Siemens SINUMERIK 840D sl Parts list manual

Valid for
Control
SINUMERIK 840D sl
SINUMERIK 840D sl (export version)
Drive
SINAMICS S120
Software version
CNC Software 4.7 SP2
SINUMERIK Operate 4.7
Edition 10/15
SINUMERIK Safety Integrated
SINUMERIK 840D sl/
SINAMICS S120
Function ManualFunction ManualFunction ManualFunction ManualFunction ManualFunction ManualFunction ManualFunction ManualFunction ManualFunction ManualFunction ManualFunction ManualFunction ManualFunction ManualFunction Manual
Regulations and Standards 1
Brief Description 2
System Features 3
Safety Functions
Integrated in the Drive 4
Basic Information on
Safety Functions Integrated
in the System/Drive 5
System/Drive--
Based Safety Functions 6
Sensor/Actuator
Connection 7
Description of Data 8
Commissioning 9
Diagnostics 10
Interaction with
other Functions 11
Appendix A
Index I

SINUMERIKdocumentation
Printing history
Brief details of this edition and previous editions are listed below.
The status of each edition is shown by the code in the ”Remarks” column.
Status code in the ”Remarks” column:
ANew documentation......
BUnrevised reprint with new Order No......
CRevised edition with new status......If factual changes have been made on the page since
the last edition, this is indicated by a
new edition coding in the header on that page.
Edition Order No. Remarks
03/06 6FC5 397--4BP10--0BA0 A
03/07 6FC5 397--4BP10--1BA0 C
02/08 6FC5 397--4BP10--2BA0 C
05/09 6FC5 397--4BP10--3BA0 C
03/10 6FC5 397--4BP10--4BA0 C
02/12 6FC5 397--4BP40--3BA0 C
02/12 6FC5 397--4BP41--3BA0 C
03/13 6FC5 397--4BP40--4BA0 C
10/15 6FC5 397--4BP40--5BA3 C
Trademarks
All product designations may be trademarks or product names of Siemens AG or supplier
companies whose use by third parties for their own purposes could violate the rights of the
owners.
Siemens AG 2006--2015
We have checked that the contents of this document correspond to
the hardware and software described. Differences, however, cannot
be excluded. The information given in this publication is reviewed at
regular intervals and any corrections that might be necessary are
made in the subsequent printings. We welcome suggestions for
improvement.
Subject to change without prior notice.
Siemens--Aktiengesellschaft
Printed in the Federal Republic of Germany Siemens--Aktiengesellschaft
3ls

AChapterPreface
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Preface
Legal information
Warning notice system
This manual contains information that you must observe in order to ensure your
own personal safety as well as to avoid material damage. The notices referring to
your personal safety are highlighted in the manual by a safety alert symbol (trian-
gular symbol), notices referring only to equipment damage have no safety alert
symbol. Depending on the hazard level, warnings are indicated in a descending
order as follows.
!Danger
indicates that death or severe personal injury will result if proper precautions are
not taken.
!Warning
indicates that death or severe personal injury may result if proper precautions are
not taken.
!Caution
with a warning triangle indicates that minor personal injury can result if proper
precautions are not taken.
Notice
indicates that material damage can result if proper precautions are not taken.
If more than one level of danger is simultaneously applicable, the warning notice
for the highest level is used. A warning note in a warning triangle indicating possi-
ble personal injury may also include a warning note relating to material damage.

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Qualified personnel
The product/system described in this documentation may be operated only by per-
sonnel qualified for the specific task in accordance with the relevant documenta-
tion, in particular its warning notices and safety instructions. Because of their trai-
ning and experience, qualified personnel can recognize any risks involved with
handling this product/system and avoid any possible dangers.
Proper use of Siemens products
Note the following:
!Warning
Siemens equipment may only be used for the applications indicated in the catalog
and in the relevant technical documentation. If third--party products and
components are used, they must be recommended or approved by Siemens. To
ensure trouble--free and safe operation of the products, they must be appropriately
transported, stored, assembled, installed, commissioned, operated and
maintained. The permissible ambient conditions must be complied with. The notes
in the associated documentation must be complied with.
SINUMERIK documentation
The SINUMERIK documentation is organized in the following categories:
SGeneral documentation
SUser documentation
SManufacturer/service documentation
Additional information
Information on the following topics is available at the link (www.siemens.com/mo-
tioncontrol/docu):
SOrdering documentation/overview of documentation
SAdditional links to download documents
SUsing documentation online (finding and searching in manuals/information)
Please send any questions about the technical documentation (e.g. suggestions
for improvement, corrections) to the following address:
[e-mail]

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My Documentation Manager (MDM)
Under the following link you will find information to individually compile OEM--speci-
fic machine documentation based on the Siemens content:
www.siemens.com/mdm
Training
For information about the range of training courses, refer to:
Swww.siemens.com/sitrain
SITRAIN – training courses from Siemens for products, systems and solutions
in automation technology
Swww.siemens.com/sinutrain
SinuTrain -- training software for SINUMERIK
FAQs
You can find Frequently Asked Questions in the Service&Support pages under
Product Support.
www.siemens.com/automation/service&support
SINUMERIK
You can find information on SINUMERIK under the following link:
www.siemens.com/sinumerik
Target group
This documentation is intended for manufacturers/end users of machine tools and
production machines who use SINUMERIK 840D sl and SINAMICS S120 and the
integrated safety functions (SINUMERIK Safety Integrated R)
Benefits
With the Function Manual, the target group can develop, write, test and debug pro-
grams and software user interfaces.

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Standard scope
This documentation describes the functionality of the standard scope. Additions or
revisions made by the machine manufacturer are documented by the machine ma-
nufacturer.
Other functions not described in this documentation might be executable in the
control system. This does not, however, represent an obligation to supply such
functions with a new controller or when servicing.
For the sake of simplicity, this documentation does not contain all detailed informa-
tion about all types of the product and cannot cover every conceivable case of in-
stallation, operation, or maintenance.
Technical support
You can find telephone numbers for other countries for technical support in the In-
ternet at ”Contact” (www.siemens.com/automation/service&support).
CompactFlash cards for users:
SSINUMERIK CNC supports the file systems FAT16 and FAT32 for Compact-
Flash cards. You may need to format the memory card if you want to use a me-
mory card from another device or if you want to ensure the compatibility of the
memory card with the SINUMERIK. However, formatting the memory card will
permanently delete all data on it.
SDo not remove the memory card while it is being accessed. This can lead to
damage of the memory card and the SINUMERIK as well as the data on the
memory card.
SIf you cannot use a memory card with the SINUMERIK, it is probably because
the memory card is not formatted for the control system (e.g. Ext3 Linux file
system), the memory card file system is faulty, or it is the wrong type of me-
mory card.
SInsert the memory card carefully with the correct orientation into the memory
card slot (observe indicators such as arrow or similar). This way you avoid me-
chanical damage to the memory card or the device.
SOnly use memory cards that have been approved by Siemens for use with SI-
NUMERIK. Even though the SINUMERIK keeps to the general industry stan-
dards for memory cards, it is possible that memory cards from some manufac-
turers will not function perfectly in this device or are not completely compatible
with it (you can obtain information on compatibility from the memory card manu-
facturer or supplier).
SThe ”CompactFlash Card5000 Industrial Grade” from SanDisk has been ap-
proved for SINUMERIK (Order Number 6FC5313--5AG00.0AA0).

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Standard scope
The main areas covered by this description of functions are as follows:
SRegulations and standards
SBrief description
SSystem Features
SSafety Functions integrated in the drive
SBasics on the safety functions integrated in the system/drive
SSafety functions integrated in the system/drive
SConnecting Sensors/Actuators
SData Description
SCommissioning
SDiagnostics
SInteraction with other functions
Separate documents are available for the user--oriented activities. These include,
for example, the creation of part programs and operation of the control systems.
Separate information is also available for operations that the machine tool manu-
facturer must carry out. These include, for example, configuring/engineering, instal-
lation and programming the PLC.
Notes on how to use this manual
The following help functions are available with this description of functions:
SOverall table of contents
SAppendix with abbreviations and references, glossary
SIndex
If you require information about a certain term, please look for this particular term
under the chapter Index in the Appendix. Both the chapter number and the page
number, where you will find this particular information are listed there.
Documentation Edition 10/15
Note
The documentation Edition 10/15 describes the scope of functions for the following
products and software release:
SINUMERIK 840D sl with software release 4.7 SP2

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Notes
Note
This symbol always appears in the document where further information is
provided.
Test certificates
The Safety Integrated functions of the SINUMERIK are generally certified by inde-
pendent institutes. An up--to--date list of certified components is available on re-
quest from your local Siemens office. If you have any questions relating to certi-
fications that have not been completed, please ask your Siemens contact.

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Content
1 Regulations and standards 1-15..............................................
1.1 General information 1-15..............................................
1.1.1 Objective 1-15.......................................................
1.1.2 Functional safety 1-16................................................
1.2 Safety of machinery in Europe 1-16....................................
1.2.1 Machinery directive (2006/42/EC) 1-17.................................
1.2.2 Harmonized European standards 1-17..................................
1.2.3 Standards for implementing safety--related controls 1-19..................
1.2.4 EN ISO 13849--1 1-20................................................
1.2.5 EN 62061 1-21......................................................
1.2.6 Series of standards EN 61508 (VDE 0803) 1-23.........................
1.2.7 EN 60204--1 1-24....................................................
1.2.8 EN 61800--5--2 1-24..................................................
1.2.9 Risk analysis/assessment 1-25........................................
1.2.10 Risk minimization 1-27................................................
1.2.11 Residual risk 1-27....................................................
1.3 Machine safety in the USA 1-28.......................................
1.3.1 Minimum requirements of the OSHA 1-28...............................
1.3.2 NRTL Listing 1-29....................................................
1.3.3 NFPA 79 1-29.......................................................
1.3.4 ANSI B11 1-30......................................................
1.4 Machine safety in Japan 1-31..........................................
1.5 Equipment regulations 1-31...........................................
1.6 Other safety--related issues 1-32.......................................
1.6.1 Information sheets from the various regulatory bodies 1-32................
1.6.2 Additional references 1-32............................................
2 Brief description 2-33.......................................................
2.1 Control/drive system 2-33.............................................
2.2 Safety technology integrated in the system 2-35.........................
2.2.1 Overview of the safety functions integrated in the system 2-36.............
2.3 Safety technology integrated in the drive 2-38...........................
2.3.1 Overview of the safety functions integrated in the drive 2-39...............
2.4 Comparison of the function names 2-40.................................
3 System Features 3-41.......................................................
3.1 System requirements 3-41............................................
3.2 Latest information 3-43...............................................
3.3 Certifications 3-44...................................................
3.4 Probability of failure 3-44..............................................
3.5 Safety information & instructions and residual risks 3-45..................
3.5.1 General residual risks for PDS (Power Drive Systems) 3-45...............
3.5.2 Additional safety information & instructions and residual risks for
Safety Integrated 3-47................................................

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4 Safety Functions integrated in the drive 4-51..................................
4.1 General information about SINAMICS Safety Integrated 4-51..............
4.1.1 Explanations and terminology 4-51.....................................
4.1.2 Supported functions 4-53.............................................
4.1.3 Supported functions: HLA module 4-53.................................
4.1.4 Parameter, checksum, version, password 4-54...........................
4.1.5 Forced checking procedure 4-56.......................................
4.2 Safety instructions 4-58...............................................
4.3 Safe Torque Off (STO) 4-60...........................................
4.4 Safe Stop 1 (SS1, time controlled) 4-63.................................
4.4.1 SS1 (time--controlled) with OFF3 4-63..................................
4.4.2 SS1 (time--controlled) with external stop 4-65............................
4.4.3 Overview of important parameters
(see Chapter 8.2.2 ”Description of parameters”) 4-65.....................
4.5 Safe Brake Control (SBC) 4-66........................................
4.6 Control via terminals on the Control Unit and the power unit 4-69...........
4.6.1 Simultaneity and tolerance time of the two monitoring channels 4-71........
4.6.2 Bit pattern test 4-72..................................................
4.7 Commissioning the STO, SBC and SS1 functions 4-74...................
4.7.1 General information about commissioning safety functions 4-74............
4.7.2 Sequence when commissioning STO, SBC and SS1 4-76.................
4.7.3 Safety faults 4-80....................................................
4.8 Acceptance test and acceptance report 4-82............................
4.9 Overview of parameters and function diagrams 4-82......................
4.10 PLC drives 4-84.....................................................
5 Basics on the safety functions integrated in the system/drive 5-85..............
5.1 Monitoring cycle 5-85.................................................
5.2 Crosswise data comparison (CDC) 5-87................................
5.3 Forced checking procedure 5-88.......................................
5.4 Actual value conditioning 5-90.........................................
5.4.1 Encoder types 5-90..................................................
5.4.2 Encoder adjustment, calibrating the axes 5-95...........................
5.4.3 Axis states 5-96.....................................................
5.4.4 User agreement 5-99.................................................
5.4.5 Taking into account selector gearboxes 5-101.............................
5.4.6 Actual value synchronization (slip for 2--encoder systems) 5-103............
5.4.7 Encoder limit frequency 5-104..........................................
5.5 Enabling the safety--related functions 5-105..............................
5.6 Switching the system on/off 5-107.......................................
6 Safety functions integrated in the system/drive 6-109...........................
6.1 Safe standstill (SH) 6-109..............................................
6.1.1 Switch--off signal paths 6-112...........................................
6.1.2 Testing the switch--off signal paths 6-113.................................

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6.2 Safe operating stop (SBH) 6-115........................................
6.2.1 Selecting/deselecting the safe operating stop 6-116.......................
6.2.2 Effects when the limit is exceeded for SBH 6-119.........................
6.3 Safe Stops A--F 6-122.................................................
6.3.1 General information 6-122..............................................
6.3.2 Description of STOP A 6-129...........................................
6.3.3 Description of STOP B 6-132...........................................
6.3.4 Description of STOP C 6-133...........................................
6.3.5 Braking behavior for STOP B/C 6-135...................................
6.3.6 Description of STOP D 6-135...........................................
6.3.7 Description of STOP E 6-138...........................................
6.3.8 Description of STOP F 6-140...........................................
6.3.9 Forced checking procedure of the external STOPs 6-144...................
6.3.10 Canceling stopping delay times 6-145....................................
6.4 Safe acceleration monitoring (SBR) 6-147................................
6.5 Safely reduced speed (SG) 6-151.......................................
6.5.1 Speed monitoring, encoder limit frequency 6-152..........................
6.5.2 Selecting/deselecting safely reduced speed 6-153.........................
6.5.3 Effects when the limit value is exceeded for SG 6-156.....................
6.5.4 Override for safely reduced speed 6-159.................................
6.5.5 Example: Override for safely reduced speed 6-162........................
6.6 Safe speed range identification ”n<nx” 6-164.............................
6.6.1 Base function ”n<nx” 6-164.............................................
6.6.2 Function ”Synchronization, hysteresis and filtering n<nx” 6-166.............
6.7 Safe software limit switches (SE) 6-171..................................
6.7.1 Effects when an SE responds 6-172.....................................
6.8 Safety software cams and safety cam track (SN) 6-175....................
6.8.1 Safe software cams (4 cam pairs) 6-176.................................
6.8.2 Safe cam track 6-180..................................................
7 Connecting Sensors/Actuators 7-189..........................................
7.1 Safety--relevant input/output signals 7-189...............................
7.1.1 Overview of the SGEs/SGAs and their structure 7-189.....................
7.1.2 Forced checking procedure of SPL signals 7-195..........................
7.1.3 Connecting sensors -- actuators using the 3--terminal concept 7-197.........
7.1.4 Sensor connection using the 4--terminal concept 7-200.....................
7.1.5 Multiple distribution and multiple interlocking 7-201........................
7.2 Connecting I/O via PROFIsafe 7-204....................................
7.2.1 Function description 7-204.............................................
7.2.2 System structure 7-206................................................
7.2.3 Configuring and parameterizing the PROFIsafe I/O 7-208..................
7.2.4 Parameterizing the F master (NCK) 7-215................................
7.2.5 Parameterizing the PROFIsafe communication (NCK) 7-215................
7.2.6 parameterizing the SPL--SGE interface 7-218.............................
7.2.7 Parameterizing the SPL--SGA interface 7-223............................
7.2.8 Module type (NCK) 7-227..............................................
7.2.9 Parameterizing the F master (PLC) 7-227................................
7.2.10 Response times 7-228.................................................
7.2.11 Functionality of the SPL input/output data 7-231...........................
7.2.12 Functional secondary conditions 7-232...................................

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7.2.13 PROFIsafe communication behavior when system errors occur 7-233........
7.3 Modular PROFIsafe I/O interface 7-234..................................
7.3.1 PROFIsafe input modules 7-234........................................
7.3.2 PROFIsafe output modules 7-237.......................................
7.4 Safety--related CPU--CPU communication (F_DP communication) 7-239.....
7.4.1 Configuring and parameterizing the F_DP communication 7-242............
7.4.2 Sender F_SENDDP 7-245.............................................
7.4.3 Receiver F_RECVDP 7-256............................................
7.4.4 Mapping the SIMATIC blocks 7-269.....................................
7.4.5 Parameterizing the PLC 7-271..........................................
7.4.6 Clock cycle setting of the F_DP communication 7-272.....................
7.4.7 Response times of the F_DP communication 7-272........................
7.4.8 Boot behavior of the F_DP communication 7-275..........................
7.4.9 Communication error after the control boots and active SPL processing 7-277
7.4.10 Communication error when the control boots before SPL
processing starts 7-280................................................
7.4.11 Acknowledging a communication error with channel_1 reset 7-280...........
7.4.12 F_DP communication for a system error 7-281............................
7.4.13 NCK/PLC data exchange 7-283.........................................
7.4.14 Effects on the SPL 7-283..............................................
7.4.15 Functionality of the SPL input/output data 7-284...........................
7.4.16 Boundary conditions 7-285.............................................
7.5 Safe programmable logic (SPL) 7-286...................................
7.5.1 Fundamentals 7-286..................................................
7.5.2 Synchronized actions for Safety Integrated 7-291.........................
7.5.3 User configurations 7-292..............................................
7.5.4 NCK--SPL program 7-293..............................................
7.5.5 Starting the SPL 7-295................................................
7.5.6 Language scope for SAFE.SPF 7-301...................................
7.5.7 Diagnostics/commissioning 7-307.......................................
7.5.8 Safe software relay 7-308..............................................
7.5.9 System variables for SINUMERIK 840D sl 7-316..........................
7.5.10 Behavior after power on / mode change / reset 7-321......................
7.5.11 SPL data on the PLC side 7-321........................................
7.5.12 Direct communications between NCK and PLC--SPL 7-323.................
7.6 Safe Brake Test (SBT) 7-324...........................................
7.6.1 Applications 7-324....................................................
7.6.2 Parameterization 7-325................................................
7.6.3 Torque limits 7-329....................................................
7.6.4 Traversing direction for the brake test 7-330..............................
7.6.5 Brake control for SINUMERIK 840D sl 7-330.............................
7.6.6 Sequence 7-331......................................................
7.6.7 Description of FB11 7-334..............................................
7.6.8 Application example 7-336.............................................
7.6.9 Boundary conditions 7-343.............................................
7.7 Safety Info Channel and Safety Control Channel 7-344.....................
8 Data Description 8-347........................................................
8.1 Machine data for SINUMERIK 840D sl 8-347.............................
8.1.1 Overview of the machine data 8-347.....................................
8.1.2 Description of machine data 8-354......................................

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8.2 Parameters for SINAMICS S120 8-430..................................
8.2.1 Parameter overview 8-431.............................................
8.2.2 Description of parameters 8-437........................................
8.3 NCK--MD, that are read from Safety Integrated 8-494......................
8.4 Drive parameters that are read from the NCK--SI 8-495....................
8.5 Protection checksum 8-497............................................
8.6 Interface signals 8-498................................................
8.6.1 Interface signals for SINUMERIK 840D sl 8-499...........................
8.6.2 Description of the interface signal 8-500..................................
8.6.3 PLC data block (DB 18) 8-510..........................................
8.6.4 Axis signals: Safety Control Channel (SCC) / Safety Info Channel (SIC) 8-528
8.7 System variables 8-530................................................
8.7.1 System variables for SINUMERIK 840D sl 8-530..........................
8.7.2 Description of the system variables 8-536................................
9 Commissioning 9-549........................................................
9.1 Pictures of the user interface and softkeys 9-550..........................
9.2 Procedure when commissioning the drive for the first time 9-562............
9.3 Series commissioning 9-568............................................
9.4 Changing machine data 9-570..........................................
9.5 Acceptance test 9-572.................................................
9.5.1 General information 9-572..............................................
9.5.2 Conventional acceptance test 9-580.....................................
9.5.3 Acceptance test support 9-583..........................................
9.6 Replacing a motor or encoder 9-588.....................................
10 Diagnostics 10-597.........................................................
10.1 Troubleshooting procedure 10-597....................................
10.1.1 Service displays 10-598..............................................
10.1.2 Safety Integrated global checksums 10-614............................
10.1.3 Integrating safety SPL user alarms 10-618.............................
10.1.4 Trace bit graphics for Safety Integrated 10-624..........................
10.2 NCK safety alarms for Sinumerik 840D sl 10-633........................
10.3 Safety messages for SINAMICS S120 10-741..........................
10.3.1 General information 10-741...........................................
10.3.2 List of faults and alarms 10-744.......................................
10.4 Safety PLC alarms 10-794...........................................
10.5 Reducing the number of alarms 10-796................................
10.5.1 Alarm suppression 10-796............................................
10.5.2 Assigning priorities to alarms 10-798...................................
11 Interaction with other functions 11-801......................................
11.1 Limiting the speed setpoint 11-801....................................
11.2 Setpoint exchange 11-802............................................
11.3 Measuring system changeover 11-805.................................

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11.4 Gantry axes 11-805.................................................
11.5 Parking axis 11-805.................................................
11.6 Incremental encoder functionality 11-806...............................
11.7 OEM applications 11-807............................................
11.8 NCU link 11-808....................................................
11.9 Behavior of the Sim--NCK systems 11-808.............................
11.10 Behavior of Safety Integrated when the communication fails 11-810........
11.10.1 Delayed pulse cancellation in the event of communication failure 11-810...
A Appendix A-815..............................................................
A.1 Customer Support A-815...............................................
A.2 References A-817.....................................................
A.3 Abbreviations A-818...................................................
A.4 Terms A-823..........................................................
Index I-825..................................................................

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Regulations and standards
1.1 General information
1.1.1 Objective
Manufacturers and operators of technical equipment and products are responsible
in minimizing the risk from plants, machines and other technical equipment corres-
ponding to state--of--the--art technology. Regulations and standards are essential
documents that define the minimum requirements to minimize risks. By maintaining
these minimum requirements, the company erecting a plant or a manufacturer of a
machine or a piece of equipment can prove that they have fulfilled their obligation
to exercise care and diligence.
Safety systems are designed to minimize potential hazards for both people and the
environment by means of suitable technical equipment, without restricting industrial
production and the use of machines more than necessary. Protection of man and
the environment is to be standardized using internationally harmonized safety stan-
dards. Further, unfair competition due to different local requirements is to be avoi-
ded.
There are different concepts and requirements in the various regions and countries
of the world when it comes to ensuring the appropriate degree of safety. The legis-
lation and the requirements of how and when proof is to be given and whether
there is an adequate level of safety are just as different as the assignment of
responsibilities.
For manufacturers of machines and companies that erect plants and systems it is
important that the local legislation and regulations always apply for that country
where the machine or plant is being operated. For instance, the control system of a
machine, that is to be used in the US, must fulfill the local US requirements even if
the machine manufacturer (OEM) is based in the European Economic Area (EEA).
1

Regulations and standards
1.2 Safety of machinery in Europe
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SINUMERIK 840D sl/SINAMICS S120 SINUMERIK Safety Integrated (FBSI sl) -- 10.2015 Edition
1.1.2 Functional safety
From the perspective of the object to be protected, safety is indivisible. The causes
of hazards and therefore also the technical measures to avoid them can vary signi-
ficantly. This is the reason that a differentiation is made between different types of
safety -- e.g. by specifying the cause of possible hazards. ”Functional safety” is
involved if safety depends on the correct function.
In order to achieve the functional safety of a machine or plant, it is necessary that
the safety--related parts of the protection and control devices function correctly.
And not only this, when faults develop, they must behave so that either the plant
remains in a safe state or it is brought into a safe state.
In this case, it is necessary to use specially qualified technology that fulfills the re-
quirements described in the relevant standards. The requirements to achieve func-
tional safety are based on the following basic goals:
SAvoiding systematic faults,
SControlling systematic faults,
SControlling random faults or failures.
The level of the functional safety achieved is expressed using different terms in the
standards. In EN 61508, EN 62061, EN 61800--5--2: ”Safety Integrity Level” (SIL)
and EN ISO 13849--1 ”Performance Level” (PL).
1.2 Safety of machinery in Europe
The EU Directives that apply to the implementation of products are based on Arti-
cle 95 of the EU contract, which regulates the free exchange of goods. These are
based on a new global concept (”new approach”, ”global approach”):
SEC directives only specify general protection goals and define basic safety re-
quirements.
STechnical details can be defined by means of standards by Standards Associa-
tions that have the appropriate mandate from the commission of the European
Parliament and Council (CEN, CENELEC). These standards are harmonized in
line with a specific directive and listed in the official journal of the commission of
the European Parliament and Council. Legislation does not specify that certain
standards have to be complied with. When the harmonized standards are com-
plied with, then it can be assumed that all of the applicable safety requirements
and specifications of the directives involved are fulfilled.
In order to market or sell a product in the European Economic Area (EEA), this
product must fulfill the protective goals and requirements of all of the applicable EC
directives. For machines, in addition to the machinery directive, these can also inc-
lude e.g. the EMC directive, the noise protection directive, the guideline for explo-
sion protection, the low--voltage directive.

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1.2.1 Machinery directive (2006/42/EC)
With the introduction of a European Economic Area, a decision was made that the
domestic standards and regulations of all of the EEA Member States – that are
involved with the technical implementation of machines -- would be harmonized.
This means that the machinery directive had to be implemented -- as an internal
market directive -- as far as the content was concerned -- in the domestic legisla-
tion of the individual Member States. For the Machinery Directive, this was realized
with the aim of achieving standard safety objectives and, in turn, removing techni-
cal trade barriers. Corresponding to its definition ”a machine is an assembly of lin-
ked parts or components -- at least one of which moves”, this directive is extremely
extensive. With the revised version from 2006, the range of applications has been
expanded to include, among other things, ”Logic units for safety functions”.
The machinery directive involves the implementation of machines. The basic safety
and health requirements specified in Annex I of the Directive must be fulfilled for
the safety of machines.
The protective goals must be responsibly implemented in order to fulfill the require-
ments for conformity with the directive.
The manufacturer of a machine must provide proof that his machine is in com-
pliance with the basic requirements. This verification is facilitated by means of har-
monized standards.
1.2.2 Harmonized European standards
The two Standards Organizations CEN (Comité Européen de Normalisation) and
CENELEC (Comité Européen de Normalisation Électrotechnique), mandated by
the EU Commission, drew--up harmonized European standards in order to preci-
sely specify the requirements of the EC directives for a specific product. These
standards (EN standards) are published in the official journal of the commission of
the European Parliament and Council and must be included without revision in do-
mestic standards. They are designed to fulfill basic health and safety requirements
as well as the protective goals specified in Annex I of the Machinery Directive.
When the harmonized standards are complied with, then there is an ”automatic
assumption” that the directive is fulfilled. This means that the manufacturer may
then assume that he has complied with the safety aspects of the directive under
the assumption that they are also handled in that particular standard. However, not
every European Standard is harmonized in this sense. Key here is the listing in the
official journal of the commission of the European Parliament and Council.

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European standards relating to the safety of machines are structured in a hierarchi-
cal manner as follows:
SA standards (basic standards)
SB standards (group standards)
SC standards (product standards)
Type A standards/basic standards
A standards include basic terminology and definitions relating to all types of
machine.
A standards are aimed primarily at the bodies responsible for setting the B and C
standards. The measures specified here for minimizing risk, however, may also be
useful for manufacturers if no applicable C standards have been defined.
Type B standards/group standards
B standards cover all safety--related standards for various different machine types.
B standards are also aimed primarily at the bodies responsible for setting C stan-
dards. They can also be useful for manufacturers during the machine design and
construction phases, however, if no applicable C standards have been defined.
A further sub--division has been made for B standards, and more precisely in:
-- Type B1 standards for higher--level safety aspects, e.g. basic ergonomic
principles, safety clearances from hazards, minimum clearances to avoid
crushing parts of the body.
-- Type B2 standards for protective safety devices are defined for various
machine types – e.g. Emergency Stop devices, two--hand operating circuits,
interlocking elements, contactless protective devices, safety--related parts of
controls.
Type C standards/product standards
C standards are standards for specific products – for instance, machine tools,
woodworking machines, elevators, packaging machines, printing machines etc.
Product standards list requirements for specific machines. The requirements can,
under certain circumstances, deviate from the basic and group standards. Type
C/product standards have the highest priority for machine manufacturers The
machine manufacturer can then assume that it fulfills the basic requirements of
Attachment I of the machinery directive (automatic presumption of compliance).
If no product standard has been defined for a particular machine, type B standards
can be applied when the machine is being constructed.
A complete list of the standards and the mandated draft standards are available on
the Internet at the following address:
http://www.newapproach.org/
Recommendation: Due to the rapid pace of technical development and the asso-
ciated changes in machine concepts, the standards (and C standards in particular)
should be checked to ensure that they are up to date. Where appropriate, note that
the application of a particular standard may not be mandatory provided that all the
safety requirements of the applicable EC directive are fulfilled.

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1.2.3 Standards for implementing safety--related controls
If the functional safety of the machine depends on control functions, then the con-
trol must be implemented so that the probability of failure of the safety--related
functions is sufficiently low. The standards EN ISO 13849--1 and EN 62061 define
guidelines for implementing safety--related machine controls which, when properly
applied, ensure that all the safety requirements of the EC Machinery Directive are
fulfilled. These standards ensure that the relevant safety requirements of the Ma-
chinery Directive are fulfilled.
-- 3 (from PL b)
EN 61508
Any architectures,
all SIL 1
Defined architectures, restricted
maximum PL for electronics
EN 62061
Safety of machinery
Functional safety, safety--
related electrical, electronic
and programmable electronic
control systems
EN ISO 13849
Safety of machinery
Safety--related parts of
controls
functional safety, safety--related electrical/electronic/
programmable electronic control systems
(Parts0to7)
systems, that execute safety functions or guarantee functional safety
Universal use for electrical, electronic and programmable electronic
Sector standard EN 62061 for
the area of machines below
EN 61508
For deviations from the defined
architectures, reference to
EN 61508
The areas of application of EN ISO 13849--1, EN 62061, and the series of
EN 61508 standards are very similar. In order to help users make a decision, the
application areas of both standards are listed in a common table in the introduction
to the standard. Either EN ISO 13849--1 or EN 62061 are applied depending on
the technology (mechanical, hydraulic, pneumatic, electrical, electronic, program-
mable electronic), risk classification, or architecture.

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Systems for executing
safety--related control
functions
EN ISO 13849--1 EN 62061
ANon--electrical (e.g. hydraulic,
pneumatic)
XNot covered
BElectromechanical (e.g. relay
and/or basic electronics)
Restricted to the designated ar-
chitectures (see comment 1)
and max. up to PL = e
All architectures and max. up to
SIL 3
CComplex electronics (e.g. pro-
grammable electronics)
Restricted to the designated ar-
chitectures (see comment 1)
and max. up to PL = d
All architectures and max. up to
SIL 3
DA combined with B Restricted to the designated ar-
chitectures (see comment 1)
and max. up to PL = e
X
See comment 3
EC combined with B Restricted to the designated ar-
chitectures (see comment 1)
and max. up to PL = d
All architectures and max. up to
SIL 3
FC combined with A or
C combined with A and B
X
See comment 2
X
See comment 3
”X” indicates that the point is covered by this standard.
Comment 1:
Designated architectures are described in Annex B of EN ISO 13849--1 and provide a simplified basis for
the quantification
Comment 2:
For complex electronics: Using designated architectures in compliance with EN ISO 13849--1 up to
PL = d or every architecture in compliance with EN 62061
Comment 3:
For non--electrical systems: Use parts/components that correspond to EN ISO 13849--1 as subsystems
1.2.4 EN ISO 13849--1
EN ISO 13849--1 is based on previous standard EN 954--1, and additionally
requires a quantitative consideration of the safety functions. The following safety--
related parameters are required for components/devices:
SCategory (structural requirement)
SPL: Performance Level
SMTTFd: Mean time to dangerous failure
SDC: Diagnostics Coverage
SCCF: Common Cause Failure
The standard describes how the performance level (PL) is calculated for safety--
related components of the controller on the basis of designated architectures. In
the event of any deviations from this, EN ISO 13849--1 refers to EN 61508.
When combining several safety--related parts to form a complete system, the stan-
dard explains how to determine the resulting PL.