Siemens SINAMICS Series Parts list manual

Safety Integrated
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SINAMICS
G130, G150, S120 Chassis, S120
Cabinet Modules, S150
Safety Integrated
Function Manual
Firmware version 4.8
07/2016
A5E03264275A
Preface
Safety information
1
Introduction
2
General information about
SINAMICS Safety Integrated
3
Description of Safety
Integrated functions
4
Controlling the safety
functions
5
Commissioning and
acceptance test
6

Siemens AG
Division Process Industries and Drives
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E03264275A
Ⓟ
08/2016 Subject to change
Copyright © Siemens AG 2005 - 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 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
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
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, 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 complied with. The information in the relevant documentation must be 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 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.

Safety Integrated
Function Manual, 07/2016, A5E03264275A 5
Preface
Target group
This documentation is intended for machine manufacturers, commissioning engineers, and
service personnel who use the SINAMICS drive system.
Standard version
The scope of the functionality described in this document can differ from that of the actually
supplied drive system.
●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 controller or when servicing.
●The documentation can also contain descriptions of functions that are not available in a
particular product version of the drive system. The functionalities 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
In case of questions, please contact us through the following hotline:
Time zone Europe / Africa
Phone
[phone]
Fax
[phone]
Internet
https://support.industry.siemens.com/sc/ww/en/sc/2090
Time zone Americas
Phone
[phone]
Fax
[phone]
E-mail
[e-mail]
Time zone Asia/Pacific
Phone
[phone]
Fax
[phone]
E-mail
support.asia.autom[email protected]om

Preface
Safety Integrated
6Function Manual, 07/2016, A5E03264275A
Note
Country
-specific telephone numbers for technical support are provided under the following
Internet address:
https://www.automation.siemens.com/aspa_app
Spare parts
You can find spare parts on the Internet at:
https://support.industry.siemens.com/sc/de/en/sc/2110
Internet address for SINAMICS
http://www.siemens.com/sinamics.
Internet address for Safety Integrated
http://www.siemens.com/safety
This address contains detailed application examples for Safety Integrated.

Safety Integrated
Function Manual, 07/2016, A5E03264275A 7
Table of contents
Preface ................................................................................................................................................... 5
1 Safety information ................................................................................................................................... 9
1.1 Industrial security ....................................................................................................................10
2 Introduction........................................................................................................................................... 13
3 General information about SINAMICS Safety Integrated........................................................................ 15
3.1 Supported functions ................................................................................................................15
3.1.1 SINAMICS G130.....................................................................................................................18
3.1.1.1 Basic functions........................................................................................................................18
3.1.1.2 Extended Functions ................................................................................................................18
3.1.2 SINAMICS G150.....................................................................................................................20
3.1.2.1 Basic functions........................................................................................................................20
3.1.2.2 Extended Functions ................................................................................................................20
3.1.3 SINAMICS S120 chassis ........................................................................................................22
3.1.3.1 Basic functions........................................................................................................................22
3.1.3.2 Extended Functions ................................................................................................................22
3.1.4 SINAMICS S120 Cabinet Modules, booksize format .............................................................24
3.1.4.1 Basic functions........................................................................................................................24
3.1.4.2 Extended Functions ................................................................................................................24
3.1.5 SINAMICS S120 Cabinet Modules, chassis format................................................................26
3.1.5.1 Basic functions........................................................................................................................26
3.1.5.2 Extended Functions ................................................................................................................26
3.1.6 SINAMICS S150 .....................................................................................................................28
3.1.6.1 Basic functions........................................................................................................................28
3.1.6.2 Extended Functions ................................................................................................................28
3.2 Drive monitoring with or without encoder................................................................................29
4 Description of Safety Integrated functions ............................................................................................. 31
4.1 Preconditions for Safety Integrated Basic Functions..............................................................31
4.2 Preconditions for Safety Integrated Extended Functions .......................................................32
5 Controlling the safety functions.............................................................................................................. 33
5.1 Control possibilities .................................................................................................................33
5.2 Control of "STO" and "SS1" via terminal module for option K82 ............................................34
5.2.1 Terminal module for control of "STO" and "SS1" for SINAMICS G150..................................34
5.2.2 Terminal module for control of "STO" and "SS1" for SINAMICS S120 Cabinet Modules ......39
5.2.2.1 General information ................................................................................................................39
5.2.2.2 Use of the K82 option with Control Unit CU320-2 ..................................................................43
5.2.2.3 Use of the K82 option with Control Unit CU320-2 ..................................................................44
5.2.2.4 Wiring......................................................................................................................................44
5.2.3 Terminal module for control of "STO" and "SS1" for SINAMICS S150 ..................................44
5.3 Control of "STO" and "SS1" via terminals on the Control Unit and the Motor/Power
Module ....................................................................................................................................50

Table of contents
Safety Integrated
8Function Manual, 07/2016, A5E03264275A
5.3.1 Simultaneity and tolerance time of the two monitoring channels........................................... 53
5.3.2 Bit pattern test........................................................................................................................ 55
5.3.3 Control of "STO" and "SS1" for SINAMICS G130 ................................................................. 56
5.3.4 Control of "STO" and "SS1" for SINAMICS G150 ................................................................. 62
5.3.5 Control of "STO" and "SS1" for SINAMICS S120 Chassis .................................................... 68
5.3.6 Control of "STO" and "SS1" for SINAMICS S120 Cabinet Modules...................................... 74
5.3.7 Control of "STO" and "SS1" for SINAMICS S150.................................................................. 80
5.4 Activating "SBC" via the Safe Brake Adapter ........................................................................ 86
5.4.1 Activating "SBC" via the Safe Brake Adapter for option K88 (230 V AC).............................. 86
5.4.2 Safe Brake Adapter SBA 230 V AC for SINAMICS G130/SINAMICS S120 Chassis ........... 90
5.5 Control by way of PROFIsafe ................................................................................................ 95
5.6 Control via TM54F.................................................................................................................. 96
5.6.1 Control via TM54F for SINAMICS G130, S120 Chassis ....................................................... 96
5.6.2 Control via option K87 for SINAMICS S120 Cabinet Modules .............................................. 96
5.6.3 Control via K87 for SINAMICS S150 ..................................................................................... 96
5.7 Motion monitoring without selection....................................................................................... 97
6 Commissioning and acceptance test ..................................................................................................... 99
Index ...................................................................................................................................................101

Safety Integrated
Function Manual, 07/2016, A5E03264275A 9
Safety information
1
Safety notices
WARNING
Risk of death if the safety instructions and remaining risks are not carefully observed
If the safety instructions and residual risks are not observed in the associated
documentation, accidents involving severe injuries or death can occur.
•Observe the safety instructions given in the associated documentation.
•When assessing the risk, take into account residual risks.
WARNING
Danger to life or malfunctions of the machine as a result of incorrect or changed parameter
assignment
Machines can malfunction as a result of incorrect or changed parameter assignment, 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).

Safety information
1.1 Industrial security
Safety Integrated
10 Function Manual, 07/2016, A5E03264275A
1.1
Industrial security
Note
Industrial security
Siemens provides products and solutions with industrial security functions that support the
secure operation of plants, solutions, machines, devices, and/or networks. They are
important compon
ents 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 sol
utions, it 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. Any third-party products that may be in use must
also be taken into accoun
t. For more information about industrial security, visit Hotspot-Text
(
http://www.siemens.com/industrialsecurity).
To receive information about product updates on a regular basis, register for ou
r product
newsletter. For more information, visit Hotspot
-Text (https://support.industry.siemens.com).
WARNING
Danger due to unsafe operating states caused by software manipulation
Software manipulations (e.g. viruses, trojans, malware, worms) can cause unsafe operating
states in your system that may lead to death, serious injury, and property damage.
•Update your software regularly.
You will find relevant information and newsletters at this address
(http://www.siemens.com/industrialsecurity).
•Integrate the automation and drive components into a holistic, state-of-the-art industrial
security concept for the plant or machine.
You will find further information at this address (https://support.industry.siemens.com).
•Make sure that you include all installed products into the holistic industrial security
concept.
Note
Industrial Security Configuration Manual
You can
find a Configuration Manual on the topic of Industrial Security at this address
(
https://support.industry.siemens.com/cs/ww/en/view/108862708).

Safety information
1.1 Industrial security
Safety Integrated
Function Manual, 07/2016, A5E03264275A 11
Note
Malfunctions as a result of withdrawing and inserting components
Malfunctions can occur by withdrawing and inserting components that are used for Safety
Integrated without having to exit the fail
-safe state. For example, PROFIsafe communication
is not reestablished after this
event.
•
Withdrawing and inserting components used for Safety Integrated (power units, Sensor
Modules, TM54F) in operation
and
in the deactivated state is
not
permissible. Activating
the components always requires a POWER ON.
Note
Approval of option K82
Only circuits that have been manufactured by the OEM or by certified factories or that have
been installed by the authorized service for option K82, possess an approval. Possible plant
-
side reproductions by non
-certified manufacturers do not possess this approval!
An up
-to-date list of authorized factories is available on request from your local Siemens
office.

Safety information
1.1 Industrial security
Safety Integrated
12 Function Manual, 07/2016, A5E03264275A

Safety Integrated
Function Manual, 07/2016, A5E03264275A 13
Introduction
2
This document is a supplement to the "SINAMICS S120 Safety Integrated Function Manual"
which serves as the basis for the functional scope of the Safety Integrated functions.
The "SINAMICS S120 Safety Integrated Function Manual" is available on the Internet at the
following address (https://support.industry.siemens.com/cs/ww/en/ps/13231/man).
This document contains additional information on the use of the Safety Integrated functions
with the following SINAMICS converters:
●SINAMICS G130
●SINAMICS G150
●SINAMICS S120 Chassis
●SINAMICS S120 Cabinet Modules
●SINAMICS S150

Introduction
Safety Integrated
14 Function Manual, 07/2016, A5E03264275A

Safety Integrated
Function Manual, 07/2016, A5E03264275A 15
General information about SINAMICS Safety
Integrated
3
3.1
Supported functions
All of the Safety Integrated functions available under SINAMICS are listed in this section.
SINAMICS makes a distinction between Safety Integrated Basic Functions and Safety
Integrated Extended Functions.
The safety functions listed here are in conformance with:
●Safety Integrity Level (SIL) 2 according to IEC 61508
●Category 3 according to DIN EN ISO 13849-1
●Performance Level (PL) d according to DIN EN ISO 13849-1
The safety functions correspond to the functions according to DIN EN 61800-5-2 (under the
assumption that they are defined there).
The following Safety Integrated functions (SI functions) are available:
●
Safety Integrated Basic Functions
These functions are part of the standard scope of the drive and can be used without
requiring an additional license. These functions are always available, and do not require
an encoder and/or do not place any special requirements on the encoder used.
–Safe Torque Off (STO)
Safe Torque Off is a safety function to avoid unexpected startup in accordance with
EN 60204-1. STO prevents the supply of energy to the motor which can generate a
torque and corresponds to Stop Category 0.
–Safe Stop 1 (SS1, time-controlled)
Safe Stop 1 is based on the "Safe Torque Off" function. This means that a Category 1
stop according to EN 60204-1 can be implemented.
–Safe Brake Control (SBC)
Safe Brake Control safely controls a holding brake.1)

General information about SINAMICS Safety Integrated
3.1 Supported functions
Safety Integrated
16 Function Manual, 07/2016, A5E03264275A
●
Safety Integrated Extended Functions
These functions require an additional safety license. Extended Functions with encoder
require an encoder with safety capability.
–Safe Torque Off (STO)
Safe Torque Off is a safety function that prevents the drive from restarting
unexpectedly according to EN- 60204-1.
–Safe Stop 1 (SS1, time- and acceleration-controlled)
Safe Stop 1 is based on the "Safe Torque Off" function. This means that a Category 1
stop according to EN 60204-1 can be implemented.
–Safe Brake Control (SBC)
Safe Brake Control safely controls a holding brake.1)
–Safe Operating Stop (SOS)
Safe Operating Stop protects against unintentional movement. The drive is in closed-
loop control mode and is not disconnected from the power supply.
–Safe Stop 2 (SS2)
Safe Stop 2 safely brakes the motor with a subsequent transition into the "Safe
Operating Stop" state (SOS). This means that a Category 2 stop according to EN
60204-1 can be implemented.
–Safely-Limited Speed (SLS)
Safely Limited Speed monitors that the drive does not exceed a preset speed/velocity
limit.
–Safe Speed Monitor (SSM)
Safe Speed Monitor safely identifies when a speed limit is undershot in both directions
of motion, e.g. to identify zero speed. A fail-safe output signal is available for further
processing.
–Safe Direction (SDI)
Safe Direction is used to safely monitor the direction of motion.
–Safely-Limited Position (SLP)
Safely-Limited Position ensures that a freely definable traversing range is not left.
–Transferring safe position values (SP)
The "Transfer safe position values (SP)" function enables you to transfer a safe
position to a higher-level controller via PROFIsafe.
–Safe gearbox stage switchover
The "Safe gearbox stage switchover" function facilitates reliable switching between
different gearbox stages. The switchover is only possible via PROFIsafe.
–Safe Brake Test (SBT)
The diagnostic function "Safe Brake Test" function (SBT) checks the required holding
torque of a brake (operating or holding brake).
1) Note on Power/Motor Modules with chassis format:
For chassis format, SBC is only supported by Power/Motor Modules with article number
...3 or higher. A Safe Brake Adapter is also required for this design.

General information about SINAMICS Safety Integrated
3.1 Supported functions
Safety Integrated
Function Manual, 07/2016, A5E03264275A 17
Note
Parallel use of Safety Integrated Functions
All Safety Integrated Functions can be used simultaneously.
Exce
ption:
If SOS and SLS are activated simultaneously, SOS has higher priority and overrides the SLS
reaction.
Invalid operating modes for Safety Integrated Extended Functions "without encoder"
●Current controller clock cycles 31.25 µs and 62.5 μs (for Double Motor Modules with two
configured safety drives) are not permissible.
●For the independent setting of current controller clock cycle and pulse frequency in
conjunction with Safety Integrated "without encoder", the following system clock cycles
are not permissible:
–Double Motor Modules <125 μs
–All other components: <62.5 μs
–p9589 must be set = 3300 to allow the current controller clock cycle and pulse
frequency to be independently set.
●For chassis format devices, the following also applies:
–For chassis format devices, operation without encoder is only permissible for induction
motors, however
not
for synchronous motors.
–No operation involving parallel connections
–Optimized pulse patterns cannot be selected for SIMOTICS FD
–Only using parameter p1810 = factory setting, this includes:
- No wobbling
- No fine setting of the pulse frequency
●No "shaft generator" functionality
●Induction motors up to a maximum of 1000 kW; for extremely large machines, it is
necessary to adapt parameter p9585

General information about SINAMICS Safety Integrated
3.1 Supported functions
Safety Integrated
18 Function Manual, 07/2016, A5E03264275A
3.1.1
SINAMICS G130
3.1.1.1
Basic functions
Requirements
The Safety Integrated Basic Functions are part of the standard scope of the drive and can be
used without an additional license.
Supported Safety Integrated Basic Functions
Safety function
Abbreviation
Safe Torque Off
STO
Yes
Safe Stop 1
SS1
Yes
Safe Brake Control
SBC
Using Safe Brake Adapter
Control options
●Control Unit and terminal (on the power unit)
●PROFIsafe and terminal (on the power unit)
3.1.1.2
Extended Functions
Requirements
●Option
F01
: Safety license for one axis
Note
The term "axes" should also be interpreted
as "drives".
●For Extended Functions with encoder:
Two SMC30 Sensor Modules (HTL/TTL encoders)

General information about SINAMICS Safety Integrated
3.1 Supported functions
Safety Integrated
Function Manual, 07/2016, A5E03264275A 19
Supported Safety Integrated Extended Functions
Safety function
Abbreviation
With encoder 1)
Without encoder
Safe Torque Off
STO
Yes
Yes
2)
Safe Stop 1
SS1
Yes Yes2)
Safe Brake Control
SBC
Yes
Yes
2)
Safe Operating Stop
SOS
Yes
No
Safe Stop 2
SS2
Yes
No
Safely-Limited Speed
SLS
Yes
Yes
2)
Safe Speed Monitor
SSM
Yes
Yes
2)
Safe Direction
SDI
Yes
Yes
2)
Safely-Limited Position
SLP
Yes
No
Safe referencing/homing
SR
Yes
No
Transferring safe position values
SP
Yes
Yes
2)
Safe Brake Test
SBT
Yes
No
Safe Acceleration Monitor
SAM
Yes
Yes
2)
Safe Brake Ramp
SBR
No
Yes
2)
Safe gearbox stage switchover
--
Yes
No
1)
Two SMC30 Sensor Modules (HTL/TTL encoders)
2)
The use of this safety function without an encoder is permitted only for induction motors.
3) Using Safe Brake Adapter.
Control options
●Terminal Module TM54F
●PROFIsafe

General information about SINAMICS Safety Integrated
3.1 Supported functions
Safety Integrated
20 Function Manual, 07/2016, A5E03264275A
3.1.2
SINAMICS G150
3.1.2.1
Basic functions
Requirements
The Safety Integrated Basic Functions are part of the standard scope of the drive and can be
used without an additional license.
Supported Safety Integrated Basic Functions
Safety function
Abbreviation
Safe Torque Off
STO
Yes
Safe Stop 1
SS1
Yes
Safe Brake Control
SBC
Via option K88
Control options
●With option
K82
: Terminal Module for controlling safety functions "STO" and "SS1"
●Control Unit and terminal (on the power unit)
●PROFIsafe and terminal (on the power unit)
3.1.2.2
Extended Functions
Requirements
●Option
K01
: Safety license for one axis
Note
The term "axes" should also be interpreted as "drives".
●For Extended Functions with encoder:
Options
K50 and K52
: Two SMC30 Sensor Modules (HTL/TTL encoders)