability and Support .................................................................... 4
2Automation function....................................................................................... 5
2.1 Description of the function example.................................................................. 5
2.2 Advantages / customer benefits ....................................................................... 7
3Components that are required ...................................................................... 8
3.1 Hardware Components..................................................................................... 8
3.2 Software components ..................................................................................... 10
3.2.1 Engineering software ...................................................................................... 10
3.2.2 Firmware......................................................................................................... 10
4Configuration and wiring ............................................................................. 11
4.1 Overview of the hardware configuration ......................................................... 11
4.2 Connecting-up the hardware components...................................................... 12
4.2.1 Connecting-up the control voltage .................................................................. 12
4.2.2 Principle connection between the F-CPU and TM54F.................................... 13
4.2.3 DRIVE-CLiQ interconnection .......................................................................... 14
4.3 Important settings at the hardware components............................................. 15
5Overview and operator control.................................................................... 17
5.1 Description of the operator control.................................................................. 17
5.2 Summary of the input signals ......................................................................... 18
6Project example ............................................................................................ 20
6.1 Passwords ...................................................................................................... 20
6.2 Hardware configuration of the fail-safe control ............................................... 21
6.3 Programming the fail-safe control................................................................... 23
6.4 SINAMICS parameterization of the motion functions ..................................... 26
6.5 Parameterizing the control of the safety functions (TM54F) ........................... 34
6.6 Parameterizing the safety functions integrated in the drive ............................ 37
6.7 Acceptance test .............................................................................................. 43
7History ........................................................................................................... 43

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1 Warranty, Liability and Support
We accept no liability for information contained in this document.
Any claims against us – based on whatever legal reason – resulting
from the use of the examples, information, programs, engineering and
performance data etc., described in this Safety Functional Example
shall be excluded. Such an exclusion shall not apply in the case of
mandatory liability, e.g. under the German Product Liability Act (“Pro-
dukthaftungsgesetz”), in case of intent, gross negligence, or injury of
life, body or health, guarantee for the quality of a product, fraudulent
concealment of a deficiency or breach of a condition which goes to
the root of the contract (“wesentliche Vertragspflichten”). However,
claims arising from a breach of a condition which goes to the root of
the contract shall be limited to the foreseeable damage which is in-
trinsic to the contract, unless caused by intent or gross negligence or
based on mandatory liability for injury of life, body or health. The
above provisions do not imply a change in the burden of proof to your
detriment.
Copyright© 2009 Siemens I DT. It is not permissible to transfer or
copy these Application Examples or excerpts of them without first
having prior authorization from Siemens I DT in writing.
For questions about this document please use the following
e-mail-address:
[email protected]

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2 Automation function
2.1 Description of the function example
The following safety functions according to IEC 61800-5-2 have been integrated into
SINAMICS S120 drives:
Name Function Description
STO Safe Torque Off – The torque-generating power feed to the motor is
disconnected in a safety-relevant fashion
– Restart is interlocked using a restart/power-on
inhibit.
(Category 0 stop function acc. to EN 60204-1)
SBC Safe Brake Control – SBC is only used when there is a motor brake; the
motor brake is connected to the power connector
via the outputs.
– SBC always responds in conjunction with STO or
when internal safety monitoring functions respond
with safety-relevant pulse cancellation.
SS1 Safe Stop 1 – The drive is quickly stopped along the OFF3 ramp
– and is monitored in a safety-relevant fashion at
the same time
– After a delay time has expired or the shutdown
speed is reached, a transition is made to STO
(Category 1 stop function acc., to EN 60204-1)
SS2 Safe Stop 2 – The drive is quickly stopped along the OFF3 ramp
– and is monitored in a safety-relevant fashion at
the same time
– After a delay time has expired or the shutdown
speed is reached, a transition is made to SOS;
the drive remains in closed-loop control
(Category 2 stop function acc., to EN 60204-1)
SOS Safe Operating Stop – This function is used to safely monitor the stand-
still position of a drive. The drive remains in
closed-loop control.
SLS Safely-Limited Speed – The drive speed is safely monitored
– Parameterizable shutdown response when the
limit value is violated
SSM Safe Speed Monitor – Safety-relevant display when a speed limit is
fallen below (n < nx)
The control of these extended safety functions can be realized using
PROFIsafe with PROFIBUS and also using a TM54F terminal expansion
module.

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Task description
The extended safety functions integrated in the SINAMICS S120 drives are
to be controlled from a TM54F via hardware signals. The drives belong to
different drive groups. The safety-relevant logical pre-processing of the
input signals is handled in an F-CPU.
This application should comply with SIL 2 acc. to EN 62061:2005, ISO
13849-1:2006 PL d or EN 954-1:1996 Category 3.
Solution
Hardware overview
The control of the safety functions SS1 and SLS via the TM54F terminal
expansion module connected to a SINAMICS S120 drive group is shown in
this function example. The SLS initiates a Stop C (SS2 → SOS) as re-
sponse to the fault at the particular drive.
The drive group in the booksize format comprises an infeed and a Double
Motor Module. The motor is controlled using a CU320 Control Unit. The ex-
panded setpoint channel is used to enter the speed setpoint. The two ser-
vomotors – that are independent of one another – are controlled by the
Double Motor Module. A Smart Line Module is used as infeed.
The safety-relevant signals are detected using the fail-safe inputs of an F-
CPU and are then evaluated in the F-CPU. The pre-processed signals are
transferred to the TM54F terminal expansion module via the fail-safe
outputs of the F-CPU. This means that the safety functions integrated in the
drive are controlled in the SINAMICS S120.

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When an Emergency Stop is requested, both of the drives are stopped by
the SS1 safety function integrated in the drive. The torque-generating
power feed to the motor is interrupted in a safety-relevant fashion using
safe pulse cancellation. The restart inhibit is activated.
Each drive is assigned a safety door. If this safety door is opened, then the
associated motor is operated at a lower speed and the set speed limit value
is safely monitored using the SLS function. The other drive is not influ-
enced.
Other ways of using the TM54F terminal expansion module and controlling
the safety functions via PROFIsafe are described in additional function ex-
amples.
2.2 Advantages / customer benefits
•The safety functions integrated in the drive are controlled in a
simple fashion
•Simple design/configuring using standardized technology
•The existing system can be simply and quickly expanded.
•Space-saving configuration using integrated safety functions –
additional hardware is not required
Complex safety concepts can be implemented using this as basis.

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3 Components that are required
The hardware components and software versions that are required to im-
plement this function example are listed in this chapter.
3.1 Hardware Components
Table 3-1
Components Type Order No./Ordering data Qty. Manufact.
Power supply PS307 5A 6ES7 3071EA00-0AA0 1 Siemens
IM151-7 F-CPU 6ES7 151-7FA01-0AB0 1 Siemens
SIMATIC ET200S
CPU SIMATIC Micro Memory Card,
512KB
6ES7 953-8LJ11-0AA0 1 Siemens
PM-E 6ES7 138-4CB10-0AB0 1 Siemens
SIMATIC ET200S
Power Module SIMATIC DP, Terminal Module
TM-P15C23-A0
6ES7 193-4CD30-0AA0 1 Siemens
F-DI 4/8 6ES7 138-4FA02-0AB0 1 Siemens
SIMATIC ET200S
fail-safe input module SIMATIC DP, Terminal Module
TM-E30C44-01
6ES7 193-4CG30-0AA0 1 Siemens
F-DO 4 6ES7 138-4FB01-0AB0 1 Siemens
SIMATIC ET200S
fail-safe output module SIMATIC DP, Terminal Module
TM
6ES7 193-4CG30-0AA0 1 Siemens
F-CPU operator components
Components Type Order No./Ordering data Qty. Manufact.
Empty pushbutton housing Empty housing for 4 command
positions, pushbutton in the
enclosure, for metric gland, gray
cover
3SB3 804-0AA3 1 Siemens
3SB3 mushroom pushbutton
(Ø 32 mm), plastic, round with
holder
3SB3 000-1FA20 1 SiemensEmergency Stop command
device
-S3
Base element, 1OE, screw
connection
3SB3 420-0C 2 Siemens
3SB3 illuminated pushbutton with
flat actuator knob, green, with holder
3SB3 001-0AA41 1 Siemens
Base element 1S, screw connection 3BS3 420-0B 1 Siemens
Reset button
-S4
Lamp socket with integrated LED for
base mounting, green, 24V DC
3SB3 420-1PC 1 Siemens
3SB3 knob-operated switch, I-0-II,
latching, 2x50°switching angle,
black, not illuminated, with holder
3SB3 000-2DA11 1 SiemensSafety door/gate simulation
switch
-S1
Base element 1S, screw connection 3BS3 420-0B 2 Siemens
3SB3 knob-operated switch, I-0-II,
latching, 2x50°switching angle,
black, not illuminated, with holder
3SB3 000-2DA11 1 SiemensSafety door/gate simulation
switch
-S2
Base element 1S, screw connection 3BS3 420-0B 2 Siemens

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SINAMICS operator components
Components Type Order No./Ordering data Qty. Manufact.
Empty pushbutton housing Empty housing for 4 command
positions, pushbutton in the
enclosure, for metric gland, gray
cover
3SB3 804-0AA3 1 Siemens
Round actuator knob, O-I, latching,
50° switching angle, black with
holder, not illuminated
3SB3000-2KA11 1 SiemensDrives, ON/OFF1 switch
-S6
Base element 1S, screw connection 3BS3 420-0B 1 Siemens
Actuator, round pushbuttoon with
flat actuator, black with holder, not
illuminated
3SB3000-0AA11 1 SiemensReset button
-S7
Base element 1S, screw connection 3BS3 420-0B 1 Siemens
Actuator, round pushbuttoon with
flat actuator, black with holder, not
illuminated
3SB3000-0AA11 1 SiemensMax. speed button
-S8
Base element 1S, screw connection 3BS3 420-0B 1 Siemens
Drive
Components Type Order No./Ordering data Qty. Manufact.
CU320 6SL3 040-0MA00-0AA1 1 SiemensSINAMICS CU320
Compact Flash card for SINAMICS
CU320
6SL3054-0CE01-1AA0 1 Siemens
SINAMICS safety license SINAMICS license, Safety
Integrated extended functions for
CompactFlash card
6SL3074-0AA10-0AA0 2 Siemens
SINAMICS Smart Line Module SLM 5 kW / 230 V 6SL3130-6AE15-0AA0-
Z=220V
1 Siemens
SINAMICS Terminal Module TM54F 6SL3 055-0AA00-3BA0 1 Siemens
Load resistors
R1 .. R8
1kOhm 1W Type PO595-0
Style 0207
Power Metaloxide film
resistors
8 Yageo
Europe
ST 2,5-QUATTRO-TG 3038451 8 Phoenix
Contact
Load resistor terminals
(R1..R8)
Component plug
P-CO
3036796 8 Phoenix
Contact
SINAMICS Double Motor
Module
DMM 6SL3 120-2TE21-0AA3 1 Siemens
Synchronous servomotor 1FK7
COMPACT, 3000 rpm, 0.82 kW
1FK7 042-5AF71-1FG0 1 SiemensMotors
Synchronous servomotor 1FK7
COMPACT, 3000 rpm, 0.82 kW
1FK7 042-5AF71-1DG0 1 Siemens
DRIVE-CLiQ cable
TM54F to CU320:
SINAMICS DRIVE-CLiQ cable
IP20/IP20 length: 0.41 m
6SL3060-4AP00-0AA0 1 Siemens
DRIVE-CLiQ cable
SLM zu CU320:
SINAMICS DRIVE-CLiQ cable
IP20/IP20 length: 0.41 m
6SL3060-4AP00-0AA0 1 Siemens
DRIVE-CLiQ cable
DMM to CU320:
SINAMICS DRIVE-CLiQ cable
IP20/IP20 length: 0.41 m
6SL3060-4AP00-0AA0 1 Siemens
Signal cable
DMM to Motor1:
Pre-fabricated signal cable
(SINAMICS DRIVE-CLiQ) connector
IP20/IP67, with 24 V MOTION-
CONNECT 500 length (M) = 2
6FX5002-2DC10-2AA0 1 Siemens

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Components Type Order No./Ordering data Qty. Manufact.
Signal cable
DMM to Motor2:
Pre-fabricated signal cable
(SINAMICS DRIVE-CLiQ) connector
IP20/IP67, with 24 V MOTION-
CONNECT 500 length (M) = 2
6FX5002-2DC10-2AA0 1 Siemens
Power cable
DMM to motor1:
Pre-fabricated power cable
(1FT/1FK/1PH to SINAMICS) 4x1.5
C, connector size 1/1.5 mm2
UL/CSA DESINA, MOTION-
CONNECT 500 Dmax=11.5 mm,
length (m) = 2
6FX5002-5CS01-1AC0 1 Siemens
Power cable
DMM to motor2:
Pre-fabricated power cable
(1FT/1FK/1PH to SINAMICS) 4x1.5
C, connector size1/1.5 mm2UL/CSA
DESINA, MOTION-CONNECT 500
Dmax=11.5 mm, length (m) = 2
6FX5002-5CS01-1AC0 1 Siemens
Note The function example was tested with the hardware components listed
here. Other components that have the same function can be alternatively
used. If other components are used it may be necessary to use a
different parameterization and also change the component wiring.
3.2 Software components
3.2.1 Engineering software
Table 3-2
Components Type Order No./Ordering data Qty. Manufact.
STEP 7 V5.4 SP2 6ES7810-4CC08-0YA5 1 Siemens
S7 Distributed Safety
Programming
V5.4 SP3 6ES7833-1FC02-0YA5 1 Siemens
STARTER V4.1 SP1 6SL3072-0AA00-0AG0 1 Siemens
or, as an alternative to the STARTER software:
SIMOTION SCOUT V4.1 SP1 6AU1810-1BA41-1XA0 1 Siemens
3.2.2 Firmware
All of the SINAMICS components must have firmware release V2.5 SP1 or
higher.

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4 Configuration and wiring
4.1 Overview of the hardware configuration
Basic configuration

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4.2 Connecting-up the hardware components
4.2.1 Connecting-up the control voltage
24V DC wiring

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4.2.2 Principle connection between the F-CPU and TM54F
Connecting F-DO P/M switching (F-CPU) →F-DI (TM54F)
Load resistor dimensioning
If the manufacturer documentation contains specific conditions for the digi-
tal output, for example, a minimum load resp. a maximum load resistor,
these must be considered accordingly.
For example, a maximum load of 1kΩis specified for SIMATIC ET200S I/O
module 4 F-D .
As a result, two additional 1 kΩload resistors with a permanent load capac-
ity of at least P = U²/R = (28.8V)²/1 kΩ= 830 mW are required for connect-
ing such an F-DO to a TM54F F-DI.
Note: When using closed-loop controlled SITOP power supply units, the
voltage tolerance on the 24V side is significantly lower than the maximum
admissible tolerance of +20% for the supply voltage at the ET200S mod-
ules. In this case, the power transformed at the resistor is lower than the
maximum power calculated above.

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4.2.3 DRIVE-CLiQ interconnection
DRIVE-CLiQ interconnection

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4.3 Important settings at the hardware components
In this function example, the PROFIBUS interfaces of the F-CPU and the
CU320 are only used for programming. The safety-relevant signal ex-
change between the F-CPU and TM54F is only realized through the hard-
wired 24V signals.
SINAMICS Control Unit CU320
•PROFIBUS address = 3
•The PROFIBUS address is set at the DIL switch below the blind
cover of the Control Unit.
SIMATIC IM151-7 F-CPU
•PROFIBUS address = 4
•When commissioning the system, the programming device must
be configured as the only master connected to the bus.

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Prerequisites for operation
•The SIMATIC ET200S components must be mounted and con-
nected with one another, latched on the mounting rail. The
PROFIsafe addresses of the fail-safe input and output modules
must be set using the DIL switch; also refer to Chapter 6.2
Hardware configuration of the fail-safe control.
•All of the components are connected-up as explained in Chapter
4.2 Connecting-up the hardware components.
•The DRIVE-CLiQ topology of the SINAMICS components is care-
fully observed.
•The motors are connected to the Motor Module using the power
and encoder cables.
•The Motor Module is correctly connected to the infeed (DC link and
24 V DC control voltage).
•The infeed is connected to the line supply.
•The components are supplied with 24 V DC.

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5 Overview and operator control
5.1 Description of the operator control
Hardware overview
The Emergency Stop pushbutton –S3 is released to power-up the system.
The safety function SS1 is de-selected at both drives using reset button –
S4 via output F-DO 0 of the F-CPU; pulse cancellation at the drives is with-
drawn. The drives can then be moved (operated) using the knob-operated
switch –S6.
When safety door 1 is closed (knob-operated switch -S1, ON switch posi-
tion), drive 1 rotates with n=800 rpm. If safety door 1 (switch –S1) is
opened, the data set is changed-over in drive 1 and for drive 1 the setpoint
speed is n=20 rpm. When switch -S1 is opened, the SLS safety function in
drive 1 is activated. By closing safety door 1, a speed of n=800 rpm is again
entered (speed setpoint). Drive 2 is not influenced.
If safety door 2 is closed (knob-operated switch –S2, switch position ON)
then a setpoint speed of n=333 rpm is entered for drive 2. If safety door 2
(switch –S2) is opened, then drive 2 has a speed setpoint of n=33 rpm as
the data set is changed-over. When switch –S2 is open, the SLS safety
function in drive 2 is activated. By closing safety door 2, a speed setpoint of
n=333 rpm is again entered. Also in this case, drive 1 is not influenced.
If safety door 1 (knob-operated switch –S1, center position) is opened, then
the SLS function is activated for drive 1. Drive 2 is not influenced. When
opening safety door 2 (knob-operated switch -S2, center position) the SLS
function for drive 2 is activated.

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The motors rotate in opposite directions.
When button –S8 is pressed, the drives receive a higher setpoint - inde-
pendent of the position of the safety door. For drive 1, n=1000 rpm and for
drive 2, n=666 rpm. When the safety door is open, then an SLS limited
value is violated and the drive involved is stopped using an internal SS2
(Stop C), and for n=0 rpm is brought into SOS. In order to continue to oper-
ate the drive, the alarm, initiated by the internal SS2 (Stop C) as well as the
"Internal Event" message signal in the TM54F must be acknowledged using
the –S4 reset button.
5.2 Summary of the input signals
Digital inputs of the CU320
DI0 Digital input CU320 Æ–
DI1 ON/OFF1 (1 signal, positive signal
edge) and stopping (0 signal) (switch –
S6)
ÆBoth drives are started
DI2 Acknowledgement of the SINAMICS
fault messages (1 signal, pushbutton –
S7)
ÆThe SINAMICS fault messages are
acknowledged at all of the drive
objects
DI3 A higher setpoint speed is entered
(1 signal, pushbutton –S8)
ÆA high setpoint speed is entered; this
is used to violate the SLS limit as
simulation (1 signal)

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F-DIs of the F-CPU
F-DI0/F-DI4 Emergency Stop pushbutton ÆSS1 in both drives
ÆAcknowledges the Emergency Stop
function
F-DI1 Reset button
ÆAcknowledges an Internal Event in
TM54F
ÆSLS_door_1 – 0 signal; drive_1
operates at a low speed.
Protective door_1 open
ÆSLS in drive 1 activated
ÆSLS_door_1 – 1 signal; drive_1
operates at the normal speed.
F-DI2/F-DI6
Protective door_1 closed
ÆSLS in drive 1 not activated.
ÆSLS_door_2; drive_2 operates at a
low speed.
Protective door_2 open
ÆSLS in drive_2 activated
ÆSLS_door_2 – 1 signal; drive_2
operates at the normal speed.
F-DI3/F-DI7
Protective door_2 closed
ÆSLS in drive_2 not activated.
Note The drives can only be operated when the infeed is powered-up and the
DC link is charged.

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6 Project example
In this chapter, you will learn how the individual components must be pa-
rameterized. Both STARTER as well as also SIMOTION SCOUT can be
used as engineering software for SINAMICS S120. Distributed Safety is re-
quired to program the F-CPU.
A description is subsequently given as to how the software project associ-
ated with this function example was set-up.
6.1 Passwords
For reasons of simplicity, in the project, one common safety password is
used for the SIMATIC components for both the program and hardware.
One password is also used for the safety configuring of the SINAMICS
components for the drives and for the TM54F terminal expansion module.
•Safety password on the F-CPU: "0"
•Safety password on SINAMICS: "1"
These passwords should be changed for real applications!