Siemens SINAMICS G120 Function Manual
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Siemens SINAMICS G120 Function Manual

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

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Summary of Contents for Siemens SINAMICS G120

  • Page 1 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 SINAMICS Answers for industry.
  • Page 3 ___________________ Safety Integrated Function Manual, Introduction SINAMICS G120 ___________________ Description ___________________ Activation SINAMICS ___________________ Commissioning SINAMICS G120 ___________________ Safety Integrated Function Manual, Servicing and maintenance SINAMICS G120 Alarms, faults and system ___________________ messages Function Manual ___________________ System properties ___________________ Appendix 07/2010 Edition, Firmware V4.3.2...
  • Page 4 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.

  • Page 5: Table Of Contents

    Forced dormant error detection ....................40 Activation ..............................43 Overview ............................43 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 Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 6 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 Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 7 Safe Stop 1, SS1 ........................122 4.8.5.4 Safely Limited Speed, SLS ......................123 4.8.6 Completion of certificate ......................125 Servicing and maintenance........................127 Replacing the inverter components ...................127 Replacing the Control Unit ......................129 Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 8 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...

  • Page 9: Introduction

    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.

  • Page 10: Guide Through This Manual

    Hardware Installation Manual, Power Modules Hardware Installation Manual, Comprehensive information on every Power Power Modules Module. Available for: (refer to the lefthand column) ● PM230 ● PM240 ● PM250 ● PM260 Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 11 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)  Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 12: Commissioning Guidelines

    ② Operating instructions Fail-safe digital inputs (Page 43) ③ Operating instructions ④ Commissioning (Page 69) ⑤ Operating instructions ⑥ Acceptance test - Completion of commissioning (Page 116) Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 13 Fail-safe digital inputs (Page 43) ③ Operating instructions Activation via PROFIsafe (Page 60) ④ Commissioning (Page 69) ⑤ Operating instructions ⑥ Acceptance test - Completion of commissioning (Page 116) Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 14: Notation

    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...

  • Page 15: Description

    Description Figure 2-1 Overview of products for drive technology with integrated safety functions Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 16: Sinamics G120 Safety Functions

    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).

  • Page 17: Examples Of How The Safety Functions Can Be Applied

    Description 2.2 Examples of how the safety functions can be applied 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...

  • Page 18: Preconditions And Constraints

    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.

  • Page 19: Impermissible Functions

    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. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 20: Safe Torque Off, Sto

    (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. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 21: Safe Stop 1, Ss1

    OFF3 ramp-down time. The OFF3 ramp-down time is set with parameter P1135. Note The motor is decelerated until it reaches a standstill. The braking of the motor cannot be interrupted by deselecting SS1 during braking. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 22 STO irrespective of how motor standstill is first detected. Switch on the motor ● To switch the motor on again, you have to first deactivate SS1 and then specify the ON command again. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 23 SS1) has been enabled. ● When the "SAFE" LED flashes slowly, this indicates that one of the safety functions (in this case, SS1) is currently active. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 24: Safely Limited Speed, Sls

    – If the motor has already been switched on when SLS is selected, the motor behaves differently depending on the load speed. These two scenarios are described below. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 25 (in this case, SLS) has been enabled. ● When the "SAFE" LED flashes slowly, this indicates that one of the safety functions (in this case, SLS) is active. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 26 This case is illustrated in the diagram below. ● When you deselect SLS, the motor continues following its speed setpoint. Figure 2-7 Selecting and deselecting the SLS safety function at high speeds Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 27: Switching On The Motor When Sls Is Active

    Dynamic response ● Activate SLS. ● Switch on the motor within 5 seconds (ON command). Figure 2-8 Switching on the motor when SLS is active Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 28: Switching Between Monitoring Thresholds

    – The SBR ramp has reached the "SLS monitoring" value. – The load speed has decreased to the "SLS monitoring" value and the "SS1 delay" has elapsed. This case is illustrated in the diagram below. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 29 ● The inverter switches the speed setpoint limit (r9733) to the higher value. ● The inverter immediately switches the monitoring threshold to the higher value. Figure 2-9 Switching between different monitoring thresholds Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 30 P9331[1], P9531[1] P9331[2], P9531[2] P9331[3], P9531[3] ● When the "SAFE" LED flashes slowly, this indicates that one of the safety functions (in this case, SLS) is currently active. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 31: Interrupting Safety Functions

    To switch the motor on again, proceed as follows: ● Deselect the STO and SS1 safety functions. ● Specify the OFF1 command. ● Switch on the motor (ON command). Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 32: Selecting Sto When Sls Is Active

    Proceed as follows if you want to deselect SLS: ● Specify the OFF1 command. ● Deselect the STO and SLS safety functions. ● Switch on the motor (ON command). Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 33 ● Switch on the motor within 5 seconds (ON command). Further information can be found in the section Switching on the motor when SLS is active (Page 27). Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 34: Selecting Ss1 When Sls Is Active

    The motor then coasts to a standstill. Figure 2-12 Selecting SS1 when SLS is active Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 35 ● Switch on the motor within 5 seconds (ON command). Further information can be found in the section Switching on the motor when SLS is active (Page 27). Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 36: Switching Off The Motor When Ss1 Is Active

    OFF2 command when the SS1 safety function is active To switch the motor on again, proceed as follows: ● Deactivate SS1. ● Specify the OFF1 command. ● Switch on the motor (ON command). Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 37: Switching Off The Motor When Sls Is Active

    When the standstill detection threshold is reached, the inverter cuts off the motor torque. The motor then coasts to a standstill. Figure 2-14 OFF1 command when the SLS safety function is active Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 38 ● Switch on the motor (ON command). The section Switching on the motor when SLS is active (Page 27) describes how to switch the motor on again when SLS is active. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 39: Switching The Motor On And Off When Sls Is Active

    ON command. To switch the motor on again, proceed as follows: ● Select STO. ● Deselect STO. ● Switch on the motor within 5 seconds (ON command). Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 40: Password

    The inverter monitors the regular test of its safety-relevant circuits, which monitor the speed of the motor and which switch off the motor torque. Figure 2-17 Forced dormant error detection Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 41 ● When the drives are at a standstill after the system has been switched on. ● When the protective door is opened. ● At defined intervals (e.g. every 8 hours). ● In automatic mode (time and event dependent). Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 42 Description 2.10 Forced dormant error detection Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 43: Activation

    Fail-safe digital input on Control Units CU240E-2 and CU240E-2 DP Terminal on the Control Unit Digital input Fail-safe input Terminal 16 DI 4 F-DI 0 Terminal 17 DI 5 Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 44: Connecting Sensors Directly

    The fail-safe digital inputs are configured for both directly connecting safety sensors, e.g. emergency stop control devices or light curtains, as well as for connecting pre-processing safety relays, e.g. fail-safe controls. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 45: Electromechanical Sensor

    Connect the external power supply to the sensors and connect the reference potentials of the inputs used to the reference potential of the external power supply. Figure 3-3 Connecting an electromechanical sensor to an external power supply Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 46: Series-Connected Electromechanical Sensors

    Connect the 24 V supply of the inverter to the sensors and connect the reference potentials of the inputs used to GND. Figure 3-4 Connecting electromechanical sensors to the inverter power supply in series Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 47: Activating Several Inverters Simultaneously

    Connect the 24 V supply of the inverter to the sensors and connect the reference potentials of the inputs used to GND. Figure 3-6 Simultaneous activation of several inverters with inverter power supply Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 48: Electronic Sensor

    Light curtains and arrays (http://support.automation.siemens.com/WW/view/en/29586138/133300). Figure 3-8 Connecting an electronic sensor Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 49: Connecting Pre-Processing Devices

    The diagrams only show how the safety relay and inverter are interconnected. Information providing full details of how the safety relay is wired can be found in the product-specific documentation: SIRIUS 3TK28 safety relays (http://support.automation.siemens.com/WW/view/en/26414637/133300). Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 50 The two terminals of the fail-safe input must be connected to each other on the inverter. Figure 3-9 Interconnecting the inverter and safety relay within the same control cabinet Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 51 5 and 7 are transferred via the first line. The signals for terminal 6 and 8 are then transferred via the second line. Figure 3-10 Interconnecting the inverter and safety relay in separate control cabinets Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 52: 3Rk3 Modular Safety System

    The two terminals of the fail-safe input must be connected to each other on the inverter. Figure 3-11 Interconnecting the inverter and Modular Safety System within the same control cabinet Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 53 Figure 3-12 Interconnecting the inverter and Modular Safety System in separate control cabinets Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 54: S7-300 I/O Modules

    Fail-safe outputs that switch to P potential are required for activating the fail-safe digital inputs of the SINAMICS G120. Of the S7-300 range, only the SM326 DO 10 x 24 V / 2 A PP I/O module fulfills this requirement.

  • Page 55: Et 200S I/O Modules

    Fail-safe outputs that switch to P potential are required for activating the fail-safe digital inputs of the SINAMICS G120. Out of the ET 200S system range, only the fail-safe relay module EM 1 F-RO DC 24 V / AC 24…230 V / 5 A fulfills this requirement.
  • Page 56 5 and 7 are transferred via the first line. The signals for terminal 6 and 8 are then transferred via the second line. Figure 3-16 Interconnecting the inverter and I/O modules in separate control cabinets Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 57: S7-400 I/O Modules

    Table 3- 3 Parameters for the discrepancy monitoring tolerance time Basic Safety Extended Safety Activation via F-DI Activation both via F-DI and PROFIsafe p9650, p9850 p10002, p10102 p9650, p9850 Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 58 Up until the end of the time interval 5 x p9650, both input signals must have a constant signal level. A constant signal level is a high or a low state, for a period of at least p9650). Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 59 If you use an input as a standard input, set the debounce time at p0724. If you use an input as a fail-safe input, set the debounce time as described above. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 60: Activation Via Profisafe

    Extended Safety CU240E-2 F ZSW0 CU240E-2 DP-F Telegram 900 STW0 STW2 Extended Safety CU240E-2 F PZD 2/2 CU240E-2 DP-F ZSW0 ZSW2 STW: Control word; ZSW: Status word Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 61: Control Word 0 And Status Word 0 (Basic Safety)

    Reserved 1 … 6 Internal Event Operation OK The inverter has detected a major fault and responded accordingly, e.g. with a STOP A Reserved 8 … 15 Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 62: Control Word 0 And Status Word 0 (Extended Safety)

    The motor torque has not yet been switched off safely. SS1 active SS1 is currently active SS1 is not active Reserved Reserved SLS active SLS is currently active SLS is not active Reserved Reserved Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 63: Control Word 2 And Status Word 2

    HIGH signal (24 V present) at terminals 16 and 17 Reserved … An overview of the fail-safe inputs can be found in the section Fail-safe digital inputs (Page 43). Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 64: Configuring Communication In Step 7 (Telegram 30)

    ● Assign the PROFIsafe telegram to the first slot of the frequency inverter. ● Assign standard telegram 1, for example, to the other slots of the inverter. The operating instructions contain further information on the telegrams and slot sequence. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 65 150 ms, for example, in OB35, set the value of F_WD_Time to 200. ● Save and compile your project and download the data to your SIMATIC CPU. ● Close HW Config. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 66: Configuring Communication In Step 7 (Telegram 900)

    (telegram 30) (Page 64). Simply choose telegram 900 instead of telegram 30 here: 3.3.8 Further steps Once you have completed the controller side, configure PROFIsafe communication in the inverter. This is described in the chapter Commissioning (Page 69). Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 67: Example: Interface To The S7 Safety Program

    Active SLS level bit 1 A detailed description of the PROFIsafe interface can be found in the section Control word 0 and status word 0 (Extended Safety) (Page 62). Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 68 Activation 3.3 Activation via PROFIsafe Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 69: Commissioning

    Offline commissioning (Page 113) describes the important points to remember when commissioning the safety functions offline. The operating instructions describe how to go online with STARTER. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 70: Selecting The Commissioning Method

    When you start commissioning, you must choose the commissioning method that best suits your application. The following overview lists the alternatives and the outcome of using a particular method. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 71 The instructions for checking the safety functions and for completing the acceptance report can be found in the section Acceptance test - Completion of commissioning (Page 116). Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 72: Basic Safety

    ● If you require the status signal "STO active" in your higher-level controller, interconnect it accordingly. ● Click the button to call up the advanced settings for STO. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 73: Assigning Parameters To The Sto

    ● Confirm the prompt for saving your settings (copy RAM to ROM). ● Switch off the Control Unit power supply for approximately 10 seconds (Power ON Reset). Only then will your changes become effective. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 74: Multiple Assignment Of The Di

    Remove pre-assignment of digital inputs DI 4 and DI 5 ● When you use the data set changeover CDS, you must delete the multiple assignment of the digital inputs for all CDS. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 75: Further Steps

    – Check whether the safety functions are functioning correctly in your application. – The instructions for the acceptance test can be found in the section Acceptance test - Completion of commissioning (Page 116). Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 76: Activating Sto Via Profisafe

    Enter the same PROFIsafe address as a hexadecimal value that you defined in the hardware configuration, see Section Configuring communication in STEP 7 (telegram 30) (Page 64). ④ ● Click the button to set the STO. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 77: Parameterizing Sto

    ● Define the time interval for forced dormant error detection and connect the appropriate message to any signal: Information on forced dormant error detection can be found in the section Forced dormant error detection (Page 40). Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 78: Activate Settings

    – Check whether the safety functions are functioning correctly in your application. – The instructions for the acceptance test can be found in the section Acceptance test - Completion of commissioning (Page 116). Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 79: Activating Sto Via Profisafe And F-Di

    Enter the same PROFIsafe address as a hexadecimal value that you defined in the hardware configuration, see Section Configuring communication in STEP 7 (telegram 30) (Page 64). ④ ● Click the button to set the STO. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 80: Assigning Parameters To The Sto

    – ③ ④ Time interval for forced dormant error detection: Information regarding forced dormant error detection can be found in the Forced dormant error detection (Page 40) section. ● Close the screen. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 81: Activate Settings

    Monitoring PROFIsafe communication The inverter monitors communication with the central controller. The inverter does not start monitoring communication until the configuration data has been received from the central controller. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 82: Multiple Assignment Of The Di

    Remove pre-assignment of digital inputs DI 4 and DI 5 ● When you use the data set changeover CDS, you must delete the multiple assignment of the digital inputs for all CDS. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 83: Further Steps

    – Check whether the safety functions are functioning correctly in your application. – The instructions for the acceptance test can be found in the section Acceptance test - Completion of commissioning (Page 116). Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 84: Extended Safety

    ● In STARTER, call up the screens displaying the fail-safe functions and click on "Change settings": 4.4.1.1 Defining the commissioning method ● Select "Motion Monitoring via Terminal" and click the button for configuring the fail-safe inputs and outputs: Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 85: Configuring Activation Via Fdi

    ● In the following screen, you assign the fail-safe inputs to the safety functions. If you do not want to use a particular safety function, set the relevant input to "(255) Statically inactive". Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 86 Choose a free F-DI to acknowledge the safety faults. If there are no free F-DIs available, you have to acknowledge the safety function faults using a different method (see Acknowledging faults using a fail-safe signal (Page 136)). Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 87: Configuring Safety Functions

    ● If you only want to use STO, close this screen and go to the section Enabling safety functions (Page 88). ④ ● If you want to use SS1 or SLS, click this button and go to the next section. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 88: Setting The Gear Ratio

    ● Close the screen for the gear ratio. ● Close the screen for forced dormant error detection. 4.4.1.6 Enabling safety functions ① ● Enable the safety functions via the drop-down menu: Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 89: Parameterizing Sto

    If you require the status signal "STO active" in your higher-level controller, interconnect it accordingly. ● Close the screen. ● If you do not use any other safety function, go directly to Section Activate settings (Page 92). Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 90: Parameterizing Ss1

    If the monitoring time and OFF3 ramp-down time are identical, the deceleration ramp and monitoring curve run parallel to each other. Longer monitoring times result in flatter monitoring curves. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 91: Parameterizing Sls

    ● Close the screen. ● If you do want to use any further safety functions, go directly to the section Activate settings (Page 92). 4.4.1.10 Parameterizing SLS Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 92: Activate Settings

    ● Confirm the prompt for saving your settings (copy RAM to ROM). ● Switch off the Control Unit power supply for approximately 10 seconds (Power ON Reset). Only then will your changes become effective. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 93: Multiple Assignment Of The Di

    Remove pre-assignment of digital inputs DI 4 and DI 5 ● When you use the data set changeover CDS, you must delete the multiple assignment of the digital inputs for all CDS. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 94: Further Steps

    – Check whether the safety functions are functioning correctly in your application. – The instructions for the acceptance test can be found in the section Acceptance test - Completion of commissioning (Page 116). Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 95: Extended Safety With Activation Via Profisafe

    ● In STARTER, call up the screens displaying the fail-safe functions and click on "Change settings": 4.4.2.1 Defining the commissioning method ● Select "Motion Monitoring via Profligate" and click the "Configuration" button: Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 96: Setting Forced Dormant Error Detection And The Profisafe Address

    – ① Actual value tolerance: Leave this set to the factory setting (12.0 °). – ② ③ Gear ratio: Enter your machine's data in accordance with the following table. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 97: Enabling Safety Functions

    – Parameterizing SBR (Page 99). ⑤ ● If you want to use the safety function "Safely Limited Speed" (SLS), follow the instructions in the section Parameterizing SLS (Page 100). Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 98: Parameterizing Sto

    ● Set the shutdown speed (standstill detection). A functional description of standstill detection can be found in the section Dynamic response of SS1 (Page 21). ● Close the screen. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 99: Parameterizing Sbr

    SS1 (Page 21). ● Close the screen. ● If you do want to use any further safety functions, go directly to the section Activate settings (Page 101). Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 100: Parameterizing Sls

    PROFIsafe telegram; see the section Configuring communication in STEP 7 (telegram 900) (Page 66). In STARTER, you then have to specify which F-DI-Status you want to transfer via PROFIsafe. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 101: Activate Settings

    If you try to set a password that is not permissible, the old password will not be changed. Further information can be found in the section Password (Page 40). Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 102: Starting Communication Via Profisafe

    – Check whether the safety functions are functioning correctly in your application. – The instructions for the acceptance test can be found in the section Acceptance test - Completion of commissioning (Page 116). Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 103: Extended Safety With Activation Via Profisafe And F-Di

    ● In STARTER, call up the screens displaying the fail-safe functions and click on "Change settings": 4.4.3.1 Defining the commissioning method ● Select "Motion Monitoring via PROFisafe and F-DI" and click the "Configuration" button: Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 104: Setting Forced Dormant Error Detection And The Profisafe Address

    – ① Actual value tolerance: Leave this set to the factory setting (12.0 °). – ② ③ Gear ratio: Enter your machine's data in accordance with the following table. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 105: Enabling Safety Functions

    – Parameterizing SBR (Page 107). ⑤ ● If you want to use the safety function "Safely Limited Speed" (SLS), follow the instructions in the section Parameterizing SLS (Page 108). Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 106: Parameterizing Sto

    – ③ ④ Time interval for forced dormant error detection: Information regarding forced dormant error detection can be found in the Forced dormant error detection (Page 40) section. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 107: Parameterizing Ss1

    If the monitoring time and OFF3 ramp-down time are identical, the deceleration ramp and monitoring curve run parallel to each other. Longer monitoring times result in flatter monitoring curves. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 108: Parameterizing Sls

    ● Close the screen. ● If you do want to use any further safety functions, go directly to the section Activate settings (Page 110). 4.4.3.8 Parameterizing SLS Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 109: Defining The F-Di Status

    STEP 7 (telegram 900) (Page 66). In STARTER, you then have to specify which F-DI-Status you want to transfer via PROFIsafe. ● Click the "Safety Inputs" button. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 110: Activate Settings

    Monitoring PROFIsafe communication The inverter monitors communication with the central controller. The inverter does not start monitoring communication until the configuration data has been received from the central controller. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 111: Multiple Assignment Of The Di

    Remove pre-assignment of digital inputs DI 4 and DI 5 ● When you use the data set changeover CDS, you must delete the multiple assignment of the digital inputs for all CDS. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 112: Further Steps

    – Check whether the safety functions are functioning correctly in your application. – The instructions for the acceptance test can be found in the section Acceptance test - Completion of commissioning (Page 116). Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 113: Offline Commissioning

    If you try to set a password that is not permissible, the old password will not be changed. Further information can be found in the section Password (Page 40). Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 114: Further Steps

    – Check whether the safety functions are functioning correctly in your application. – The instructions for the acceptance test can be found in the section Acceptance test - Completion of commissioning (Page 116). Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 115: Series Commissioning

    ● Switch off the Control Unit power supply for approximately 10 seconds (Power ON Reset). ● Go online with STARTER. ● Reset the Control Unit to the factory setting. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 116: Acceptance Test - Completion Of Commissioning

    – Test of safety functions used 3. Conclusion of the report – Inspection of safety function parameters – Recording of the checksums – Verify the data backup – Countersignatures Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 117: Reduced Acceptance Test

    Supplement to the machine No, if data are identical parameters to other identical description (checking of the (checking of checksums). machines by means of firmware versions). standard commissioning. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 118: Documentation

    Module Control Unit (Drive 1) … r0018 = … r9770[0] r9770[1] r9770[2] r9770[3] … r9870[0] r9870[1] r9870[2] r9870[3] r9390[0] r9390[1] r9390[2] r9390[3] r9590[0] r9590[1] r9590[2] r9590[3] Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 119: Function Table

    Setting the safety functions Enter the limit values for the safety functions in the following table. Drive Safety function Limit … … … … … … … … … … Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 120: Function Test

    Switch on the motor (ON command). Ensure that the correct motor is running. Select STO while the motor is running Note: Test each configured activation, e.g. via digital inputs and PROFIsafe. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 121: Safe Torque Off, Sto (Extended Safety)

    The inverter indicates neither faults nor alarms for safety functions (r0945, r2122, r2132). STO is not active. Switch on the motor (ON command). Ensure that the correct motor is running. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 122: Safe Stop 1, Ss1

    Status Initial state: The inverter is in "Ready" state (p0010 = 0).  The inverter indicates neither faults nor alarms for safety functions (r0945, r2122, r2132).  Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 123: Safely Limited Speed, Sls

    ● Routine for forced dormant error detection of the switch-off signal paths on the Control Unit. Procedure Table 4- 7 "Safely Limited Speed" (SLS) function Description Status Initial state The inverter is in "Ready" state (p0010 = 0).  Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 124 The inverter indicates neither faults nor alarms for safety functions.  The inverter indicates:  "SLS is deselected" (r9720.4 = 1). "SLS is not active" (r9722.4 = 0). Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 125: Completion Of Certificate

    Processor 1 Processor 2 Processor 1 Processor 2 [0] = Parameter [1] = Actual values … p9798 p9898 p9398[0] p9728[0] r9781[0] r9782[0] p9799 p9899 p9399[0] p9728[1] p9729[0] p9729[1] Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 126 Confirmation that the tests and checks have been carried out properly. Table 4- 8 Commissioning engineer Date Name Company/dept. Signature Confirmation that the parameters documented above are correct. Table 4- 9 Machine manufacturer Date Name Company/dept. Signature Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 127: Servicing And Maintenance

    6 S L 3 2 5 4 - 0 A M 0 0 - 0 A A 0 6 S L 3 2 5 4 - 0 A M 0 0 - 0 A A 0 same firmware version  into the new CU Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 128 Replacing Control Unit with a Control Unit of the same type and  lower firmware version  (e.g. replacing a CU with FW V4.3 with a CU with FW V4.2) Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 129: Replacing The Control Unit

    ● The inverter adopts the settings from the memory card, saves them (protected against power failure) in its internal parameter memory, and switches to "ready to start" state. ● Switch on the motor and check the function of the drive. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 130 ● In all other cases, after downloading the parameters into the inverter, the following steps are required: – Power ON Reset – Perform a reduced acceptance test. The reduced acceptance tests are described in Section Reduced acceptance test (Page 117). Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 131: Replacing The Power Module

    ● Acknowledge the fault code issued by the inverter. ● Perform a reduced acceptance test. The necessary measures are described in Chapter Reduced acceptance test (Page 117). Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 132 Servicing and maintenance 5.3 Replacing the Power Module Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 133: Alarms, Faults And System Messages

    As soon as the color of the LED RDY changes to either red or green, the LEDs on the Control Unit indicate the inverter state. LED RDY and LED BF displays Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 134 One or more safety functions are active; no safety function faults have occurred. YELLOW - rapid The inverter has detected a safety function fault and initiated a stop response. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 135: Disturbance Characteristics Of The Safety Functions

    ● The inverter detects an internal fault in its hardware or its firmware on the basis of a data cross-check (F01611). ● The inverter detects an impermissible motor speed (C01714). An "internal event" can only be acknowledged via a fail-safe signal. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 136: Acknowledging Faults Using A Fail-Safe Signal

    Other acknowledgement options You can acknowledge faults by temporarily shutting off the power supply to the inverter and then switching it on again. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 137: Stop Reactions

    A STOP F does not immediately bring about a reaction of the motor, but instead it triggers another stop: ● If fault F01611 is the cause of the STOP F, the inverter immediately triggers a STOP A. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 138: Disturbance Characteristics Of Safe Torque Off, Sto

    General fault response of safety function STO Depending on whether you have enabled STO via "Basic Safety" or "Extended Safety", the inverter signals the status of STO via r9773.1 or r9722.0. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 139 Response of safety function STO in the event of a discrepancy After the tolerance time has expired, the inverter signals the discrepancy with fault F01611 or F30611. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 140 Note: In this case, it is not possible to acknowledge by selecting and deselecting STO. 3. Specify an OFF1 command. 4. Switch the motor on again (ON command). Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 141: Disturbance Characteristics Of Safe Stop 1, Ss1

    2. Specify an OFF1 command. 3. Acknowledge the fault code (see Section Acknowledging faults using a fail-safe signal (Page 136)). 4. Switch the motor on again (ON command). Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 142 2. Acknowledge the active messages (see Section Acknowledging faults using a fail-safe signal (Page 136)). Note: In this case, it is not possible to acknowledge by selecting and deselecting STO. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 143: Disturbance Characteristics Of Safely Limited Speed, Sls

    Figure 6-7 Fault response of safety function SLS To switch the motor on again, proceed as follows: 1. Deactivate the SLS function. 2. Specify an OFF1 command. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 144 To switch the motor on again, you have to rectify the discrepancy and acknowledge the discrepancy message (see Section Acknowledging faults using a fail-safe signal (Page 136)). Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 145: List Of Alarms

    "safe braking ramp". C30711 Defect in a monitoring channel. Check the safety function parameters. Carry out an acceptance test. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 146 Check and, if necessary, modify the SLS limits. If the safety functions of the inverter have been enabled, this alarm results in the inverter triggering a stop response. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 147: List Of Faults

    0 signal. F01680 Checksum error safe monitoring Check the safety-relevant parameters. functions. Switch the Control Unit power supply off and then on again. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 148 Replace the CU if the fault cannot be acknowledged. F30656 Motor Module parameter error. Recommission the safety functions. If unsuccessful, replace the CU. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 149 Acknowledge the fault. C30770 Discrepancy error of the fail-safe inputs Check the F-DI wiring. or outputs. Perform a fail-safe acknowledgement. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 150 Alarms, faults and system messages 6.4 List of faults Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 151: System Properties

    Response times when the monitoring threshold is exceeded Table 7- 3 Response times until a response is initiated Function Response Typical Worst case STOP A or STOP B 67 ms 113 ms Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 152: Certification

    If you need help when evaluating the safety functions of your machine, an online tool for calculating PFH values is available on the Internet: Safety Evaluation Tool (www.siemens.com/safety-evaluation-tool). Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 153: Appendix

    (e.g. by specifying the cause of possible hazards). "Functional safety" is involved if safety depends on the correct function. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 154: Safety Of Machinery In Europe

    The protective goals must be implemented responsibly to ensure compliance with the Directive. Manufacturers of a machine must verify that their machine complies with the basic requirements. This verification is facilitated by means of harmonized standards. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 155: Harmonized European Standards

    ● Type B2 standards for protective safety devices are defined for different machine types (e.g. EMERGENCY STOP devices, two-hand operating circuits, interlocking elements, contactless protective devices, safety-related parts of controls). Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 156 Please note that the application of a particular standard may not be mandatory provided that all the safety requirements of the applicable EU directives are fulfilled. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 157: Standards For Implementing Safety-Related Controllers

    Complex electronics (e.g. programmable Restricted to the designated All architectures and max. up to electronics) architectures (see comment 1) SIL 3 and max. up to PL = d Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 158: En Iso 13849-1 (Previously En 954-1)

    EN ISO 13849-1:2006 refers to EN 61508. When combining several safety-related parts to form a complete system, the Standard explains how to determine the resulting PL. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 159: A.1.2.5 En 62061

    Safety-related characteristic quantities for subsystem elements (devices): ● λ: Failure rate ● B10 value: For elements that are subject to wear ● T1: Lifetime Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 160 Details of simple sub-systems that have been implemented and integrated are now available as "functional examples". Note IEC 62061 has been ratified as EN 62061 in Europe and harmonized as part of the Machinery Directive. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 161: Series Of Standards En 61508 (Vde 0803)

    EN ISO 12100-1 focuses on the risks to be analyzed and the design principles for minimizing risk. EN ISO 14121-1 describes the iterative process for assessing and minimizing risk to achieve the required level of safety. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 162 The risk assessment must then be repeated. Figure A-2 Iterative process to achieve the required level of safety to ISO 14121-1 Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 163: Risk Reduction

    Europe is that, in the USA, no legislation exists regarding machinery safety that is applicable in all of the states and that defines the responsibility of the manufacturers/supplier. A general requirement exists stating that employers must ensure a safe workplace. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 164: Minimum Requirements Of The Osha

    Stop Categories 0 and 1 (refer to NFPA 79 9.2.5.4.1.4). Like EN 60204-1, NFPA 79 no longer specifies that the electrical energy must be disconnected by electromechanical means for emergency stop functions. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 165: Ansi B11

    B11.TR-3 and SEMI S10 (semiconductors). The documented findings of a risk analysis can be used to select a suitable safety system based on the safety class of the application in question. Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 166: Machine Safety In Japan

    ● Safety Integrated: The Safety System for Industry (5th Edition and supplement), order no. 6ZB5 000-0AA01-0BA1 ● Safety Integrated - Terms and Standards - Machine Safety Terminology (Edition 04/2007), order no. E86060-T1813-A101-A1 Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 167: Information Sheets Issued By The Employer's Liability Insurance Association

    You can download the information sheets from the following Internet address (website is in German, although some of the sheets are available in English): http://www.bg-metall.de/ Click the "Downloads" quick link and select the category "Informationblätter der Fachausschüsse". Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 168 Appendix A.1 Standards and regulations Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...

  • Page 169: Index

    Brake (mechanical), 19 Countersignatures, 126 Bus fault, 134 CRC (Cyclic Redundancy Check), 40 Customer support, 40 Cyclic Redundancy Check, 40 Cable break, 139, 140, 142 Cat. (category), 152 Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 170 138, 141, 143 Fault response LED (light emitting diode), 133 SLS, 143 Light curtain, 44, 48 SS1, 141 Limit, 18, 119 STO, 138 Load revolutions, 88, 97, 105 F-DI Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 171 Operating instructions, 11, 12, 13, 69 Response time, 151 Operator Panel, 129 Risk assessment, 18 Overview Chapter, 10 Commissioning, 12, 70 Manuals, 10 S7-300, 54 Software tool, 10 S7-400, 57 Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 172 Delay time, 90, 99, 107 Third-party motor, 18 Diagnostics, 23, 31, 36 Time stamp, 125 Discrepancy, 142 Torque control, 19 Dynamic response, 21, 23 Enable, 23 Fault response, 141 Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 173 Control Unit, 117 Firmware, 117 V/f control, 18 Vector control, 18 Version Firmware, 118 Hardware, 118 Safety function, 118 Wire break, 57 Wiring examples, 10 ZSW (status word), 60 Safety Integrated Function Manual, SINAMICS G120 Function Manual, 07/2010, FW 4.3.2, A5E03052391B AA...
  • Page 174 Siemens AG We reserve the right to make technical Industry Sector changes. Drive Technologies © Siemens AG 2010 Motion Control Systems Postfach 3180 91050 ERLANGEN GERMANY www.siemens.com/sinamics-g120...

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