Siemens SINUMERIK Series Parts list manual

SINUMERIK
SINUMERIK 828D, SINAMICS S120
Safety Integrated
Function Manual
Valid for:
CNC software Version 4.7 SP2
10/2015
6FC5397-3EP40-5BA3
Preface
Safety instructions 1
Overview of Safety
Integrated functions 2
Commissioning - drive-based 3
Commissioning - TM54F 4
Commissioning - acceptance
tests 5
Commissioning - application
example 6
Diagnostics 7
System Features 8
Standards and specifications 9
Appendix A

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.
Siemens AG
Division Digital Factory
Postfach 48 48
90026 NÜRNBERG
GERMANY
Order number: 6FC5397-3EP40-5BA3
Ⓟ 11/2015 Subject to change
Copyright © Siemens AG 2012 - 2015.
All rights reserved

Preface
SINUMERIK documentation
The SINUMERIK documentation is organized in the following categories:
● General documentation
● User documentation
● Manufacturer/service documentation
Additional information
You can find information on the following topics under the link (www.siemens.com/
motioncontrol/docu):
● Ordering documentation/overview of documentation
● Additional links to download documents
● Using documentation online (find and search in manuals/information)
Please send any questions about the technical documentation (e.g. suggestions for
improvement, corrections) to the following address:
(mailto:[email protected])
My Documentation Manager (MDM)
Under the following link you will find information to individually compile OEM-specific machine
documentation based on the Siemens content: MDM (www.siemens.com/mdm)
Training
For information about the range of training courses, refer under:
● SITRAIN (www.siemens.com/sitrain) - training courses from Siemens for automation
products, systems and solutions
● SinuTrain (www.siemens.com/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).
Safety Integrated
Function Manual, 10/2015, 6FC5397-3EP40-5BA3 3

SINUMERIK
You can find information on SINUMERIK under the following link: (www.siemens.com/
sinumerik)
Target group
Project engineers, technologists (of the machine manufacturers), commissioning engineers
(for systems or machines), and programmers.
Benefits
The function manual describes the functions so that the target group knows them and can
select them. It provides the target group with the information required to implement the
functions.
Planning and configuration phase, implementation phase, setup and commissioning phase.
Standard version
This documentation only describes the functionality of the standard version. Extensions or
changes made by the machine manufacturer are documented by the machine manufacturer.
Other functions not described in this documentation might be executable in the control. This
does not, however, represent an obligation to supply such functions with a new control or when
servicing.
Further, for the sake of simplicity, this documentation does not contain all detailed information
about all types of the product and cannot cover every conceivable case of installation, operation
or maintenance.
Technical Support
Country-specific telephone numbers for technical support are provided in the Internet under
"Contact" (www.siemens.com/automation/service&support).
EC Declaration of Conformity
The EC declaration of conformity for the EMC directive can be found in the Internet
(www.siemens.com/automation/service&support).
There, as search term, enter the number 15257461 or contact your local Siemens office.
Preface
Safety Integrated
4Function Manual, 10/2015, 6FC5397-3EP40-5BA3

Table of contents
Preface.........................................................................................................................................................3
1Safety instructions........................................................................................................................................9
1.1 Fundamental safety instructions..............................................................................................9
1.1.1 General safety instructions.......................................................................................................9
1.1.2 Handling electrostatic sensitive devices (ESD)......................................................................12
1.1.3 Industrial security...................................................................................................................13
1.1.4 Residual risks of power drive systems...................................................................................13
1.2 Safety Integrated safety instructions......................................................................................16
1.3 Probability of failure of the safety functions............................................................................19
1.4 Residual risk...........................................................................................................................20
2 Overview of Safety Integrated functions.....................................................................................................23
2.1 Supported functions...............................................................................................................24
2.2 Safety Integrated Basic Functions.........................................................................................27
2.2.1 Safe Torque Off (STO)...........................................................................................................27
2.2.2 Safe Stop 1 (SS1)..................................................................................................................28
2.2.3 Safe Brake Control (SBC)......................................................................................................29
2.3 Safety Integrated Extended Functions...................................................................................30
2.3.1 Safe Torque Off (STO)...........................................................................................................30
2.3.2 Safe Stop 1 (SS1)..................................................................................................................30
2.3.3 Safe Brake Control (SBC)......................................................................................................32
2.3.4 Safe Operating Stop (SOS)....................................................................................................33
2.3.5 Safe Stop 2 (SS2)..................................................................................................................34
2.3.6 Safely Limited Speed (SLS)...................................................................................................36
2.3.7 Safe Speed Monitor (SSM)....................................................................................................40
2.3.8 Safe Direction (SDI)...............................................................................................................42
2.3.9 Safely-Limited Position (SLP)................................................................................................44
2.3.10 Safe Brake Test (SBT)...........................................................................................................45
3 Commissioning - drive-based.....................................................................................................................47
3.1 Introduction............................................................................................................................47
3.2 Activating the commissioning mode.......................................................................................49
3.3 Canceling the commissioning mode......................................................................................51
3.4 Exit the commissioning mode................................................................................................52
3.5 Copying or confirming SI data................................................................................................54
3.6 Working with parameter lists..................................................................................................56
3.7 Safety overview......................................................................................................................57
3.7.1 Calling the overview and detailed views................................................................................57
3.7.2 Safety Integrated overview.....................................................................................................58
3.7.3 Safety Integrated overview - details.......................................................................................59
Safety Integrated
Function Manual, 10/2015, 6FC5397-3EP40-5BA3 5

3.7.4 Safety Integrated overview - checksums...............................................................................60
3.8 Making the basic safety settings............................................................................................62
3.8.1 Calling the basic setting dialog...............................................................................................62
3.8.2 Options...................................................................................................................................64
3.8.3 Configuration..........................................................................................................................66
3.8.4 Encoder parameterization......................................................................................................67
3.8.5 Telegram configuration..........................................................................................................70
3.9 Safety Integrated functions....................................................................................................71
3.9.1 Calling function dialogs..........................................................................................................71
3.9.2 Safe Torque Off (STO)/Safe Stop 1 (SS1) - basis function....................................................72
3.9.3 Safe Torque Off (STO) - extended function...........................................................................73
3.9.4 Safe Brake Control (SBC)......................................................................................................75
3.9.5 Safe Stop 1 (SS1) Extended Function...................................................................................77
3.9.6 Safe Stop 2 (SS2)/Safe Operating Stop (SOS)......................................................................78
3.9.7 Safely Limited Speed (SLS)...................................................................................................80
3.9.8 Safe Speed Monitor (SSM)....................................................................................................81
3.9.9 Safe Acceleration Monitor (SAM)...........................................................................................83
3.9.10 Safe Direction (SDI)...............................................................................................................84
3.9.11 Safely Limited Position (SLP).................................................................................................85
3.9.12 Safe Brake Test (SBT)...........................................................................................................88
4 Commissioning - TM54F............................................................................................................................93
4.1 Introduction............................................................................................................................93
4.2 Activating the commissioning mode.......................................................................................95
4.3 Canceling the commissioning mode......................................................................................97
4.4 Exit the commissioning mode................................................................................................99
4.5 Configuring the TM54F........................................................................................................102
4.5.1 Calling the configuration range............................................................................................102
4.5.2 Configuration........................................................................................................................103
4.5.3 Inputs...................................................................................................................................105
4.5.4 Outputs.................................................................................................................................106
4.5.5 Drive groups.........................................................................................................................108
4.5.6 Working with parameter lists................................................................................................110
4.5.7 TM54F checksums...............................................................................................................111
5 Commissioning - acceptance tests...........................................................................................................113
5.1 Introduction..........................................................................................................................113
5.2 Content of the complete acceptance test.............................................................................115
5.3 Sequence of an acceptance test..........................................................................................119
5.3.1 Calling an acceptance test...................................................................................................119
5.3.2 Setting areas of the acceptance test....................................................................................120
5.3.3 Configuring and performing an acceptance test..................................................................126
6 Commissioning - application example......................................................................................................133
6.1 Planning...............................................................................................................................133
6.1.1 Creating a function table......................................................................................................133
6.1.2 From the function table to the logic diagram........................................................................134
6.2 Preconditions for commissioning.........................................................................................137
Table of contents
Safety Integrated
6Function Manual, 10/2015, 6FC5397-3EP40-5BA3

6.3 Parameterizing the TM54F...................................................................................................139
6.3.1 Configuring the drive groups................................................................................................139
6.3.2 Connecting safe outputs......................................................................................................142
6.3.3 TM54F terminal description..................................................................................................144
6.4 Controlling with the SIRIUS 3SK or SIRIUS 3RK relay........................................................146
6.4.1 Controlling the TM54F with SIRIUS 3SK.............................................................................146
6.4.2 Control of the TM54F with SIRIUS 3RK...............................................................................151
6.5 Configuration of the SI functions for the drive......................................................................154
6.5.1 Activating Safety Integrated.................................................................................................154
6.5.2 Encoder parameterization....................................................................................................156
6.5.3 Setting parameters SLS1-4, SBC, SS1, SS2.......................................................................158
6.6 SINUMERIK 828D control system.......................................................................................160
6.6.1 SIC/SCC interface................................................................................................................160
7 Diagnostics...............................................................................................................................................161
7.1 Calling diagnostic views.......................................................................................................161
7.2 Safety Integrated diagnostics overview................................................................................163
7.3 Safety Integrated drives.......................................................................................................164
7.3.1 Basic functions.....................................................................................................................164
7.3.2 Extended functions...............................................................................................................165
7.4 TM54F..................................................................................................................................167
7.4.1 Configuration........................................................................................................................167
7.4.2 Inputs...................................................................................................................................168
7.4.3 Outputs.................................................................................................................................169
7.4.4 Drive groups.........................................................................................................................171
7.5 Safety Integrated checksums...............................................................................................173
7.5.1 Safety Integrated checksum.................................................................................................173
7.5.2 Safety Integrated global checksums....................................................................................174
7.5.3 TM54F checksums...............................................................................................................175
7.5.4 Drive checksums..................................................................................................................177
7.6 Safety Integrated alarms......................................................................................................179
7.7 Acknowledging hardware replacement................................................................................180
8 System Features......................................................................................................................................183
8.1 Latest information.................................................................................................................183
8.2 Certifications........................................................................................................................185
9 Standards and specifications....................................................................................................................187
9.1 General................................................................................................................................187
9.2 Safety of machinery in Europe.............................................................................................189
9.2.1 Safety of machinery in Europe.............................................................................................189
9.2.2 Harmonized European Standards........................................................................................189
9.3 Machine safety in the USA...................................................................................................191
9.3.1 Machine safety in the USA...................................................................................................191
9.3.2 Minimum requirements of the OSHA...................................................................................191
9.3.3 NRTL listing..........................................................................................................................192
Table of contents
Safety Integrated
Function Manual, 10/2015, 6FC5397-3EP40-5BA3 7

9.3.4 NFPA 79...............................................................................................................................192
9.3.5 ANSI B11.............................................................................................................................193
9.4 Machine safety in Japan......................................................................................................194
9.4.1 Machine safety in Japan......................................................................................................194
9.5 Equipment regulations.........................................................................................................195
9.5.1 Equipment regulations.........................................................................................................195
9.6 Other safety-related issues..................................................................................................196
9.6.1 Information sheets issued by the Employer's Liability Insurance Association......................196
9.6.2 Additional references...........................................................................................................196
A Appendix...................................................................................................................................................197
A.1 Abbreviations.......................................................................................................................197
A.2 Documentation overview SINUMERIK 828D.......................................................................200
Index.........................................................................................................................................................201
Table of contents
Safety Integrated
8Function Manual, 10/2015, 6FC5397-3EP40-5BA3

Safety instructions 1
1.1 Fundamental safety instructions
1.1.1 General safety instructions
DANGER
Danger to life due to live parts and other energy sources
Death or serious injury can result when live parts are touched.
● Only work on electrical devices when you are qualified for this job.
● Always observe the country-specific safety rules.
Generally, six steps apply when establishing safety:
1. Prepare for shutdown and notify all those who will be affected by the procedure.
2. Disconnect the machine from the supply.
– Switch off the machine.
– Wait until the discharge time specified on the warning labels has elapsed.
– Check that it really is in a no-voltage condition, from phase conductor to phase
conductor and phase conductor to protective conductor.
– Check whether the existing auxiliary supply circuits are de-energized.
– Ensure that the motors cannot move.
3. Identify all other dangerous energy sources, e.g. compressed air, hydraulic systems, or
water.
4. Isolate or neutralize all hazardous energy sources by closing switches, grounding or short-
circuiting or closing valves, for example.
5. Secure the energy sources against switching on again.
6. Ensure that the correct machine is completely interlocked.
After you have completed the work, restore the operational readiness in the inverse sequence.
WARNING
Danger to life through a hazardous voltage when connecting an unsuitable power supply
Touching live components can result in death or severe injury.
● Only use power supplies that provide SELV (Safety Extra Low Voltage) or PELV-
(Protective Extra Low Voltage) output voltages for all connections and terminals of the
electronics modules.
Safety Integrated
Function Manual, 10/2015, 6FC5397-3EP40-5BA3 9

WARNING
Danger to life when live parts are touched on damaged devices
Improper handling of devices can cause damage.
For damaged devices, hazardous voltages can be present at the enclosure or at exposed
components; if touched, this can result in death or severe injury.
● Ensure compliance with the limit values specified in the technical data during transport,
storage and operation.
● Do not use any damaged devices.
WARNING
Danger to life through electric shock due to unconnected cable shields
Hazardous touch voltages can occur through capacitive cross-coupling due to unconnected
cable shields.
● As a minimum, connect cable shields and the cores of cables that are not used at one end
at the grounded housing potential.
WARNING
Danger to life due to electric shock when not grounded
For missing or incorrectly implemented protective conductor connection for devices with
protection class I, high voltages can be present at open, exposed parts, which when touched,
can result in death or severe injury.
● Ground the device in compliance with the applicable regulations.
WARNING
Danger to life due to fire spreading if housing is inadequate
Fire and smoke development can cause severe personal injury or material damage.
● Install devices without a protective housing in a metal control cabinet (or protect the device
by another equivalent measure) in such a way that contact with fire is prevented.
● Ensure that smoke can only escape via controlled and monitored paths.
Safety instructions
1.1 Fundamental safety instructions
Safety Integrated
10 Function Manual, 10/2015, 6FC5397-3EP40-5BA3

WARNING
Danger to life through unexpected movement of machines when using mobile wireless
devices or mobile phones
Using mobile wireless devices or mobile phones with a transmit power > 1 W closer than
approx. 2 m to the components may cause the devices to malfunction, influence the functional
safety of machines therefore putting people at risk or causing material damage.
● Switch the wireless devices or mobile phones off in the immediate vicinity of the
components.
WARNING
Danger to life due to fire if overheating occurs because of insufficient ventilation clearances
Inadequate ventilation clearances can cause overheating of components with subsequent
fire and smoke. This can cause severe injury or even death. This can also result in increased
downtime and reduced service lives for devices/systems.
● Ensure compliance with the specified minimum clearance as ventilation clearance for the
respective component.
WARNING
Danger to life when safety functions are inactive
Safety functions that are inactive or that have not been adjusted accordingly can cause
operational faults on machines that could lead to serious injury or death.
● Observe the information in the appropriate product documentation before commissioning.
● Carry out a safety inspection for functions relevant to safety on the entire system, including
all safety-related components.
● Ensure that the safety functions used in your drives and automation tasks are adjusted
and activated through appropriate parameterizing.
● Perform a function test.
● Only put your plant into live operation once you have guaranteed that the functions relevant
to safety are running correctly.
Note
Important safety notices for Safety Integrated functions
If you want to use Safety Integrated functions, you must observe the safety notices in the Safety
Integrated manuals.
Safety instructions
1.1 Fundamental safety instructions
Safety Integrated
Function Manual, 10/2015, 6FC5397-3EP40-5BA3 11

WARNING
Danger to life or malfunctions of the machine as a result of incorrect or changed
parameterization
As a result of incorrect or changed parameterization, machines can malfunction, which in turn
can lead to injuries or death.
● Protect the parameterization (parameter assignments) against unauthorized access.
● Respond to possible malfunctions by applying suitable measures (e.g. EMERGENCY
STOP or EMERGENCY OFF).
1.1.2 Handling electrostatic sensitive devices (ESD)
Electrostatic sensitive devices (ESD) are individual components, integrated circuits, modules
or devices that may be damaged by either electric fields or electrostatic discharge.
NOTICE
Damage through electric fields or electrostatic discharge
Electric fields or electrostatic discharge can cause malfunctions through damaged individual
components, integrated circuits, modules or devices.
● Only pack, store, transport and send electronic components, modules or devices in their
original packaging or in other suitable materials, e.g conductive foam rubber of aluminum
foil.
● Only touch components, modules and devices when you are grounded by one of the
following methods:
– Wearing an ESD wrist strap
– Wearing ESD shoes or ESD grounding straps in ESD areas with conductive flooring
● Only place electronic components, modules or devices on conductive surfaces (table with
ESD surface, conductive ESD foam, ESD packaging, ESD transport container).
Safety instructions
1.1 Fundamental safety instructions
Safety Integrated
12 Function Manual, 10/2015, 6FC5397-3EP40-5BA3

1.1.3 Industrial security
Note
Industrial security
Siemens provides products and solutions with industrial security functions that support the
secure operation of plants, solutions, machines, equipment and/or networks. They are
important components in a holistic industrial security concept. With this in mind, Siemens’
products and solutions undergo continuous development. Siemens recommends strongly that
you regularly check for product updates.
For the secure operation of Siemens products and solutions, 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. Third-party products that may be in use should also
be considered. For more information about industrial security, visit this address (http://
www.siemens.com/industrialsecurity).
To stay informed about product updates as they occur, sign up for a product-specific
newsletter. For more information, visit this address (http://support.automation.siemens.com).
WARNING
Danger as a result of unsafe operating states resulting from software manipulation
Software manipulation (e.g. by viruses, Trojan horses, malware, worms) can cause unsafe
operating states to develop in your installation which can result in death, severe injuries and/
or material damage.
● Keep the software up to date.
You will find relevant information and newsletters at this address (http://
support.automation.siemens.com).
● Incorporate the automation and drive components into a holistic, state-of-the-art industrial
security concept for the installation or machine.
You will find further information at this address (http://www.siemens.com/
industrialsecurity).
● Make sure that you include all installed products into the holistic industrial security concept.
1.1.4 Residual risks of power drive systems
The control and drive components of a drive system are approved for industrial and commercial
use in industrial line supplies. Their use in public line supplies requires a different configuration
and/or additional measures.
These components may only be operated in closed housings or in higher-level control cabinets
with protective covers that are closed, and when all of the protective devices are used.
These components may only be handled by qualified and trained technical personnel who are
knowledgeable and observe all of the safety instructions on the components and in the
associated technical user documentation.
Safety instructions
1.1 Fundamental safety instructions
Safety Integrated
Function Manual, 10/2015, 6FC5397-3EP40-5BA3 13

When assessing the machine's risk in accordance with the respective local regulations (e.g.,
EC Machinery Directive), the machine manufacturer must take into account the following
residual risks emanating from the control and drive components of a drive system:
1. Unintentional movements of driven machine components during commissioning, operation,
maintenance, and repairs caused by, for example,
– Hardware and/or software errors in the sensors, control system, actuators, and cables
and connections
– Response times of the control system and of the drive
– Operation and/or environmental conditions outside the specification
– Condensation/conductive contamination
– Parameterization, programming, cabling, and installation errors
– Use of wireless devices/mobile phones in the immediate vicinity of the control system
– External influences/damage
2. In the event of a fault, exceptionally high temperatures, including an open fire, as well as
emissions of light, noise, particles, gases, etc. can occur inside and outside the inverter,
e.g.:
– Component failure
– Software errors
– Operation and/or environmental conditions outside the specification
– External influences/damage
Inverters of the Open Type/IP20 degree of protection must be installed in a metal control
cabinet (or protected by another equivalent measure) such that contact with fire inside and
outside the inverter is not possible.
3. Hazardous shock voltages caused by, for example,
– Component failure
– Influence during electrostatic charging
– Induction of voltages in moving motors
– Operation and/or environmental conditions outside the specification
– Condensation/conductive contamination
– External influences/damage
4. Electrical, magnetic and electromagnetic fields generated in operation that can pose a risk
to people with a pacemaker, implants or metal replacement joints, etc., if they are too close
5. Release of environmental pollutants or emissions as a result of improper operation of the
system and/or failure to dispose of components safely and correctly
Safety instructions
1.1 Fundamental safety instructions
Safety Integrated
14 Function Manual, 10/2015, 6FC5397-3EP40-5BA3

Note
The components must be protected against conductive contamination (e.g. by installing them
in a control cabinet with degree of protection IP54 according to IEC 60529 or NEMA 12).
Assuming that conductive contamination at the installation site can definitely be excluded, a
lower degree of cabinet protection may be permitted.
For more information about residual risks of the components in a drive system, see the relevant
sections in the technical user documentation.
Safety instructions
1.1 Fundamental safety instructions
Safety Integrated
Function Manual, 10/2015, 6FC5397-3EP40-5BA3 15

1.2 Safety Integrated safety instructions
Additional safety instructions and residual risks
Additional safety information and residual risks not specified in this section are included in the
relevant sections of this Function Manual.
DANGER
Risk minimization through Safety Integrated
Safety Integrated can be used to minimize the level of risk associated with machines and
plants.
However, safe operation of a system or machine based on Safety Integrated is only possible
if the following preconditions are fully satisfied:
● The machine builder (OEM) precisely knows and observes this technical user
documentation - including the documented limitations, safety information and residual
risks.
● The machine builder (OEM) carefully and professionally designs, constructs and
configures the system/machine. This must then be verified through careful and thorough
acceptance tests by qualified personnel and the results documented.
● The machine builder (OEM) implements and validates all the measures required in
accordance with the system/machine risk analysis by means of the programmed and
configured Safety Integrated functions or by other means.
The use of Safety Integrated does not replace the machine/plant risk assessment carried out
by the machine manufacturer as required by the EC machinery directive.
In addition to using Safety Integrated functions, further risk reduction measures must be
implemented.
WARNING
Danger to life as a result of inactive Safety Integrated functions while powering up
The Safety Integrated functions are only activated after the system has completely powered
up. System startup is a critical operating state with increased risk. When accidents occur, this
can result in death or severe injury.
● Stay completely away from any hazardous areas while the system powers up.
● For vertical axes, check that the drives are in a no-torque state.
WARNING
Regulations from EN 60204-1
The Emergency Stop function must bring the machine to a standstill according to stop
category 0 or 1 (STO or SS1).
The machine must not restart automatically after EMERGENCY STOP.
When individual safety functions (Extended Functions) are deactivated, an automatic restart
is permitted under certain circumstances depending on the risk analysis (except when
Emergency Stop is reset). An automatic start is permitted when a protective door is closed,
for example.
Safety instructions
1.2 Safety Integrated safety instructions
Safety Integrated
16 Function Manual, 10/2015, 6FC5397-3EP40-5BA3

WARNING
Danger to life when the system powers up after hardware and/or software has been changed
or replaced
After hardware and/or software components have been modified or replaced, it is only
permissible for the system to run up and the drives to be activated with the protective devices
closed. Changes to the system that have not been thoroughly tested can initiate undesirable
functions. For persons in the hazardous area, this can result in death or severe injury.
● Carry out the following tests after a change or replacement (see ChapterAcceptance test
(Page 113)):
– A complete acceptance test
– A partial acceptance test
– A simplified function test
● Before personnel may re-enter the hazardous area, the drives MUST be tested to ensure
that they exhibit stable control behavior by briefly moving them in both the plus and minus
directions (+/–).
● Ensure that nobody is in the hazardous area during the test.
● When switching on, carefully observe that Safety Integrated functions are only available
and can only be selected after the system has completely powered up.
WARNING
Danger to life when the drive coasts down for an STO or STOP A
The Category 0 stop function in accordance with EN 60204-1 (STO or STOP A acc. to Safety
Integrated) means that the drives are not actively braked. They coast to a stop (this may take
some time depending on the level of kinetic energy involved). In the case of a fault
(malfunction), this can result in death or severe injury.
● Carefully take this response into account when designing the protective door interlocking
logic.
WARNING
Danger to life as a result of a malfunction due to an acceptance test that has not been carried
out after changes to parameters have been made
Safety Integrated functions cannot detect parameter changes made by the machine builder
(OEM). Incorrect parameter changes for SI functions can result in accidents leading to death
or severe injury.
● After making a change to a parameter, always carry out an acceptance test and document
the values in an acceptance report.
● Only use the system or machine after the acceptance test has been successfully
completed.
Safety instructions
1.2 Safety Integrated safety instructions
Safety Integrated
Function Manual, 10/2015, 6FC5397-3EP40-5BA3 17

WARNING
Danger to life as a result of different responses of the Safety Integrated functions when
replacing a Motor Module or a motor
Motor Modules or the motor must be replaced with a device of the same type, as the parameter
settings will otherwise lead to an incorrect response of the Safety Integrated functions.
Functionality that has been modified can result in accidents leading to death or severe injury.
● Always replace a component by an identical component of precisely the same type.
● Recalibrate and carefully test the drive involved when replacing an encoder.
● Carefully test the functionality after replacement.
WARNING
Danger to life as a result of parameterized safety functions, which are only available to a
restricted extent, when an internal or external fault occurs
If an internal or external fault occurs, none or only some of the parameterized safety functions
are available during the STOP F response triggered by the fault. In the case of a fault
(malfunction), this can result in death or severe injury.
● Carefully take this into account when parameterizing a delay time between STOP F and
STOP B. This is especially true for vertical axes.
Safety instructions
1.2 Safety Integrated safety instructions
Safety Integrated
18 Function Manual, 10/2015, 6FC5397-3EP40-5BA3

1.3 Probability of failure of the safety functions
The probability of failure of safety functions must be specified in the form of a PFH value
(Probability of Failure per Hour) according to IEC 61508, IEC 62061 and DIN EN ISO 13849-1.
The PFH value of a safety function depends on the safety concept of the control system and
the drive device, its hardware configuration and the PFH values of the components used to
implement a safety function.
For the SINUMERIK 828 and the SINAMICS S120 drive device, PFH values are made
available depending on the hardware configuration (number of drives, control type, number of
encoders used). The various integrated safety functions are not differentiated.
● The PFH values of the individual safety components of SINUMERIK 828 and
SINAMICS S120 are available in theInternet (https://support.industry.siemens.com/cs/
document/76254308?lc=en-WW).
● The PFH values of all safety components from Siemens are available in the Safety
Evaluation Tool (http://www.industry.siemens.com/topics/global/en/safety-integrated/
machine-safety/safety-evaluation-tool/Pages/default.aspx).
Safety instructions
1.3 Probability of failure of the safety functions
Safety Integrated
Function Manual, 10/2015, 6FC5397-3EP40-5BA3 19

1.4 Residual risk
The fault analysis enables machine manufacturers to determine the residual risk at their
machine with regard to the drive unit. The following residual risks are known:
WARNING
Danger to life as a result of hardware faults relating to the intrinsic principle: PFH value
Due to the intrinsic potential of hardware faults, electrical systems are subject to additional
residual risk, which can be expressed by means of the PFH value.
● Take into account these residual risks when designing your machine and where necessary
apply suitable countermeasures.
WARNING
Danger to life when a drive accelerates in an uncontrolled fashion
Faults in the absolute track (C-D track), cyclic interchange of the drive phases (V-W-U instead
of U-V-W) and reversal of the control direction may cause acceleration of the drive. Category
1 and 2 stop functions according to EN 60204-1 (fault response functions Stop B to D
according to Safety Integrated) that are provided are however not effective due to the fault.
● Category 0 stop function according to EN 60204-1 (fault response function Stop A
according to Safety Integrated) is not activated until the transition or delay time set in the
parameter has expired. These faults are detected when SAM is selected (fault reaction
functions STOP B/C) and stop function category 0 according to EN 60204-1 (fault reaction
function STOP A according to Safety Integrated) is triggered as early as possible
regardless of this delay. Electrical faults (defective components or similar) may also lead
to the response stated above.
WARNING
Danger to life when a drive moves when two power transistors simultaneously fail (breakdown
of depletion layer)
The simultaneous breakdown of depletion layer of 2 power transistors (one in the upper and
the other offset in the lower inverter bridge) in the inverter may cause the drive to move briefly.
This can result in accidents leading to death or severe injury.
● Take suitable measures to prevent unexpected drive movement, for example, by using a
brake equipped with safety monitoring (Safe Brake Control).
WARNING
Danger to life as a result of brief, higher speeds when limit values are violated
Violation of limits may briefly lead to a speed higher than the speed setpoint, or the axis may
pass the defined position to a certain extent, depending on the dynamic response of the drive
and on parameter settings. When accidents occur, this can result in death or severe injury.
● Take into account this situation when designing your machine and where necessary apply
suitable countermeasures.
Safety instructions
1.4 Residual risk
Safety Integrated
20 Function Manual, 10/2015, 6FC5397-3EP40-5BA3