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.................................