Siemens SINAMICS G120 Parts list manual

Answers for industry.
SINAMICS
SINAMICS G120
Frequency inverter
with Control Units CU240E-2 CU240E-2 DP
CU240E-2 F CU240E-2 DP-F
Function Manual Safety Integrated · 07/2010

Safety Integrated Function Manual,
SINAMICS G120
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SINAMICS
SINAMICS G120
Safety Integrated Function Manual,
SINAMICS G120
Function Manual
07/2010 Edition, Firmware V4.3.2
07/2010, FW 4.3.2
A5E03052391B AA
Introduction 1
Description
2
Activation
3
Commissioning
4
Servicing and maintenance
5
Alarms, faults and system
messages
6
System properties
7
Appendix
A

Legal information
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
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
NOTICE
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
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 for the specific task, 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 adhered to. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of the 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
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E03052391B AA
Ⓟ 06/2010
Copyright © Siemens AG 2010.
Technical data subject to change

Safety Integrated Function Manual, SINAMICS G120
Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA 5
Table of contents
1 Introduction................................................................................................................................................ 9
1.1 About this manual ..........................................................................................................................9
1.2 Guide through this manual...........................................................................................................10
1.3 Overview of documentation .........................................................................................................10
1.4 Commissioning guidelines ...........................................................................................................12
1.5 Notation........................................................................................................................................14
2 Description............................................................................................................................................... 15
2.1 SINAMICS G120 safety functions................................................................................................16
2.2 Examples of how the safety functions can be applied.................................................................17
2.3 Preconditions and constraints......................................................................................................18
2.3.1 General conditions .......................................................................................................................18
2.3.2 Permissible and prohibited applications ......................................................................................18
2.3.3 Impermissible functions ...............................................................................................................19
2.4 Safe Torque Off, STO ..................................................................................................................20
2.5 Safe Stop 1, SS1 .........................................................................................................................21
2.5.1 Basic principle of operation..........................................................................................................21
2.5.2 Dynamic response of SS1 ...........................................................................................................21
2.6 Safely Limited Speed, SLS ..........................................................................................................24
2.6.1 Basic principle of operation..........................................................................................................24
2.6.2 Selecting SLS when the motor is switched on.............................................................................24
2.6.3 Switching on the motor when SLS is active.................................................................................27
2.6.4 Switching between monitoring thresholds ...................................................................................28
2.7 Interrupting safety functions.........................................................................................................31
2.7.1 Selecting STO when SS1 is active ..............................................................................................31
2.7.2 Selecting STO when SLS is active ..............................................................................................32
2.7.3 Selecting SS1 when SLS is active...............................................................................................34
2.7.4 Switching off the motor when SS1 is active.................................................................................36
2.7.5 Switching off the motor when SLS is active.................................................................................37
2.7.6 Switching the motor on and off when SLS is active.....................................................................39
2.8 Password .....................................................................................................................................40
2.9 Checksum ....................................................................................................................................40
2.10 Forced dormant error detection ...................................................................................................40
3 Activation................................................................................................................................................. 43
3.1 Overview ......................................................................................................................................43
3.2 Activation via F-DI........................................................................................................................43
3.2.1 Fail-safe digital inputs ..................................................................................................................43
3.2.2 Connecting sensors directly.........................................................................................................44
3.2.2.1 Permitted sensors ........................................................................................................................44
3.2.2.2 Electromechanical sensor............................................................................................................45

Table of contents
Safety Integrated Function Manual, SINAMICS G120
6 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA
3.2.2.3 Series-connected electromechanical sensors ............................................................................ 46
3.2.2.4 Activating several inverters simultaneously ................................................................................ 47
3.2.2.5 Electronic sensor......................................................................................................................... 48
3.2.3 Connecting pre-processing devices............................................................................................ 49
3.2.3.1 Permissible pre-processing devices ........................................................................................... 49
3.2.3.2 3TK28 safety relay ...................................................................................................................... 49
3.2.3.3 3RK3 Modular Safety System..................................................................................................... 52
3.2.3.4 S7-300 I/O modules .................................................................................................................... 54
3.2.3.5 ET 200S I/O modules.................................................................................................................. 55
3.2.3.6 S7-400 I/O modules .................................................................................................................... 57
3.2.4 F-DI signal filtering ...................................................................................................................... 57
3.3 Activation via PROFIsafe ............................................................................................................ 60
3.3.1 Communication via PROFIsafe................................................................................................... 60
3.3.2 Telegram types ........................................................................................................................... 60
3.3.3 Control word 0 and status word 0 (Basic Safety)........................................................................ 61
3.3.4 Control word 0 and status word 0 (Extended Safety) ................................................................. 62
3.3.5 Control word 2 and status word 2 ............................................................................................... 63
3.3.6 Configuring communication in STEP 7 (telegram 30)................................................................. 64
3.3.7 Configuring communication in STEP 7 (telegram 900)............................................................... 66
3.3.8 Further steps ............................................................................................................................... 66
3.3.9 Example: Interface to the S7 safety program..............................................................................67
4 Commissioning ........................................................................................................................................ 69
4.1 Commissioning: Offline or online ................................................................................................ 69
4.2 Selecting the commissioning method .........................................................................................70
4.3 Basic Safety ................................................................................................................................ 72
4.3.1 Activate STO via F-DI. ................................................................................................................ 72
4.3.1.1 Defining the commissioning method ........................................................................................... 72
4.3.1.2 Assigning parameters to the STO............................................................................................... 73
4.3.1.3 Activate settings .......................................................................................................................... 73
4.3.1.4 Multiple assignment of the DI...................................................................................................... 74
4.3.1.5 Further steps ............................................................................................................................... 75
4.3.2 Activating STO via PROFIsafe.................................................................................................... 76
4.3.2.1 Defining the commissioning method ........................................................................................... 76
4.3.2.2 Parameterizing STO.................................................................................................................... 77
4.3.2.3 Activate settings .......................................................................................................................... 78
4.3.2.4 Further steps ............................................................................................................................... 78
4.3.3 Activating STO via PROFIsafe and F-DI..................................................................................... 79
4.3.3.1 Defining the commissioning method ........................................................................................... 79
4.3.3.2 Assigning parameters to the STO............................................................................................... 80
4.3.3.3 Activate settings .......................................................................................................................... 81
4.3.3.4 Multiple assignment of the DI...................................................................................................... 82
4.3.3.5 Further steps ............................................................................................................................... 83
4.4 Extended Safety.......................................................................................................................... 84
4.4.1 Extended Safety with activation via F-DI .................................................................................... 84
4.4.1.1 Defining the commissioning method ........................................................................................... 84
4.4.1.2 Configuring activation via FDI ..................................................................................................... 85
4.4.1.3 Configuring safety functions........................................................................................................ 87
4.4.1.4 Setting forced dormant error detection ....................................................................................... 87
4.4.1.5 Setting the gear ratio................................................................................................................... 88
4.4.1.6 Enabling safety functions ............................................................................................................ 88
4.4.1.7 Parameterizing STO.................................................................................................................... 89
4.4.1.8 Parameterizing SS1 .................................................................................................................... 90

Table of contents
Safety Integrated Function Manual, SINAMICS G120
Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA 7
4.4.1.9 Parameterizing SBR ....................................................................................................................90
4.4.1.10 Parameterizing SLS .....................................................................................................................91
4.4.1.11 Activate settings...........................................................................................................................92
4.4.1.12 Multiple assignment of the DI.......................................................................................................93
4.4.1.13 Further steps................................................................................................................................94
4.4.2 Extended Safety with activation via PROFIsafe ..........................................................................95
4.4.2.1 Defining the commissioning method............................................................................................95
4.4.2.2 Setting forced dormant error detection and the PROFIsafe address ..........................................96
4.4.2.3 Setting the gear ratio....................................................................................................................96
4.4.2.4 Enabling safety functions.............................................................................................................97
4.4.2.5 Parameterizing STO ....................................................................................................................98
4.4.2.6 Parameterizing SS1 .....................................................................................................................98
4.4.2.7 Parameterizing SBR ....................................................................................................................99
4.4.2.8 Parameterizing SLS ...................................................................................................................100
4.4.2.9 Defining the F-DI status .............................................................................................................100
4.4.2.10 Activate settings.........................................................................................................................101
4.4.2.11 Starting communication via PROFIsafe.....................................................................................102
4.4.2.12 Further steps..............................................................................................................................102
4.4.3 Extended Safety with activation via PROFIsafe and F-DI .........................................................103
4.4.3.1 Defining the commissioning method..........................................................................................103
4.4.3.2 Setting forced dormant error detection and the PROFIsafe address ........................................104
4.4.3.3 Setting the gear ratio..................................................................................................................104
4.4.3.4 Enabling safety functions...........................................................................................................105
4.4.3.5 Parameterizing STO ..................................................................................................................106
4.4.3.6 Parameterizing SS1 ...................................................................................................................107
4.4.3.7 Parameterizing SBR ..................................................................................................................107
4.4.3.8 Parameterizing SLS ...................................................................................................................108
4.4.3.9 Defining the F-DI status .............................................................................................................109
4.4.3.10 Activate settings.........................................................................................................................110
4.4.3.11 Starting communication via PROFIsafe.....................................................................................110
4.4.3.12 Multiple assignment of the DI.....................................................................................................111
4.4.3.13 Further steps..............................................................................................................................112
4.5 Offline commissioning................................................................................................................113
4.5.1 Offline parameterization.............................................................................................................113
4.5.2 Downloading parameters...........................................................................................................113
4.5.3 Further steps..............................................................................................................................114
4.6 Series commissioning ................................................................................................................115
4.7 Restoring the factory setting ......................................................................................................115
4.8 Acceptance test - Completion of commissioning.......................................................................116
4.8.1 Prerequisites and authorized persons .......................................................................................116
4.8.2 Complete acceptance test .........................................................................................................116
4.8.3 Reduced acceptance test ..........................................................................................................117
4.8.4 Documentation...........................................................................................................................118
4.8.5 Function test...............................................................................................................................120
4.8.5.1 Safe Torque Off, STO (Basic Safety) ........................................................................................120
4.8.5.2 Safe Torque Off, STO (Extended Safety) ..................................................................................121
4.8.5.3 Safe Stop 1, SS1 .......................................................................................................................122
4.8.5.4 Safely Limited Speed, SLS ........................................................................................................123
4.8.6 Completion of certificate ............................................................................................................125
5 Servicing and maintenance.................................................................................................................... 127
5.1 Replacing the inverter components ...........................................................................................127
5.2 Replacing the Control Unit.........................................................................................................129

Table of contents
Safety Integrated Function Manual, SINAMICS G120
8 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA
5.3 Replacing the Power Module .................................................................................................... 131
6 Alarms, faults and system messages..................................................................................................... 133
6.1 Operating states indicated on LEDs .........................................................................................133
6.2 Disturbance characteristics of the safety functions................................................................... 135
6.2.1 Cause of fault ............................................................................................................................ 135
6.2.2 Acknowledging faults using a fail-safe signal............................................................................136
6.2.3 STOP reactions......................................................................................................................... 137
6.2.4 Disturbance characteristics of Safe Torque Off, STO............................................................... 138
6.2.5 Disturbance characteristics of Safe Stop 1, SS1 ...................................................................... 141
6.2.6 Disturbance characteristics of Safely Limited Speed, SLS....................................................... 143
6.3 List of alarms............................................................................................................................. 145
6.4 List of faults ............................................................................................................................... 147
7 System properties.................................................................................................................................. 151
7.1 Response times ........................................................................................................................ 151
7.2 Certification ............................................................................................................................... 152
7.3 Probability of failure of the safety functions (PFH value).......................................................... 152
A Appendix................................................................................................................................................ 153
A.1 Standards and regulations ........................................................................................................ 153
A.1.1 General information................................................................................................................... 153
A.1.1.1 Aims .......................................................................................................................................... 153
A.1.1.2 Functional safety ....................................................................................................................... 153
A.1.2 Safety of machinery in Europe.................................................................................................. 154
A.1.2.1 Machinery Directive................................................................................................................... 154
A.1.2.2 Harmonized European Standards............................................................................................. 155
A.1.2.3 Standards for implementing safety-related controllers ............................................................. 157
A.1.2.4 EN ISO 13849-1 (previously EN 954-1).................................................................................... 158
A.1.2.5 EN 62061 .................................................................................................................................. 159
A.1.2.6 Series of standards EN 61508 (VDE 0803) .............................................................................. 161
A.1.2.7 Risk analysis/assessment......................................................................................................... 161
A.1.2.8 Risk reduction ........................................................................................................................... 163
A.1.2.9 Residual risk.............................................................................................................................. 163
A.1.3 Machine safety in the USA........................................................................................................ 163
A.1.3.1 Minimum requirements of the OSHA ........................................................................................ 164
A.1.3.2 NRTL listing............................................................................................................................... 164
A.1.3.3 NFPA 79.................................................................................................................................... 164
A.1.3.4 ANSI B11................................................................................................................................... 165
A.1.4 Machine safety in Japan ........................................................................................................... 166
A.1.5 Equipment regulations .............................................................................................................. 166
A.1.6 Other safety-related issues ....................................................................................................... 166
A.1.6.1 Additional references ................................................................................................................ 166
A.1.6.2 Information sheets issued by the Employer's Liability Insurance Association.......................... 167
Index...................................................................................................................................................... 169

Safety Integrated Function Manual, SINAMICS G120
Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA 9
Introduction 1
1.1 About this manual
Who requires this manual and why?
This manual is aimed primarily at machine and plant manfacturers, commissioning
engineers, and service personnel. It describes the integrated safety functions of the
SINAMICS G120 inverter and enables the target groups specified to parameterize and
commission the integrated safety functions of the inverter correctly.
What is described in this manual?
This manual covers all the information, procedures and operations required for the following
scenarios:
● Activating the safety functions via fail-safe digital inputs or PROFIsafe.
● Commissioning the safety functions.
● Performing diagnostics for the safety functions.
The appendix contains an overview of the applicable regulations and standards for using the
safety functions.
What other information do you need?
This manual alone is not sufficient for installing or commissioning the standard inverter
functions. An overview of the documentation available and the associated applications is
provided in the sectionOverview of documentation (Page 10).
Mistakes and improvements
If you encounter mistakes when reading this manual or if you have any suggestions for how
it can be improved, please contact us at the following address or send your suggestion by E-
mail:
Siemens AG
Drive Technologies
Motion Control Systems
Postfach 3180
91050 Erlangen, Germany
E-mail (mailto:documentation.standard.d[email protected])
If you have further questions
Further information is provided in the STARTER PC tool's online help, the parameter manual
and the installation instructions. In addition, you will find Internet product support: Product
support (http://support.automation.siemens.com/WW/view/en/4000024).

Introduction
1.2 Guide through this manual
Safety Integrated Function Manual, SINAMICS G120
10 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA
1.2 Guide through this manual
Chapter Why do you need this information?
Description (Page 15) This chapter contains detailed information on the safety functions
of the inverter.
Activation (Page 43) If you use the fail-safe inputs of the inverter, this chapter contains
a series of wiring examples to help you. Refer to the relevant
example for the wiring you require for your particular application.
Read the description in this chapter if you want to configure
PROFIsafe communication.
Commissioning (Page 69) This chapter describes the different commissioning methods and
helps you choose the most appropriate method for your
application.
Alarms, faults and system
messages (Page 133)
This chapter contains information on the diagnostics and
troubleshooting procedures for the safety functions.
System properties (Page 151) This chapter provides an overview of all the key properties and
data of the safety functions.
Appendix (Page 153) The appendix contains an overview of the standards and
regulations that you, the machine manufacturer or operator, must
observe when using the safety functions.
1.3 Overview of documentation
Manuals and software are available for every inverter application:
Table 1- 1 Documentation for SINAMICS G120
Planning and configuring Installation and
connection
Commissioning Service and maintenance
SIZER
engineering tool
--- --- ---
Configuration Manual
Selecting geared motors,
motors and inverters
using calculation
examples
--- --- ---
Hardware Installation Manual, Power Modules
Comprehensive information on every Power
Module. Available for:
● PM230
● PM240
● PM250
● PM260
--- Hardware Installation Manual,
Power Modules
(refer to the lefthand column)

Introduction
1.3 Overview of documentation
Safety Integrated Function Manual, SINAMICS G120
Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA 11
Planning and configuring Installation and
connection
Commissioning Service and maintenance
Function Manual, Safety Integrated
Comprehensive information about the integrated safety functions of the CU240E-2 Control Unit
Operating instructions
Contains extensive information for most applications. Available for the following Control Units:
● CU230P-2
● CU240B-2 and CU240E-2
● CU240E and CU240S
--- --- STARTER
Commissioning tool
Getting Started
For entry level personnel to switch on the motor for the first time.
Available for Control Units:
● CU230P-2
● CU240B-2 and CU240E-2
● CU240E
● CU240S
---
--- --- Parameter Manual
Contains detailed lists of all parameters, alarms and faults as well as
graphic function block diagrams. Available for the following Control
Units:
● CU230P-2
● CU240B-2 and CU240E-2
● CU240E and CU240S
This is how you find the software and the manuals
SIZER You obtain SIZER on a DVD
(Order number: 6SL3070-0AA00-0AG0)
and can be downloaded from the Internet:
SIZER (http://support.automation.siemens.com/WW/view/en/10804987/130000)
Configuration Manual You can obtain the Configuration Manual from your local sales office
STARTER You obtain STARTER on a DVD (Order number: 6SL3072-0AA00-0AG0)
and can be downloaded from the Internet:
STARTER (http://support.automation.siemens.com/WW/view/en/10804985/130000)
Getting Started A paper copy of "Getting Started" is provided with each Control Unit
Operating instructions
and manuals
All of the manuals can be downloaded from the Internet:
Customer support (http://support.automation.siemens.com/WW/view/en/22339653/133300)
and are also available on DVD:
SD Manual Collection - all of the manuals on low-voltage motors, geared motors and low-
voltage inverters, 5 languages
Order number: 6SL3298-0CA00-0MG0 (supplied once)
Order number: 6SL3298-0CA10-0MG0 (update service for 1 year; supplied 4 times)

Introduction
1.4 Commissioning guidelines
Safety Integrated Function Manual, SINAMICS G120
12 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA
1.4 Commissioning guidelines
The steps for commissioning the safety functions form part of the activities for
commissioning the entire drive. Depending on whether you activate the safety functions via
fail-safe inputs or connect the inverter to PROFIsafe, we recommend that you use one the
following two commissioning procedures.
Activation via fail-safe digital inputs (F-DI)
Information on the commissioning
steps can be found in the following
sections or manuals:
①
STEP 7 manuals
②
Operating instructions
and
Fail-safe digital inputs (Page 43)
③
Operating instructions
④
Commissioning (Page 69)
⑤
Operating instructions
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Introduction
1.4 Commissioning guidelines
Safety Integrated Function Manual, SINAMICS G120
Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA 13
Activation via PROFIsafe (and, where appropriate, via F-DI)
Information on the commissioning
steps can be found in the following
sections or manuals:
①
STEP 7 manuals
②
Operating instructions
and
Fail-safe digital inputs (Page 43)
③
Operating instructions
and
Activation via PROFIsafe
(Page 60)
④
Commissioning (Page 69)
⑤
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Acceptance test - Completion of
commissioning (Page 116)

Introduction
1.5 Notation
Safety Integrated Function Manual, SINAMICS G120
14 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA
1.5 Notation
The following notation is used in this documentation:
Notation for parameters:
p0918 Adjustable parameter 918
r1024 Display parameter 1024
p1070[1] Adjustable parameter 1070, index 1
p2098[1].3 Adjustable parameter 2098, index 1 bit 3
p0099[0...3] Adjustable parameter 99, indices 0 to 3
p0795.4 Adjustable parameter 795, bit 4
Notation for faults and alarms:
F12345 Fault 12345
A67890 Alarm 67890
C01700 Message 1700 for safety functions
These messages can be faults or alarms, see the sections List of alarms
(Page 145) and List of faults (Page 147).

Safety Integrated Function Manual, SINAMICS G120
Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA 15
Description 2
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Description
2.1 SINAMICS G120 safety functions
Safety Integrated Function Manual, SINAMICS G120
16 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA
2.1 SINAMICS G120 safety functions
Note
The entries in italics in the following tables apply for Control Units CU240S DP-F and
CU240S PN-F. These Control Units are not described in this manual. Information on these
Control Units can be found in Function Manual: SINAMICS G120, SINAMICS G120D,
SIMATIC ET200S FC, SIMATIC ET200pro FC
(http://support.automation.siemens.com/WW/view/en/31676845).
Table 2- 1 SINAMICS G120 safety functions
Abbreviation Description (DE/EN) Function Available with
Control Unit
STO Sicher abgeschaltetes
Moment
Safe Torque Off
The motor is switched safely to zero
torque.
CU240E-2
CU240E-2 DP
CU240E-2 F
CU240E-2 DP-F
CU240S DP-F
CU240S PN F
SS1 Sicherer Stopp 1
Safe Stop 1
The motor is shutdown safely.
An encoder for measuring the motor
speed is not required.
CU240E-2 F
CU240E-2 DP-F
CU240S DP-F
CU240S PN-F
SLS Sicher begrenzte
Geschwindigkeit
Safely Limited Speed
The speed of the motor is limited
safely.
An encoder for measuring the motor
speed is not required.
CU240E-2 F
CU240E-2 DP-F
CU240S DP-F
CU240S PN-F
SBC Sichere
Bremsenansteuerung
Safe Brake Control
Activation of the motor holding brake
is controlled safely.
CU240S DP-F
CU240S PN-F
Table 2- 2 Fail-safe communication with SINAMICS G120
Communication Available with
Control Unit
PROFIsafe via PROFIBUS CU240E-2 DP
CU240E-2 DP-F
CU240S DP-F
PROFIsafe via PROFINET CU240S PN-F

Description
2.2 Examples of how the safety functions can be applied
Safety Integrated Function Manual, SINAMICS G120
Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA 17
Table 2- 3 Certification of SINAMICS G120 safety functions
Standard Available with
Control Unit
EN 954-1 Cat. 3 CU240S DP-F
CU240S PN-F
EN ISO 13849-1 Cat. 3 / PL d CU240E-2
CU240E-2 DP
CU240E-2 F
CU240E-2 DP-F
CU240S DP-F
CU240S PN-F
EN 61508 SIL 2 CU240E-2
CU240E-2 DP
CU240E-2 F
CU240E-2 DP-F
CU240S DP-F
CU240S PN-F
2.2 Examples of how the safety functions can be applied
Description of problem Suitable
safety function
Solution
When the emergency stop button is
pressed, a stationary motor must not start
unintentionally.
STO Activate the inverter via terminals using
an emergency stop button.
A central emergency stop button is
designed to prevent more than one drive
from starting unintentionally.
STO Evaluate the emergency stop button in a
central control, activate the inverter via
PROFIsafe.
Having opened a protective door, the
machine operator must enter the
hazardous zone around a machine and
run a conveyor belt at low speed.
SLS Activate the inverter via terminals using a
button to move the conveyor belt.
When a protective door is opened, the
motor must be stationary.
SS1 Activate the SS1 function in the inverter
and enable the protective door as soon
as the inverter signals back "Power
removed".

Description
2.3 Preconditions and constraints
Safety Integrated Function Manual, SINAMICS G120
18 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA
2.3 Preconditions and constraints
2.3.1 General conditions
Prerequisites for using fail-safe functions
1. The machine risk assessment (e.g. in compliance with EN ISO 1050, "Safety of
machinery - Risk assessment - Part 1: Principles") allows inverter safety functions to be
used in accordance with SIL 2 or PL d.
2. The closed-loop speed control of the inverter must function properly. Each fail-safe drive
train must be set up in such a way that all the operating procedures performed by the
driven machine can be properly monitored and that the inverter operates below its limit
values (for current, temperature, voltage, etc.). The drive train comprises an inverter,
motor, brake and driven machine. The performance and parameters of the inverter must
be compatible with both the connected motor and the application in question.
3. Once the machine has been successfully commissioned, you must review the typical
operating conditions and operate the machine close to the permissible limit values. The
fail-safe inverter must not malfunction during this test.
Permissible control modes for using fail-safe functions
When the above-mentioned conditions are fulfilled, all of the fail-safe functions can be used
for both V/f control and vector control.
Permissible motors for using fail-safe functions
When the above-mentioned conditions are fulfilled, all of the fail-safe functions can be used
for induction motors from SIEMENS and other manufacturers.
2.3.2 Permissible and prohibited applications
The safety function STO may be used without any restrictions in all applications.
WARNING
Suspended loads
If the motor can be accelerated by the mechanical system of the connected machine part
after the motor has been switched off, encoderless safety functions SS1 and SLS must not
be used.
Whether or not a mechanical brake is installed is irrelevant here.

Description
2.3 Preconditions and constraints
Safety Integrated Function Manual, SINAMICS G120
Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA 19
Examples:
1. For the hoisting gear of a crane, the suspended load can accelerate the motor as soon as
the motor is switched off. In this case, encoderless safety functions SS1 and SLS must
not be used.
Even if the mechanical brake of the hoisting gear is applied after the motor has been
switched off, this is of no significance regarding the fact that safety functions SS1 and
SLS are prohibited in this application.
2. A horizontal conveyor is always braked to a standstill due to friction as soon as the motor
is switched off. In this case, encoderless safety functions SS1 and SLS can be used
without restriction.
WARNING
Synchronous motors
If you operate the inverter with a synchronous motor, encoderless safety functions SS1 and
SLS must not be used.
WARNING
PM240 FSGX Power Module
Encoderless safety functions SS1 and SLS must not be used in conjunction with the PM240
FSGX Power Module.
2.3.3 Impermissible functions
NOTICE
Certain inverter functions can cause significant fluctuations in the motor speed. When
safety function SS1 or SLS is active, the monitoring mechanism of the function may be
activated or the inverter triggers a STOP F response.
The following inverter functions must not be used when safety function SS1 or SLS is
active:
Torque control
Motor identification
Flying restart
DC braking
Compound braking
Furthermore, the control mode must not be switched (either via p1300 or via the DDS
changeover function) when SS1 and SLS are active.
More detailed information on the abovementioned inverter functions can be found in the
operating instructions.

Description
2.4 Safe Torque Off, STO
Safety Integrated Function Manual, SINAMICS G120
20 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA
2.4 Safe Torque Off, STO
STO functions as follows:
● The operator activates the STO safety function via a fail-safe input or via PROFIsafe
(safe bus communication).
● The inverter cuts off the motor torque.
● To switch the motor on again, you have to first deactivate STO and then specify the ON
command again.
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Diagnostics of the safety functions
● Bit r9773.1 indicates the status of the motor.
Bit 0 in PROFIsafe status word 0 has the same function.
● The yellow "SAFE" LED on the front of the Control Unit indicates that one of the safety
functions (in this case, STO) has been enabled.
● When the "SAFE" LED flashes slowly, this indicates that one of the safety functions (in
this case, STO) is currently active.