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
03.06
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. . . . . . . . . . . . . . . . . . . . . . . . .