Siemens SINUMERIK 840D sl Parts list manual

SINUMERIK
SINUMERIK 840D sl
Safety Integrated
Function Manual
Valid for
Control system
SINUMERIK 840D sl / 840DE sl
Software version
NCU system software for 840D sl/840DE sl 4.8 SP2
12/2017
6FC5397-4BP40-6BA1
Preface
Fundamental safety
instructions 1
Regulations and standards 2
Brief description 3
System features 4
Safety Functions integrated
in the drive 5
Basics regarding the safety
functions integrated in the
system/drive 6
Safety functions integrated in
the system/drive 7
Connecting sensors and
actuators 8
Data descriptions 9
Commissioning 10
Diagnostics 11
Interaction with other
functions 12
Appendix 13

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
Document order number: 6FC5397-4BP40-6BA1
Ⓟ 01/2018 Subject to change
Copyright © Siemens AG 2006 - 2017.
All rights reserved

Preface
SINUMERIK documentation
The SINUMERIK documentation is organized into the following categories:
● General documentation/catalogs
● User documentation
● Manufacturer/service documentation
Additional information
You can find information on the following topics at the following address:
● Ordering documentation/overview of documentation
● Additional links to download documents
● Using documentation online (find and search in manuals/information)
If you have any questions regarding the technical documentation (e.g. suggestions,
corrections), please send an e-mail to the following address.
mySupport/Documentation
At the following address, you can find information on how to create your own individual
documentation based on Siemens' content, and adapt it for your own machine documentation.
Training
At the following address, you can find information about SITRAIN (Siemens training on
products, systems and solutions for automation and drives).
FAQs
You can find Frequently Asked Questions in the Service&Support pages under Product
Support.
SINUMERIK
You can find information about SINUMERIK at the following address.
Safety Integrated
Function Manual, 12/2017, 6FC5397-4BP40-6BA1 3

Target group
This publication is intended for:
● Project engineers
● Technologists (from machine manufacturers)
● System startup engineers (Systems/Machines)
● 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.
Standard version
This documentation only describes the functionality of the standard version. Extensions or
changes made by the machine tool manufacturer are documented by the machine tool
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 at the
following address in the "Contact" area.
Preface
Safety Integrated
4Function Manual, 12/2017, 6FC5397-4BP40-6BA1

Table of contents
Preface.........................................................................................................................................................3
1Fundamental safety instructions.................................................................................................................11
1.1 General safety instructions.....................................................................................................11
1.2 Equipment damage due to electric fields or electrostatic discharge......................................14
1.3 Warranty and liability for application examples......................................................................14
1.4 Industrial security...................................................................................................................15
1.5 Residual risks of power drive systems...................................................................................16
2 Regulations and standards.........................................................................................................................17
2.1 General..................................................................................................................................17
2.1.1 Objective................................................................................................................................17
2.1.2 Functional safety....................................................................................................................17
2.2 Machine safety in Europe.......................................................................................................18
2.2.1 Machinery directive (2006/42/EC)..........................................................................................18
2.2.2 Harmonized European standards..........................................................................................19
2.2.3 Standards for implementing safety-related controls...............................................................20
2.2.4 EN ISO 13849-1.....................................................................................................................21
2.2.5 EN 62061...............................................................................................................................21
2.2.6 Series of standards EN 61508 (VDE 0803)...........................................................................23
2.2.7 EN 60204-1............................................................................................................................24
2.2.8 EN 61800-5-2.........................................................................................................................24
2.2.9 Risk analysis/assessment......................................................................................................25
2.2.10 Risk reduction........................................................................................................................26
2.2.11 Residual risk...........................................................................................................................27
2.3 Machine safety in the USA.....................................................................................................27
2.3.1 Minimum requirements of the OSHA.....................................................................................27
2.3.2 NRTL listing............................................................................................................................28
2.3.3 NFPA 79.................................................................................................................................28
2.3.4 ANSI B11...............................................................................................................................29
2.4 Machine safety in Japan........................................................................................................29
2.5 Equipment regulations...........................................................................................................30
2.6 Other safety-related issues....................................................................................................30
2.6.1 Information sheets from the various regulatory bodies..........................................................30
2.6.2 Additional references.............................................................................................................30
2.6.3 Additional information ............................................................................................................31
3 Brief description..........................................................................................................................................33
3.1 Control/drive systems.............................................................................................................33
3.2 Safety technology integrated in the system...........................................................................34
3.2.1 Overview of the safety functions integrated in the system.....................................................35
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3.3 Safety technology integrated in the drive...............................................................................36
3.3.1 Overview of the safety functions integrated in the drive.........................................................38
3.4 Comparison of the function names........................................................................................38
4 System features..........................................................................................................................................41
4.1 System requirements.............................................................................................................41
4.2 Current information................................................................................................................43
4.3 Certifications..........................................................................................................................44
4.4 Probability of failure................................................................................................................44
4.5 Safety information & instructions and residual risks...............................................................44
4.5.1 General residual risks for PDS (Power Drive Systems).........................................................44
4.5.2 Additional safety information & instructions and residual risks for Safety Integrated.............46
5 Safety Functions integrated in the drive.....................................................................................................51
5.1 General information about SINAMICS Safety Integrated.......................................................51
5.1.1 Explanations and terminology................................................................................................51
5.1.2 Supported functions...............................................................................................................52
5.1.3 Supported functions: HLA module.........................................................................................53
5.1.4 Parameter, checksum, version, password.............................................................................54
5.1.5 Forced checking procedure....................................................................................................56
5.2 Safety instructions..................................................................................................................57
5.3 Safe Torque Off (STO)...........................................................................................................58
5.4 Safe Stop 1 (SS1, time-controlled).........................................................................................61
5.4.1 SS1 (time-controlled) with OFF3............................................................................................61
5.4.2 SS1 (time-controlled) with external stop................................................................................63
5.4.3 Overview of important parameters.........................................................................................63
5.5 Safe Brake Control (SBC)......................................................................................................64
5.6 Control via terminals on the Control Unit and the power unit.................................................66
5.6.1 Features.................................................................................................................................66
5.6.2 Simultaneity and tolerance time of the two monitoring channels...........................................68
5.6.3 Bit pattern test........................................................................................................................69
5.7 Commissioning the STO, SBC and SS1 functions.................................................................70
5.7.1 General information about commissioning safety functions...................................................70
5.7.2 Sequence when commissioning STO, SBC and SS1............................................................71
5.7.3 Safety faults...........................................................................................................................75
5.8 Acceptance test and acceptance report.................................................................................77
5.9 Overview of parameters and function diagrams.....................................................................77
5.10 Connecting external SINAMICS drives as PLC/NC axes.......................................................78
6 Basics regarding the safety functions integrated in the system/drive.........................................................81
6.1 Monitoring cycle.....................................................................................................................81
6.2 Crosswise data comparison (CDC)........................................................................................81
6.3 Forced checking procedure....................................................................................................82
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6.4 Actual value conditioning.......................................................................................................84
6.4.1 Encoder types........................................................................................................................84
6.4.2 Encoder adjustment, calibrating the axes..............................................................................89
6.4.3 Axis states..............................................................................................................................90
6.4.4 User agreement.....................................................................................................................92
6.4.5 Selector gearboxes................................................................................................................94
6.4.5.1 Taking into account selector gearboxes.................................................................................94
6.4.5.2 Gearbox with direction of rotation reversal.............................................................................95
6.4.6 Actual value synchronization (slip for 2-encoder systems)....................................................96
6.4.7 Encoder limit frequency..........................................................................................................98
6.5 Enabling the safety-related functions.....................................................................................98
6.6 Switching the system on/off...................................................................................................99
7 Safety functions integrated in the system/drive........................................................................................101
7.1 Safe standstill (SH)..............................................................................................................101
7.1.1 Switch-off signal paths.........................................................................................................103
7.1.2 Testing the switch-off signal paths.......................................................................................105
7.2 Safe Operating Stop (SBH)..................................................................................................106
7.2.1 Selecting/deselecting the Safe Operating Stop....................................................................107
7.2.2 Effects when the limit is exceeded for SBH.........................................................................110
7.3 Safe Stops A-F.....................................................................................................................112
7.3.1 General................................................................................................................................112
7.3.2 Description of STOP A.........................................................................................................118
7.3.3 Description of STOP B.........................................................................................................120
7.3.4 Description of STOP C.........................................................................................................122
7.3.5 Braking response for STOP B/C..........................................................................................123
7.3.6 Description of STOP D.........................................................................................................123
7.3.7 Description of STOP E.........................................................................................................125
7.3.8 Description of STOP F.........................................................................................................127
7.3.9 Forced checking procedure of the external STOPs.............................................................131
7.3.10 Canceling stopping delay times...........................................................................................132
7.4 Safe Acceleration Monitor....................................................................................................134
7.5 Safely reduced speed (SG)..................................................................................................137
7.5.1 Speed monitoring, encoder limit frequency..........................................................................138
7.5.2 Selecting/deselecting safely reduced speed........................................................................139
7.5.3 Effects when the limit value is exceeded for SG..................................................................141
7.5.4 Override for safely reduced speed.......................................................................................144
7.5.5 Example: Override for safely reduced speed.......................................................................147
7.6 Safe speed range detection "n<nx"......................................................................................148
7.6.1 Basic function "n<nx"...........................................................................................................149
7.6.2 Function "Synchronization, hysteresis and filtering n<nx"....................................................150
7.7 Safe software limit switches (SE).........................................................................................154
7.7.1 Effects when an SE responds..............................................................................................155
7.8 Safety software cams and safety cam track (SN)................................................................157
7.8.1 Safe software cams (4 cam pairs)........................................................................................159
7.8.2 Safe Cam Track...................................................................................................................162
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8 Connecting sensors and actuators...........................................................................................................171
8.1 Safety-related input/output signals.......................................................................................171
8.1.1 Overview of the SGEs/SGAs and their structure.................................................................171
8.1.2 Forced checking procedure of SPL signals..........................................................................177
8.1.3 Connecting sensors - actuators using the 3-terminal concept.............................................179
8.1.4 Sensor connection using the 4-terminal concept.................................................................181
8.1.5 Multiple distribution and multiple interlocking.......................................................................183
8.2 Connecting I/O via PROFIsafe.............................................................................................184
8.2.1 Function description.............................................................................................................184
8.2.2 System structure..................................................................................................................186
8.2.3 Configuring and parameterizing the PROFIsafe I/O............................................................187
8.2.4 Parameterizing the F-master (NCK).....................................................................................193
8.2.5 Parameterizing the PROFIsafe communication (NCK)........................................................194
8.2.6 parameterizing the SPL-SGE interface................................................................................196
8.2.7 Parameterizing the SPL-SGA interface................................................................................201
8.2.8 Module type (NCK)...............................................................................................................204
8.2.9 Parameterizing the F-master (PLC).....................................................................................205
8.2.10 Response times...................................................................................................................206
8.2.11 Functionality of the SPL input/output data...........................................................................208
8.2.12 Functional secondary conditions..........................................................................................209
8.2.13 PROFIsafe communication response when system errors occur........................................210
8.3 Modular PROFIsafe I/O interface.........................................................................................211
8.3.1 PROFIsafe input modules....................................................................................................211
8.3.2 PROFIsafe output modules..................................................................................................214
8.4 Safety-related CPU-CPU communication (F_DP communication).......................................215
8.4.1 Configuring and parameterizing the F_DP communication..................................................218
8.4.2 Sender F_SENDDP..............................................................................................................221
8.4.3 Receiver F_RECVDP...........................................................................................................230
8.4.4 Mapping the SIMATIC blocks...............................................................................................241
8.4.5 Parameterizing the PLC.......................................................................................................243
8.4.6 Clock cycle setting of the F_DP communication..................................................................243
8.4.7 Response times of the F_DP communication......................................................................244
8.4.8 Boot behavior of the F_DP communication..........................................................................246
8.4.9 Communication error after the control boots and active SPL processing............................248
8.4.10 Communication error when booting before SPL processing starts......................................251
8.4.11 Acknowledging a communication error with channel_1 reset..............................................252
8.4.12 F_DP communication for a system error..............................................................................252
8.4.13 NCK/PLC data exchange.....................................................................................................254
8.4.14 Effects on the SPL...............................................................................................................254
8.4.15 Functionality of the SPL input/output data...........................................................................255
8.4.16 Supplementary conditions....................................................................................................256
8.5 Safe programmable logic.....................................................................................................256
8.5.1 Fundamentals......................................................................................................................257
8.5.2 Synchronized actions for Safety Integrated.........................................................................261
8.5.3 User configurations..............................................................................................................261
8.5.4 NCK-SPL program...............................................................................................................262
8.5.5 Starting the SPL...................................................................................................................265
8.5.6 Language scope for SAFE.SPF...........................................................................................270
8.5.7 Diagnostics/commissioning..................................................................................................275
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8.5.8 Safe software relay..............................................................................................................277
8.5.9 System variables for SINUMERIK 840D sl..........................................................................282
8.5.10 Behavior after power on/mode change/reset.......................................................................288
8.5.11 SPL data on the PLC side....................................................................................................288
8.5.12 Direct communications between NCK and PLC-SPL...........................................................289
8.6 Safe Brake Test (SBT).........................................................................................................290
8.6.1 Applications..........................................................................................................................290
8.6.2 Parameterization..................................................................................................................291
8.6.3 Torque limits.........................................................................................................................295
8.6.4 Traversing direction for the brake test..................................................................................296
8.6.5 Brake control for SINUMERIK 840D sl.................................................................................297
8.6.6 Sequence.............................................................................................................................297
8.6.7 Description of FB11..............................................................................................................300
8.6.8 Application example.............................................................................................................302
8.6.9 Supplementary conditions....................................................................................................308
8.7 Safety Information Channel and Safety Control Channel....................................................309
9 Data descriptions......................................................................................................................................311
9.1 Machine data for SINUMERIK 840D sl................................................................................311
9.1.1 Overview of the machine data..............................................................................................311
9.1.2 Description of machine data.................................................................................................317
9.2 Parameters for SINAMICS S120..........................................................................................394
9.2.1 Parameters for SINAMICS S120..........................................................................................394
9.2.2 Parameter overview.............................................................................................................395
9.2.3 Description of parameters....................................................................................................401
9.3 NCK-MD that are read from Safety Integrated.....................................................................473
9.4 Drive parameters that are read from the NCK-SI.................................................................473
9.5 Protecting checksum............................................................................................................474
9.6 Interface signals...................................................................................................................475
9.6.1 Interface signals for SINUMERIK 840D sl............................................................................476
9.6.2 Description of the interface signal........................................................................................477
9.6.3 PLC data block (DB18)........................................................................................................486
9.6.4 Axis signals: Safety Control Channel (SCC) / Safety Information Channel (SIC)................503
9.7 System variable....................................................................................................................504
9.7.1 System variable for SINUMERIK 840D sl............................................................................504
9.7.2 Description of the system variables.....................................................................................511
10 Commissioning.........................................................................................................................................523
10.1 Alarms..................................................................................................................................523
10.2 Images of the user interface and softkeys...........................................................................524
10.3 Procedure when commissioning the drive for the first time..................................................535
10.4 Series commissioning..........................................................................................................540
10.5 Changing machine data.......................................................................................................541
10.6 Acceptance test....................................................................................................................543
10.6.1 General................................................................................................................................543
10.6.2 Conventional acceptance test..............................................................................................550
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10.6.3 Acceptance test support.......................................................................................................553
10.7 Replacing a motor or encoder..............................................................................................557
10.7.1 Replacing a hardware component.......................................................................................564
11 Diagnostics...............................................................................................................................................565
11.1 Troubleshooting procedure..................................................................................................565
11.1.1 Service displays...................................................................................................................566
11.1.2 Safety Integrated global checksums....................................................................................580
11.1.3 Integrating safety SPL user alarms......................................................................................584
11.1.4 Trace bit graphics for Safety Integrated...............................................................................589
11.2 NCK safety alarms for SINUMERIK 840D sl........................................................................595
11.3 Safety messages for SINAMICS S120.................................................................................692
11.3.1 General................................................................................................................................692
11.3.2 List of faults and alarms.......................................................................................................695
11.4 Safety PLC alarms...............................................................................................................745
11.5 Reducing the number of alarms...........................................................................................746
11.5.1 Alarm suppression...............................................................................................................746
11.5.2 Assigning priorities to alarms...............................................................................................748
12 Interaction with other functions.................................................................................................................751
12.1 Limiting the speed setpoint..................................................................................................751
12.2 Setpoint switchover..............................................................................................................752
12.3 Measuring system switchover..............................................................................................754
12.4 Gantry axes..........................................................................................................................754
12.5 Parking axis..........................................................................................................................755
12.6 Incremental encoder functionality........................................................................................756
12.7 OEM applications.................................................................................................................756
12.8 NCU-Link..............................................................................................................................757
12.9 Response of the Sim-NCK systems.....................................................................................757
12.10 Response of Safety Integrated when the communication fails............................................758
12.10.1 Delayed pulse cancellation in the event of communication failure.......................................758
13 Appendix...................................................................................................................................................763
13.1 Customer support.................................................................................................................763
13.2 References...........................................................................................................................764
13.3 Abbreviations.......................................................................................................................765
13.4 List of links for SINUMERIK Safety Integrated application examples .................................769
Glossary...................................................................................................................................................771
Index.........................................................................................................................................................773
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Fundamental safety instructions 1
1.1 General safety instructions
WARNING
Electric shock and danger to life due to other energy sources
Touching live components can result in death or severe injury.
● Only work on electrical devices when you are qualified for this job.
● Always observe the country-specific safety rules.
Generally, the following six steps apply when establishing safety:
1. Prepare for disconnection. Notify all those who will be affected by the procedure.
2. Isolate the drive system from the power supply and take measures to prevent it being
switched back on again.
3. Wait until the discharge time specified on the warning labels has elapsed.
4. Check that there is no voltage between any of the power connections, and between any
of the power connections and the protective conductor connection.
5. Check whether the existing auxiliary supply circuits are de-energized.
6. Ensure that the motors cannot move.
7. Identify all other dangerous energy sources, e.g. compressed air, hydraulic systems, or
water. Switch the energy sources to a safe state.
8. Check that the correct drive system is completely locked.
After you have completed the work, restore the operational readiness in the inverse sequence.
WARNING
Electric shock due to connection to an unsuitable power supply
When equipment is connected to an unsuitable power supply, exposed components may
carry a hazardous voltage that might result in serious injury or death.
● 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.
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WARNING
Electric shock due to equipment damage
Improper handling may cause damage to equipment. 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
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
Electric shock if there is no ground connection
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
Spread of fire from built-in devices
In the event of fire outbreak, the enclosures of built-in devices cannot prevent the escape of
fire and smoke. This can result in serious personal injury or property damage.
● Install built-in units in a suitable metal cabinet in such a way that personnel are protected
against fire and smoke, or take other appropriate measures to protect personnel.
● Ensure that smoke can only escape via controlled and monitored paths.
Fundamental safety instructions
1.1 General safety instructions
Safety Integrated
12 Function Manual, 12/2017, 6FC5397-4BP40-6BA1

WARNING
Unexpected movement of machines caused by radio devices or mobile phones
When radio devices or mobile phones with a transmission power > 1 W are used in the
immediate vicinity of components, they may cause the equipment to malfunction.
Malfunctions may impair the functional safety of machines and can therefore put people in
danger or lead to property damage.
● If you come closer than around 2 m to such components, switch off any radios or mobile
phones.
● Use the "SIEMENS Industry Online Support App" only on equipment that has already been
switched off.
WARNING
Fire due to inadequate 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
Unexpected movement of machines caused by inactive safety functions
Inactive or non-adapted safety functions can trigger unexpected machine movements that
may result in 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.
Fundamental safety instructions
1.1 General safety instructions
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Function Manual, 12/2017, 6FC5397-4BP40-6BA1 13

WARNING
Malfunctions of the machine as a result of incorrect or changed parameter settings
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.
● Handle possible malfunctions by taking suitable measures, e.g. emergency stop or
emergency off.
1.2 Equipment damage due to electric fields or electrostatic discharge
Electrostatic sensitive devices (ESD) are individual components, integrated circuits, modules
or devices that may be damaged by either electric fields or electrostatic discharge.
NOTICE
Equipment damage due to 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).
1.3 Warranty and liability for application examples
The application examples are not binding and do not claim to be complete regarding
configuration, equipment or any eventuality which may arise. The application examples do not
represent specific customer solutions, but are only intended to provide support for typical tasks.
You are responsible for the proper operation of the described products. These application
examples do not relieve you of your responsibility for safe handling when using, installing,
operating and maintaining the equipment.
Fundamental safety instructions
1.3 Warranty and liability for application examples
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1.4 Industrial security
Note
Industrial security
Siemens provides products and solutions with industrial security functions that support the
secure operation of plants, systems, machines and networks.
In order to protect plants, systems, machines and networks against cyber threats, it is
necessary to implement – and continuously maintain – a holistic, state-of-the-art industrial
security concept. Siemens products and solutions only represent one component of such a
concept.
The customer is responsible for preventing unauthorized access to its plants, systems,
machines and networks. Systems, machines and components should only be connected to
the enterprise network or the internet if and to the extent necessary and with appropriate
security measures (e.g. use of firewalls and network segmentation) in place.
Additionally, Siemens’ guidance on appropriate security measures should be taken into
account. For more information about industrial security, please visit:
Industrial security (http://www.siemens.com/industrialsecurity).
Siemens’ products and solutions undergo continuous development to make them more secure.
Siemens strongly recommends to apply product updates as soon as available and to always
use the latest product versions. Use of product versions that are no longer supported, and
failure to apply latest updates may increase customer’s exposure to cyber threats.
To stay informed about product updates, subscribe to the Siemens Industrial Security RSS
Feed at:
Industrial security (http://www.siemens.com/industrialsecurity).
WARNING
Unsafe operating states resulting from software manipulation
Software manipulations (e.g. viruses, trojans, malware or worms) can cause unsafe operating
states in your system that may lead to death, serious injury, and property damage.
● Keep the software up to date.
● Incorporate the automation and drive components into a holistic, state-of-the-art industrial
security concept for the installation or machine.
● Make sure that you include all installed products into the holistic industrial security concept.
● Protect files stored on exchangeable storage media from malicious software by with
suitable protection measures, e.g. virus scanners.
Fundamental safety instructions
1.4 Industrial security
Safety Integrated
Function Manual, 12/2017, 6FC5397-4BP40-6BA1 15

1.5 Residual risks of power drive systems
When assessing the machine- or system-related risk in accordance with the respective local
regulations (e.g., EC Machinery Directive), the machine manufacturer or system installer 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 or system 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 electronic
components
– External influences/damage
– X-ray, ionizing radiation and cosmic radiation
2. Unusually high temperatures, including open flames, as well as emissions of light, noise,
particles, gases, etc., can occur inside and outside the components under fault conditions
caused by, for example:
– Component failure
– Software errors
– Operation and/or environmental conditions outside the specification
– External influences/damage
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
6. Influence of network-connected communication systems, e.g. ripple-control transmitters or
data communication via the network
For more information about the residual risks of the drive system components, see the relevant
sections in the technical user documentation.
Fundamental safety instructions
1.5 Residual risks of power drive systems
Safety Integrated
16 Function Manual, 12/2017, 6FC5397-4BP40-6BA1

Regulations and standards 2
2.1 General
2.1.1 Objective
Manufacturers and operators of technical equipment and products are responsible in
minimizing the risk from plants, machines and other technical equipment corresponding to
state-of-the-art technology. Regulations and standards are essential documents that define
the minimum requirements to minimize risks. By maintaining these minimum requirements,
the company erecting a plant or a manufacturer of a machine or a piece of equipment can
prove that they have fulfilled their obligation to exercise care and diligence.
Safety systems are designed to minimize potential hazards for both people and the
environment by means of suitable technical equipment, without restricting industrial production
and the use of machines more than necessary. Protection of man and the environment is to
be standardized using internationally harmonized safety standards. Further, unfair competition
due to different local requirements is to be avoided.
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 legislation and the
requirements of how and when proof is to be given and whether there is an adequate level of
safety are just as different as the assignment of responsibilities.
For manufacturers of machines and companies that erect plants and systems it is important
that the local legislation and regulations always apply for that country where the machine or
plant is being operated. For example, the control system for a machine that is to be used in
the US must fulfill local US requirements even if the machinery construction company (OEM)
is based in the European Economic Area (EEA).
2.1.2 Functional safety
From the perspective of the object to be protected, safety is indivisible. The causes of hazards
and therefore also the technical measures to avoid them can vary 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 safety" is involved if safety depends on the correct
function.
To ensure the functional safety of a machine or plant, the safety-related parts of the protection
and control devices must function correctly. In addition, the systems must behave in such a
way that either the plant remains in a safe state or it is brought into a safe state if a fault occurs.
Safety Integrated
Function Manual, 12/2017, 6FC5397-4BP40-6BA1 17

In this case, it is necessary to use specially qualified technology that fulfills the requirements
described in the relevant standards. The requirements to achieve functional safety are based
on the following basic goals:
● Avoiding systematic faults,
● Controlling systematic faults,
● Controlling random faults or failures.
The level of the functional safety achieved is expressed using different terms in the standards.
In EN 61508, EN 62061, EN 61800-5-2: "Safety Integrity Level" (SIL) and EN ISO 13849-1
"Performance Level" (PL).
2.2 Machine safety in Europe
The EU Directives that apply to the implementation of products are based on Article 95 of the
EU contract, which regulates the free exchange of goods. This is based on a new global
concept ("new approach", "global approach"):
● EC directives only specify general protection goals and define basic safety requirements.
● Technical details can be defined by means of standards by Standards Associations that
have the appropriate mandate from the Commission of the European Parliament and
Council (CEN, CENELEC). These standards are harmonized in line with a specific directive
and listed in the official journal of the commission of the European Parliament and Council.
Legislation does not specify that certain standards have to be complied with. When the
harmonized Standards are observed, it can be assumed that the safety requirements and
specifications of the Directives involved have been fulfilled.
In order to market or sell a product in the European Economic Area (EEA), this product must
fulfill the protective goals and requirements of all of the applicable EC directives. For machines,
in addition to the machinery directive, these can also include e.g. the EMC directive, the noise
protection directive, the guideline for explosion protection, the low-voltage directive.
2.2.1 Machinery directive (2006/42/EC)
When the European common market was launched, a decision was made that the domestic
standards and regulations of all of the EU Member States relating to the technical
implementation of machines would be harmonized. The consequence of this was that the
contents of the machinery directive had to be implemented in national law as an internal market
directive by the individual member states. For the Machinery Directive, this was realized with
the aim of achieving standard safety objectives and, in turn, removing technical trade barriers.
The area of application of the machinery directive corresponding to its definition "Machinery
means an assembly of linked parts or components, at least one of which moves" is extremely
comprehensive. With the revised Edition from 2006, the range of applications has been
expanded to include, among other things, "Logic units for safety functions".
The machinery directive involves the implementation of machines. The basic safety and health
requirements specified in Annex I of the Directive must be fulfilled for the safety of machines.
The protective goals must be responsibly implemented in order to fulfill the requirement relating
to conformity with the directive.
Regulations and standards
2.2 Machine safety in Europe
Safety Integrated
18 Function Manual, 12/2017, 6FC5397-4BP40-6BA1

Manufacturers of a machine must verify that their machine complies with the basic
requirements. This verification is facilitated by means of harmonized standards.
2.2.2 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 precisely specify the requirements of the
EC directives for a specific product. These standards (EN standards) are published in the
Official Journal of the commission of the European Parliament and Council and must be
included without revision in domestic standards. They are designed to fulfill basic health and
safety requirements as well as the protective goals specified in Annex I of the Machinery
Directive.
When the harmonized standards are complied with, then there is an "automatic assumption"
that the directive is fulfilled. This means that the manufacturer may then assume that he has
complied with the safety aspects of the directive under the assumption that they are also
handled in that particular standard. However, not every European Standard is harmonized in
this sense. Key here is the listing in the official journal of the commission of the European
Parliament and Council.
European standards relating to the safety of machines are structured in a hierarchical manner
as follows:
A standards (basic standards)
B standards (group standards)
C standards (product standards)
Type A standards/basic standards
A standards include basic terminology and definitions relating to all types of machine. A
standards are aimed primarily at the bodies responsible for setting the B and C standards. The
measures specified here for minimizing risk, however, may also be useful for manufacturers
if no applicable C standards have been defined.
Type B standards/group standards
B standards cover all safety-related standards for various different machine types. B standards
are aimed primarily at the bodies responsible for setting C standards. They can also be useful
for manufacturers during the machine design and construction phases, however, if no
applicable C standards have been defined. A further sub-division has been made for B
standards, and more precisely in:
●Type B1 standards for higher-level safety aspects, e.g. basic ergonomic principles, safety
clearances from hazards, minimum clearances to avoid crushing parts of the body.
●Type B2 standards for protective safety devices are defined for various machine types –
e.g. Emergency Stop devices, two-hand operating circuits, interlocking elements,
contactless protective devices, safety-related parts of controls.
Type C standards/product standards
C standards are standards for specific products – for instance, machine tools, woodworking
machines, elevators, packaging machines, printing machines etc. Product standards list
Regulations and standards
2.2 Machine safety in Europe
Safety Integrated
Function Manual, 12/2017, 6FC5397-4BP40-6BA1 19

requirements for specific machines. The requirements can, under certain circumstances,
deviate from the basic and group standards. Type C/product standards have the highest priority
for machine manufacturers who can assume that it fulfills the basic requirements of Annex I
of the Machinery Directive (automatic presumption of compliance). If no product standard has
been defined for a particular machine, type B standards can be applied when the machine is
being constructed.
A complete list of the standards and the mandated draft standards are available on the Internet
at the following address:
http://www.newapproach.org/
Recommendation: Due to the rapid pace of technical development and the associated changes
in machine concepts, the standards (and C standards in particular) should be checked to
ensure that they are up to date. Where appropriate, note that the application of a particular
standard may not be mandatory provided that all the safety requirements of the applicable EU
directive are fulfilled.
2.2.3 Standards for implementing safety-related controls
If the functional safety of a machine depends on various control functions, the controller must
be implemented in such a way that the probability of the safety functions failing is sufficiently
minimized. The standards EN ISO 13849-1 and EN 62061 define guidelines for implementing
safety-related machine controls which, when properly applied, ensure that all the safety
requirements of the EC Machinery Directive are fulfilled. These standards ensure that the
relevant safety requirements of the Machinery Directive are fulfilled.
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Regulations and standards
2.2 Machine safety in Europe
Safety Integrated
20 Function Manual, 12/2017, 6FC5397-4BP40-6BA1