Siemens SINUMERIK 840D sl Parts list manual

Valid for
Control
SINUMERIK 840D sl
SINUMERIK 840D sl (export version)
Drive
SINAMICS S120
Software version
1.3.2
03.06 Edition
SINUMERIK Safety Integrated
SINUMERIK 840D sl/
SINAMICS S120
Function ManualFunction ManualFunction ManualFunction ManualFunction ManualFunction ManualFunction ManualFunction ManualFunction ManualFunction ManualFunction ManualFunction ManualFunction ManualFunction Manual
M
Regulations and Standards 1
Brief Description 2
System Features 3
Safety Functions
Integrated in the Drive 4
Basic on the Safety
Functions Integrated
in the System/Drive 5
Safety Functions
Integrated in the System/
Drive 6
Connectinb Sensors/
Actuators 7
Data Description 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
Registered Trademarks
Any product names mentioned may be trademarks or product designations of Siemens or their
suppliers, whose use by third parties for their own purposes may infringe the rights of the
trademark owners.
©Siemens AG, 2005. All rights reserved
We have checked the contents of this manual for agreement with the
hardware and software described. Nevertheless, differences might
exist and therefore we cannot guarantee that they are completely
identical. However, the information contained in this document is
reviewed regularly and any necessary changes included in
subsequent editions. We welcome suggestions for improvement.
Subject to change without prior notice.
Siemens Aktiengesellschaft
Printed in Germany
3ls

Preface
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iii
©Siemens AG, 2006. All rights reserved
SINUMERIK 840D sl/SINAMICS S120 SINUMERIK Safety Integrated (FBSI sl) – 03.2006 Edition
Preface
Structure of the documentation
The SINUMERIK documentation is organized in 3 parts:
SGeneral Documentation
SUser documentation
SManufacturer/Service documentation
An overview of publications, which is updated monthly and also provides informa-
tion about the language versions available, can be found on the Internet at:
http://www.siemens.com/motioncontrol
Follow menu items – “Support” –> “Technical Documentation” –> “Overview of
Documentation”.
The Internet version of DOConCD (DOConWEB) is available at:
http://www.automation.siemens.com/doconweb
Information on the range of training courses and FAQs (frequently asked ques-
tions) are available in the Internet under:
http://www.siemens.com/motioncontrol and there under the menu item “Support”
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).
Standard scope
The functionality of the standard scope is described in the following documenta-
tion. The machinery construction OEM documents supplements or changes that he
makes (the machinery construction OEM).
Other functions not described in this documentation might be executable in the
control. However, no claim can be made regarding the availability of these func-
tions when the equipment is first supplied or in the event of 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
installation, operation, or maintenance.

Preface 03.06
iv ©Siemens AG, 2006. All rights reserved
SINUMERIK 840D sl/SINAMICS S120 SINUMERIK Safety Integrated (FBSI sl) – 03.2006 Edition
Technical Support
If you have any questions, please get in touch with our Hotline:
Europe and Africa time zone
A&D Technical Support
Tel.: +49 (0) 180 / 5050 – 222
Fax: +49 (0) 180 / 5050 – 223
Internet: http://www.siemens.com/automation/support-request
Email: mailto:[email protected]
Asia and Australia time zone
A&D Technical Support
Tel.: [phone]
Fax: [phone]
Internet: http://www.siemens.com/automation/support-request
Email: mailto:[email protected]
America time zone
A&D Technical Support
Tel.: [phone]
Fax: [phone]
Internet: http://www.siemens.com/automation/support-request
Email: mailto:[email protected]
Note
Country telephone numbers for technical support are provided under the following
Internet address:
Enter http://www.siemens.com/automation/service&support
Questions on the manual
If you have any queries (suggestions, corrections) in relation to this documentation,
please fax or e-mail us:
Fax: [phone] / 98 – 63315
Email: mailto:[email protected]
Fax form: Refer to the reply form at the end of the document.
SINUMERIK Internet address
http://www.siemens.com/motioncontrol

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SINUMERIK 840D sl/SINAMICS S120 SINUMERIK Safety Integrated (FBSI sl) – 03.2006 Edition
EC Declaration of Conformance
The EC Declaration of Conformity for the EMC Directive can be found/obtained
Sthe internet:
http://www.ad.siemens.de/csinfo
under product/order no. 15257461
Sthe relevant branch office of the A&D MC group of Siemens AG.
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 Senors/Actuator
SData Description
SCommissioning
SDiagnostics
SInteraction with Oher Functions
Separate documents are available for user-oriented activities. These include, for
example, generating part programs and handling controls.
Separate information is also available for operations that the machine tool
manufacturer must carry-out. These include, for example, configuring/engineering,
installation and programming the PLC.
Notes on how to use this manual
The following support functions are provided for this function description:
SOverall table of contents
SAppendix with abbreviations and references, glossary
SIndex
If you require information about a certain term, please look in the Appendix for the
specific Chapter Index for the particular term. Both the chapter number and the
page number are listed where you will find this particular information.

Preface 03.06
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SINUMERIK 840D sl/SINAMICS S120 SINUMERIK Safety Integrated (FBSI sl) – 03.2006 Edition
Documentation, 03/06 Edition
Note
The documentation 03/06 Edition describes the scope of functions for the following products
and software release:
SINUMERIK 840D sl with software release 1.3.2
Safety information
This manual contains notices that you must observe in order to ensure your per-
sonal safety, as well as to prevent damage to property. Notices which are relevant
to your own personal safety are highlighted by a safety alert symbol; notices which
are relevant only to equipment and property damage have no safety alert symbol.
The warnings appear in decreasing order of risk as given below.
!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.
Caution
without warning triangle indicates that material damage can result if proper
precautions are not taken.

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vii
©Siemens AG, 2006. All rights reserved
SINUMERIK 840D sl/SINAMICS S120 SINUMERIK Safety Integrated (FBSI sl) – 03.2006 Edition
Note
indicates that an unintended event or situation can occur if the corresponding
information is not taken into account.
If several hazards of different degrees occur, the hazard with the highest degree
must always be given priority. A warning notice accompanied by a safety alert sym-
bol indicating a risk of bodily injury can also indicate a risk of property damage.
Qualified personnel
The associated device/system may only be set up and operated using this docu-
mentation. Only qualified personnel should be allowed to commission and oper-
ate the device/system. Qualified persons are defined as persons who are autho-
rized to commission, to ground, and to tag circuits, equipment, and systems in
accordance with established safety practices and standards.
Proper use
Please note the following:
!Warning
The equipment may only be used for single purpose applications explicitly
described in the catalog and in the technical description and it may only be used
along with third-party devices and components recommended by Siemens. To
ensure trouble-free and safe operation of the product, it must be transported,
stored and installed as intended and maintained and operated with care.
Additional notes
Note
This symbol always appears in the document where further information is
provided.

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Notes

ix
©Siemens AG, 2006. All rights reserved
SINUMERIK 840D sl/SINAMICS S120 SINUMERIK Safety Integrated (FBSI sl) – 03.2006 Edition
Contents
1 Regulations and Standards 1-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 General information 1-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1.1 Objectives 1-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1.2 Functional safety 1-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Safety of machinery in Europe 1-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.1 Machinery Directive (98/37/EC) 1-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.2 Harmonized European standards 1-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.3 Standards to implement safety-related programmable electronic controls 1-20
1.2.4 prEN/ISO 13849–1 (revision from EN 954–1) 1-21. . . . . . . . . . . . . . . . . . . . . . .
1.2.5 EN IEC 62061 1-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.6 DIN EN 61508 (VDE 0803) or IEC 61508 1-24. . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.7 Risk analysis/assessment 1-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.8 Risk reduction 1-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.9 Residual risk 1-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Machine safety in the US 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 subjects and issues 1-32. . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6.1 Information sheets from the various regulatory bodies 1-32. . . . . . . . . . . . . . . .
1.6.2 Safety Integrated system manual 1-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Brief Description 2-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Control/drive system 2-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 SI system structure and basic features 2-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Overview, SI functions 2-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 System Features 3-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Fault analysis 3-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.1 Monitoring 3-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.2 Fault analysis 3-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Residual risks 3-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 System requirements 3-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Safety Functions Integrated in the Drive 4-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 General information about SINAMICS Safety Integrated 4-43. . . . . . . . . . . . . .
4.1.1 Explanations, standards and terminology 4-43. . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.2 Parameter, checksum, version, password 4-46. . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Safe standstill (SH) 4-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Safe brake control (SBC) 4-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Commissioning the SH and SBC functions 4-57. . . . . . . . . . . . . . . . . . . . . . . . . .

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4.4.1 General information about commissioning safety functions 4-57. . . . . . . . . . . .
4.4.2 Procedure for commissioning SH and SBC 4-58. . . . . . . . . . . . . . . . . . . . . . . . .
4.4.3 Safety faults 4-62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 Overview of parameters and function diagrams 4-64. . . . . . . . . . . . . . . . . . . . . .
4.6 Acceptance test and certificate 4-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.1 General information about acceptance 4-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.2 Documentation 4-68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.3 Function test 4-71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.4 Completing the log 4-75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Basics on the Safety Functions Integrated in the System/Drive 5-79. . . . . . . . . . . .
5.1 Monitoring clock cycle 5-79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Crosswise data comparison 5-80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Forced checking procedure 5-81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 Actual value conditioning 5-83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.1 Encoder types 5-83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.2 Encoder adjustment, calibrating the axes 5-87. . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.3 Axis states 5-88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.4 User agreement 5-90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.5 Taking into account selector gearboxes 5-92. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.6 Actual value synchronization (slip for 2-encoder systems) 5-94. . . . . . . . . . . . .
5.4.7 Encoder limit frequency 5-95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5 Enabling the safety-related functions 5-96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6 Switching the system on/off 5-97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Safety Functions Integrated in the System/Drive 6-99. . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Safe standstill (SH) 6-99. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1.1 Shutdown paths 6-102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1.2 Testing the shutdown paths 6-104. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Safe operating stop (SBH) 6-106. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.1 Selecting/de-selecting the safe operating stop 6-107. . . . . . . . . . . . . . . . . . . . . . .
6.2.2 Effects when the limit is exceeded for SBH 6-110. . . . . . . . . . . . . . . . . . . . . . . . .
6.3 Safe stops A-F 6-113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.1 General information 6-113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.2 Description of STOP A 6-120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.3 Description of STOP B 6-122. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.4 Description of STOP C 6-123. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.5 Description of STOP D 6-124. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.6 Description of STOP E 6-125. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.7 Description of STOP F 6-127. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.8 Forced checking procedure of the external STOPs 6-130. . . . . . . . . . . . . . . . . . .
6.4 Safe braking ramp (SBR) 6-132. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5 Safely-reduced speed (SG) 6-136. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5.1 Speed monitoring, encoder limit frequency 6-137. . . . . . . . . . . . . . . . . . . . . . . . . .
6.5.2 Selecting/de-selecting safely reduced speed 6-138. . . . . . . . . . . . . . . . . . . . . . . .
6.5.3 Effects when the limit value is exceeded for SG 6-141. . . . . . . . . . . . . . . . . . . . .
6.5.4 Override for safely-reduced speed 6-144. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5.5 Example: override for safely-reduced speed 6-147. . . . . . . . . . . . . . . . . . . . . . . . .

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6.6 Safety-related output “n<nx” 6-149. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7 Safe software limit switches (SE) 6-151. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7.1 Effects when an SE responds 6-152. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.8 Safe software cams (SN) 6-155. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.8.1 Special points to be noted 6-156. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.8.2 Effects when SN responds 6-159. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 Connecting Sensors/Actuators 7-161. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Safety-relevant input/output signals 7-161. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.1 Overview of the SGEs/SGAs and their structure 7-161. . . . . . . . . . . . . . . . . . . . .
7.1.2 Forced checking procedure of SPL signals 7-167. . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.3 Connecting sensors – actuators using the 3-terminal concept 7-170. . . . . . . . .
7.1.4 Sensor connection using the 4-terminal concept 7-173. . . . . . . . . . . . . . . . . . . . .
7.1.5 Multiple distribution and multiple interlocking 7-175. . . . . . . . . . . . . . . . . . . . . . . .
7.2 Connecting I/O via PROFIsafe 7-178. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.1 Function description 7-178. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.2 System structure 7-180. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.3 Parameterizing the F master (NCK) 7-181. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.4 Parameterizing the PROFIsafe communication (NCK) 7-182. . . . . . . . . . . . . . . .
7.2.5 Parameterizing the SPL-SGE interface 7-184. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.6 Parameterizing the SPL-SGA interface 7-188. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.7 Module type (NCK) 7-191. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.8 Parameterizing the F master (PLC) 7-191. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.9 Response times 7-192. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.10 Functional limitations 7-195. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3 Safe programmable logic (SPL) 7-196. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.1 Fundamentals 7-196. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.2 NCK-SPL program 7-200. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.3 Starting the SPL 7-202. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.4 Starting the NCK-SPL using the PROG_EVENT mechanism 7-203. . . . . . . . . .
7.3.5 Starting the NCK-SPL from the PLC user program 7-206. . . . . . . . . . . . . . . . . . .
7.3.6 Diagnostics/commissioning 7-207. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.7 Safe software relay 7-209. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.8 System variables for SINUMERIK 840D sl 7-216. . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.9 Behavior after power on / mode change / reset 7-219. . . . . . . . . . . . . . . . . . . . . .
7.3.10 SPL data on the PLC side 7-219. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.11 Direct communications between NCK and PLC-SPL 7-221. . . . . . . . . . . . . . . . .
7.4 Safe brake test (SBT) 7-223. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.1 Applications 7-223. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.2 Parameterization 7-223. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.3 Operational sequence 7-227. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.4 Limitations and constraints 7-232. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.5 Activating 7-233. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.6 Example 7-233. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 Data Description 8-235. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1 Machine data for SINUMERIK 840D sl 8-235. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1.1 Overview of the machine data 8-235. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1.2 Description of machine data 8-239. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2 Parameters for SINAMICS S120 8-281. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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8.2.1 Parameter overview 8-282. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.2 Description of parameters 8-285. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3 Interface signals 8-312. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.1 Interface signals for SINUMERIK 840Dsl 8-313. . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.2 Description of the interface signals 8-314. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.3 PLC data block (DB 18) 8-322. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4 System variables 8-329. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4.1 System variables for SINUMERIK 840Dsl 8-329. . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4.2 Description of the system variables 8-332. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 Commissioning 9-341. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1 HMI screens and softkeys 9-342. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2 Procedure when commissioning the drive for the first time 9-347. . . . . . . . . . . .
9.3 Series commissioning 9-351. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4 Changing data 9-352. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5 Acceptance test 9-353. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5.1 General information 9-353. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5.2 Conventional acceptance test 9-358. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.6 Replacing a motor or encoder 9-362. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 Diagnostics 10-369. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1 Troubleshooting procedure 10-369. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1.1 Service displays 10-369. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1.2 Diagnostics support by configuring your own extended alarm text 10-374. . . . .
10.1.3 Servo trace bit graphics for Safety Integrated 10-377. . . . . . . . . . . . . . . . . . . . . .
10.1.4 Bit graphics for SI signals in the servo trace 10-380. . . . . . . . . . . . . . . . . . . . . . . .
10.2 NCK safety alarms for Sinumerik 840D sl 10-386. . . . . . . . . . . . . . . . . . . . . . . . . .
10.3 Safety messages for SINAMICS S120 10-444. . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.1 General information 10-444. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.2 List of faults and alarms 10-447. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.4 Safety PLC alarms 10-476. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.5 Reducing the number of alarms 10-477. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.5.1 Alarm suppression 10-477. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.5.2 Assigning priorities to alarms 10-478. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 Interaction with Other Functions 11-481. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.1 Limiting the speed setpoint 11-481. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2 Measuring system changeover 11-482. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.3 Gantry axes 11-483. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.4 Parking axis 11-483. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.5 OEM applications 11-484. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.6 Behavior of Safety Integrated when Profibus fails 11-485. . . . . . . . . . . . . . . . . . .

Contents
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12 Appendix A-487. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.1 Customer Support A-487. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.2 Fault analysis tables A-489. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.3 References A-494. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.4 Abbreviations A-496. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.5 Terminology A-500. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 Index I-503. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents 03.06
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Notes

1-15
©Siemens AG, 2006. All rights reserved
SINUMERIK 840D sl/SINAMICS S120 SINUMERIK Safety Integrated (FBSI sl) – 03.2006 Edition
Regulations and Standards
1.1 General information
1.1.1 Objectives
Manufacturers and operating companies of equipment, machines and products are
responsible for ensuring the appropriate level of safety. This results in the require-
ment that plants, machines and other equipment should be made as safe as pos-
sible according to state-of-the-art technology. In this case, companies describe in
the various Standards, state-of-the-art technology that is relevant for safety. When
the relevant Standards are complied with, it can be ensured that state-of-the-art
technology has been utilized and therefore the erector/builder of a plant or a
manufacturer of a machine or a piece of equipment has fulfilled his appropriate
responsibility.
Safety systems are intended to play their role in keeping potential hazards for both
people and the environment as low as possible by using suitable technical equip-
ment, without restricting, more than absolutely necessary, industrial production and
the use of machines. The protection of man and environment has to be put on an
equal footing in all countries by applying rules and regulations that have been inter-
nationally harmonized. At the same time, this is also intended to avoid that safety
requirements in different countries have an impact on the competitive situation –
i.e. the intention is to facilitate international trade.
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 re-
sponsibilities.
What is important for manufacturers of machines and companies that erect plants
and systems is that always the local legislation and regulations apply 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 ma-
chinery construction company (OEM) is based in Europe.
1

Regulations and Standards
1.2 Safety of machinery in Europe
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1.1.2 Functional safety
Safety, from the perspective of the object to be protected, cannot be split-up. The
causes of hazards and therefore also the technical measures to avoid them can
vary significantly. This is the reason that a differentiation is made between different
types of safety – e.g. by specifying the cause of possible hazards. “Functional sa-
fety” 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 re-
mains 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 associated Standards. The requirements to achieve
functional safety are based on the following basic goals:
SAvoiding systematic faults
SControlling systematic faults
SControlling random faults or failures
The measure for the achieved functional safety is the probability of dangerous fail-
ures, the fault tolerance and the quality that should be guaranteed as a result of
freedom from systematic faults. This is expressed in the Standards using different
terms. In IEC 61508: “Safety Integrity Level” (SIL), in EN 954: “Categories” and
ISO 13849–1 “Performance Level” (PL) (this has still not been ratified).
1.2 Safety of machinery in Europe
The EU Directives, that apply to the implementation of products, based on Article
95 of the EU contract, that regulates the free exchange of goods. These are based
on a new global concept (“new approach”, “global approach”):
SEU Directives only specify generally valid safety goals and define basic safety
requirements.
STechnical details can be defined in Standards by Standards Associations that
have an appropriate mandate from the EU Commission (CEN,CENELEC).
These Standards are harmonized under a specific Directive and are listed in the
Official Journal of the EU. When the harmonized Standards are complied with,
then it can be assumed that the safety requirements and specifications of the
Directives involved are fulfilled.
SLegislation does not specify that certain standards have to be complied with.
However, when specific Standards are complied with, then it can be assumed
that the safety goals of the EU Directives involved are also fulfilled.
SEU Directives specify that the Member States must mutually recognize domes-
tic regulations.

Regulations and Standards
1.2 Safety of machinery in Europe
03.06
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©Siemens AG, 2006. All rights reserved
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The EU Directives are equal. This means that if several Directives apply for a spe-
cific piece of equipment or device, then the requirements of all of the relevant Di-
rectives apply (e.g. for a machine with electrical equipment, then the Machinery
Directive and the Low-Voltage Directive apply).
1.2.1 Machinery Directive (98/37/EC)
With the introduction of a European common market, a decision was made that the
domestic Standards and regulations of all of the EU Member States – that are in-
volved 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 legislation of the
individual Member States. For the Machinery Directive, this was realized with the
objective to achieve standard protective goals thus removing trade barriers result-
ing from technical differences. Corresponding to its definition “a machine is an as-
sembly of linked parts or components – at least one of which moves”, this Directive
is extremely extensive. The range of applications was subsequently expanded to
include “safety-related components” and “exchangeable equipment” in the form of
revision Directives.
The Machinery Directive involves the implementation of machines. It has 14 Ar-
ticles and 7 Annexes. The basic safety and health requirements specified in Annex
I of the Directive must be fulfilled for the safety of machines. The manufacturer
must carefully observe the following principles when it comes to integrating safety
(Annex I, Paragraph 1.1.2):
a) “Machinery must be constructed that it is fitted for its functions, and can be
adjusted and maintained without putting persons at risk when these opera-
tions are carried-out under the conditions foreseen by the manufacturer.“
“The measures must...eliminate...any risks of accidents...!”
b) “When selecting the appropriate solutions, the manufacturer must apply the
following basic principles – and more precisely, in the specified sequence:
SEliminate or minimize hazards (by integrating the safety concept into the
development and construction of the machine);
SApply and use the necessary protective measures to protect against dan-
gers that cannot be avoided;
SInform the user about the residual dangers due to the fact that the safety
measures applied are not completely effective.”
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 proof is made more simple by applying
harmonized Standards.

Regulations and Standards
1.2 Safety of machinery in Europe
03.06
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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 pre-
cisely specify the requirements of the EU Directives for a specific product. These
Standards (EN Standards) are published in the Official Journal of the European
Communities and must be included in domestic standards without any revisions.
These are used to fulfill the basic health and safety requirements and the protec-
tive 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. The listing in the Official
European Journal is decisive.
The European Standards for Safety of Machines is hierarchically structured as fol-
lows:
SA standards (basic standards)
SB standards (group standards)
SC standards (product standards)
Regarding type A standards/basic standards
A Standards include basic terminology and definitions that are applicable for all
machines. This includes EN ISO 12100 (previously EN 292) “Safety of Machines,
Basic Terminology, General Design Principles”.
A Standards primarily address those bodies setting the B and C Standards. How-
ever, the techniques documented there regarding minimizing risks can also be
helpful to manufacturers if there are no applicable C Standards.
Regarding type B standards/group standards
B Standards include all Standards with safety-related statements that can involve
several machine types.
B Standards also primarily address those bodies setting C Standards. However,
they can also be helpful for manufacturers when designing and constructing a ma-
chine if no C Standards apply.
For B Standards, an additional sub-division is made - and more precisely as fol-
lows:
–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 ma-
chine types – e.g. Emergency Stop devices, two-hand operating circuits,
interlocking elements, contactless protective devices, safety-related parts of
controls.

Regulations and Standards
1.2 Safety of machinery in Europe
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©Siemens AG, 2006. All rights reserved
SINUMERIK 840D sl/SINAMICS S120 SINUMERIK Safety Integrated (FBSI sl) – 03.2006 Edition
Regarding type C standards/product standards
C Standards are Standards for specific machines – 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. For
machinery construction companies (e.g. OEMs), Type C Standards/Product Stan-
dards have absolutely the highest priority. The machinery construction company
can then assume that it fulfills the basic requirements of Attachment I of the Ma-
chinery Directive (automatic presumption of compliance).
If, for a particular machine, no Product Standard is available, then Type B Stan-
dards can be used as help when designing and constructing a machine.
All of the listed Standards as well as the mandated Draft Standards are provided in
the Internet under:
http://www.newapproach.org/
Recommendation: Technical development is progressing at a tremendous pace
and with it changes and modifications to machine concepts. This is the reason that
especially when using C Standards, it should be carefully checked as to whether
they are still up-to-date. Where relevant, it should be noted that it is not mandatory
that the Standard is applied but that the safety goal must be achieved.

Regulations and Standards
1.2 Safety of machinery in Europe
03.06
1-20 ©Siemens AG, 2006. All rights reserved
SINUMERIK 840D sl/SINAMICS S120 SINUMERIK Safety Integrated (FBSI sl) – 03.2006 Edition
1.2.3 Standards to implement safety-related programmable electronic
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. This is the reason that Standard IEC 61508 must be
carefully observed when using programmable electronic systems. ISO 13849–1
and EN 954–1 and IEC 62061 provide instructions specifically addressing the sa-
fety of machine controls.
–3 (from PL b)
IEC 61508
or the
Any architectures,
all SIL 1
Defined architectures, restricted
maximum PL for electronics
IEC 62061
Safety of machinery
Functional safety, safety–
related electrical, electronic
and programmable electronic
control systems
pr EN ISO 13849 (rev)
Safety of machinery
Safety–related parts of
controllers
Functional safety, safety–related electrical/electronic/
programmable electronic control systems
(part 1 to part 7)
systems, that execute safety functions or guarantee functional safety
sector standard IEC 62061 f
area of machines below
IEC 61508
For deviations from the
designated architectures
Reference to the IEC 61508
Universal use for electrical, electronic and programmable electronic
The areas of application of ISO 13849–1 and IEC 62061 are very similar. In order
to help users make a decision, the IEC and ISO associations have defined in detail
the application areas of both Standards in a common table in the introduction to
the Standards. Either prEN ISO 13849–1 (rev) or EN IEC 62061 is applied depen-
ding on the particular technology (mechanical, hydraulic, pneumatic, electrical,
electronic, programmable electronic), risk classification and architecture.