SINAMICS S120. Safety Integrated Function Manual 01/2012 SINAMICS

Transcription

1 SINAMICS S120 Function Manual 01/2012 SINAMICS s

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3 Preface Change history 1 SINAMICS S120 Function Manual General information about SINAMICS 2 Description of Safety Integrated Basic Functions 3 Description of the Safety Integrated Extended functions 4 Control of the safety functions 5 Commissioning 6 Commissioning the functions 7 Application examples 8 Acceptance tests and acceptance reports 9 System features 10 Servicing and maintenance 11 Standards and regulations 12 A Appendix A Valid from: Firmware version 4.5 (FHS), 01/2012 6SL3097-4AR00-0BP3

4 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 relevant 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, in particular its warning notices and safety instructions. Qualified personnel are those who, based on their training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems. Proper use of Siemens products Note the following: WARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems. The permissible ambient conditions must be complied with. The information in the relevant documentation must be observed. Trademarks All names identified by are registered trademarks of Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner. Disclaimer of Liability We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions. Siemens AG Industry Sector Postfach NÜRNBERG GERMANY Order number: 6SL3097-4AR00-0BP3 P 03/2012 Technical data subject to change Copyright Siemens AG All rights reserved

5 Preface SINAMICS documentation The SINAMICS documentation is organized in the following categories: General documentation/catalogs User documentation Manufacturer/service documentation More information The following link provides information on the topics: Ordering documentation/overview of documentation Additional links to download documents Using documentation online (find and browse through manuals/information) Please send any questions about the technical documentation (e.g. suggestions for improvement, corrections) to the following address: My Documentation Manager Under the following link there is information on how to create your own individual documentation based on Siemens' content, and adapt it for your own machine documentation: Training Under the following link there is information on SITRAIN - training from Siemens for products, systems and automation engineering solutions: FAQs You can find Frequently Asked Questions in the Service&Support pages under Product Support: SINAMICS You can find information on SINAMICS under: Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3 3

6 Preface Usage phases and their documents/tools (as an example) Table 1 Usage phases and the available documents/tools Orientation Usage phase Document/tool SINAMICS S Sales Documentation Planning/configuration SIZER Configuration Tool Configuration Manuals, Motors Deciding/ordering SINAMICS S Catalogs Installation/assembly SINAMICS S120 Equipment Manual for Control Units and Additional System Components SINAMICS S120 Equipment Manual for Booksize Power Units SINAMICS S120 Equipment Manual for Chassis Power Units SINAMICS S120 Equipment Manual for AC Drives SINAMICS S120M Equipment Manual Distributed Drive Technology Commissioning STARTER commissioning tool SINAMICS S120 Getting Started SINAMICS S120 Commissioning Manual SINAMICS S120 CANopen Commissioning Manual SINAMICS S120 Function Manual SINAMICS S120/S150 List Manual Usage/operation SINAMICS S120 Commissioning Manual SINAMICS S120/S150 List Manual Maintenance/servicing SINAMICS S120 Commissioning Manual SINAMICS S120/S150 List Manual References SINAMICS S120/S150 List Manual Target group This documentation is intended for machine manufacturers, commissioning engineers, and service personnel who use the SINAMICS drive system. Benefits This Manual describes all the information, procedures and operational instructions required for commissioning and servicing SINAMICS S Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3

7 Preface Standard scope The scope of the functionality described in this document may differ from the scope of the functionality of the drive system that is actually supplied. It may be possible for other functions not described in this documentation to be executed in the drive system. However, no claim can be made regarding the availability of these functions when the equipment is first supplied or in the event of servicing. Functions that are not available in a particular product version of the drive system may be described in the documentation. The functionality of the supplied drive system should only be taken from the ordering documentation. Extensions or changes made by the machine manufacturer must be documented by the machine manufacturer. For reasons of clarity, this documentation does not contain all of the detailed information on all of the product types. This documentation cannot take into consideration every conceivable type of installation, operation and service/maintenance. Technical Support Country-specific telephone numbers for technical support are provided in the Internet under Contact: EC Declaration of Conformity The EC Declaration of Conformity for the EMC Directive can be found on the Internet at: There as a search term enter the number or contact your local Siemens office. Search guides The following guides are provided to help you locate information in this manual: 1. Contents 2. List of abbreviations 3. Index Internet address for This address contains detailed application examples for. Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3 5

8 Preface Notation The following notation and abbreviations are used in this documentation: Notation for parameters (examples): 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 r0945[2](3) Display parameter 945 index 2 of drive object 3 p Adjustable parameter 795 bit 4 Notation for faults and alarms (examples): F12345 Fault A67890 Alarm Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3

9 Preface ESD Notes CAUTION Electrostatic sensitive devices (ESD) are single components, integrated circuits or devices that can be damaged by electrostatic fields or electrostatic discharges. Regulations for the ESD handling: During the handling of electronic components, pay attention to the grounding of the person, workplace and packaging! Electronic components may be touched by persons only when these persons are grounded using an ESD bracelet, or these persons in ESD areas with a conducting floor wear ESD shoes or ESD grounding straps. Electronic components should be touched only when this is unavoidable. The touching is permitted only on the front panel or on the circuit board edge. Electronic components must not be brought into contact with plastics or clothing made of artificial fibers. Electronic components may only be placed on conducting surfaces (table with ESD coating, conducting ESD foamed material, ESD packing bag, ESD transport container). Electronic components may not be placed near display units, monitors or televisions (minimum distance from the screen > 10 cm). Measurements must only be taken on boards when the measuring instrument is grounded (via protective conductors, for example) or the measuring probe is briefly discharged before measurements are taken with an isolated measuring device (for example, touching a bare metal housing). Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3 7

10 Preface Safety notices DANGER Commissioning is absolutely prohibited until it has been completely ensured that the machine, in which the components described here are to be installed, is in full compliance with the provisions of the EC Machinery Directive. SINAMICS devices and AC motors must only be commissioned by suitably qualified personnel. The personnel must take into account the information provided in the technical customer documentation for the product, and be familiar with and follow the specified danger and warning notices. When electrical equipment and motors are operated, the electrical circuits automatically conduct a dangerous voltage. When the machine or system is operated, hazardous axis movements can occur. All of the work carried out on the electrical machine or system must be carried out with it in a no-voltage condition. SINAMICS devices with three-phase motors must only be connected to the power supply via an AC-DC residual-current-operated device with selective switching once verification has been provided that the SINAMICS device is compatible with the residual-current-operated device in accordance with IEC , Section WARNING The successful and safe operation of this equipment and motors is dependent on correct transport, proper storage, installation and mounting as well as careful operator control, service and maintenance. For special versions of the drive units and motors, information and data in the Catalogs and quotations additionally apply. In addition to the danger and warning information provided in the technical customer documentation, the applicable national, local, and plant-specific regulations and requirements must be taken into account. Only protective extra-low voltages (PELV = Protective Extra Low Voltage, DVC-A) that comply with EN can be connected to the connections and terminals between 0 V and 48 V. CAUTION The motors can have surface temperatures of over +80 C. This is the reason that temperature-sensitive components, e.g. cables or electronic components may neither be in contact nor be attached to the motor. When attaching the connecting cables, you must ensure that: they are not damaged they are not under tension they cannot come into contact with any rotating parts 8 Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3

11 Preface CAUTION As part of routine tests, SINAMICS devices are subject to a voltage test in accordance with EN Before the voltage test is performed on the electrical equipment of industrial machines in accordance with EN , Section 18.4, all connectors of SINAMICS equipment must be disconnected/unplugged to prevent the equipment from being damaged. Motors should be connected up according to the circuit diagram provided. otherwise they can be destroyed. Note When operated in dry areas, SINAMICS devices with three-phase motors conform to the Low-Voltage Directive 2006/95/EC. Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3 9

12 Preface 10 Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3

13 Table of contents Preface Change history General information about SINAMICS Drive products with integrated safety functions Supported functions Examples of how the safety functions can be applied Drive monitoring with or without encoder Description of Basic Functions Safe Torque Off (STO) Safe Stop 1 (SS1) Safe Brake Control (SBC) Description of the Extended functions Preconditions for the Safety Extended Functions Safe Torque Off (STO) Safe Stop 1 (SS1) Safe Stop 2 (SS2) Safe Operating Stop (SOS) Safely Limited Speed (SLS) Safe Speed Monitor (SSM) Safe Direction (SDI) Safely-Limited Position (SLP) Safe referencing Transferring safe position values (SP) Control of the safety functions Controlling the functions Control signals by way of terminals on the Control Unit and Motor/Power Module Simultaneity and tolerance time of the two monitoring channels Bit pattern test Activation via PROFIsafe Enabling of the control via PROFIsafe Selecting a PROFIsafe telegram Telegram format Process data...69 Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3 11

14 Table of contents S_STW1 and S_ZSW1 (Basic Functions) S_STW2 and S_ZSW2 (Basic Functions) S_STW1 and S_ZSW1 (Extended Functions) S_STW2 and S_ZSW2 (Extended Functions) Additional process data ESR response in the event of a communication error Parameters and function diagrams Control via TM54F Design Overview of the F-DIs Overview of the F-DOs Control of the Extended Functions using CU Design Overview of the F-DIs Overview of the F-DOs Motion monitoring without selection Function diagrams and parameters Commissioning firmware versions Parameter, checksum, version, password DRIVE-CLiQ rules for Functions Forced dormant error detection (test stop) Commissioning functions General information Prerequisites for commissioning the functions Default settings for commissioning functions without encoder Setting the sampling times Commissioning TM54F by means of STARTER/SCOUT Basic sequence of commissioning Configuration start screen TM54F configuration F-DI/F-DO configuration Control interface of the drive group Test stop of the TM54F Test mode 1: Evaluation of internal diagnostic signal (passive load) Test mode 2: Read back F-DO in DI (relay circuit) Test mode 3: Read back F-DO into the DI (actuator with feedback signal) Test stop mode parameters Commissioning CU310-2 using STARTER/SCOUT Basic sequence of commissioning Configuration start screen CU310-2 configuration F-DI/F-DO configuration Control interface of the drive Test stop of the CU Test mode 1: Evaluation of internal diagnostic signal (passive load) Test mode 2: Read back F-DO in DI (relay circuit) Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3

15 Table of contents Test mode 3: Read back F-DO into the DI (actuator with feedback signal) Test stop mode parameters Procedure for configuring PROFIsafe communication Configuring PROFIsafe via PROFIBUS PROFIsafe via PROFINET Requirements for PROFIsafe communication Configuring PROFIsafe via PROFINET Assigning the IP address and the name PROFIsafe configuration with STARTER Commissioning a linear/rotary axis Modular machine concept Information pertaining to series commissioning Commissioning the functions basic functions Safe Torque Off (STO) Safe Stop 1 (SS1, time controlled) SS1 (time controlled) with OFF SS1 (time controlled) without OFF Function diagrams and parameters Safe Brake Control (SBC) Fundamentals SBC for Motor Modules in the chassis format Function diagrams and parameters Safety faults Forced dormant error detection Extended Functions Extended Functions "with encoder" / "without encoder" Safe Torque Off Safe Stop 1 (SS1) Safe Stop 1 (SS1, time and acceleration controlled) Safe Stop 1 without encoder (speed controlled) Safe Stop 1 without OFF Safe Stop 1 - Parameter Safe Stop 2 (SS2) EPOS and Safe Stop Safe Operating Stop (SOS) Safely-Limited Speed (SLS) Safely-Limited Speed with encoder Safely Limited Speed without encoder Safely-Limited Speed without selection Safely Limited Speed - Parameter EPOS and safe setpoint velocity limitation Safe Speed Monitor (SSM) Safe Speed Monitor with encoder Safe Speed Monitor without encoder Parameters and function diagrams Safe Acceleration Monitor (SAM) Safe Brake Ramp (SBR) Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3 13

16 Table of contents Safe Direction (SDI) Safe Direction with encoder Safe Direction without encoder Acknowledgment for SDI with STOP C Safe Direction without selection Function diagrams and parameters Safely-Limited Position (SLP) Retraction Function diagrams and parameters Safe referencing Transferring safe position values (SP) Function diagrams and parameters Safety faults Stop responses Stop response priorities Acknowledging safety faults Message buffer Safe actual value acquisition Reliable actual value acquisition with encoder system Safe current actual value acquisition without encoder Forced dormant error detection Safety Info Channel Application examples Input/output interconnections for a safety switching device with TM54F Application examples Acceptance tests and acceptance reports Acceptance test structure Content of the complete acceptance test Content of the partial acceptance test Test scope for specific measures Safety logbook Acceptance reports Plant description - Documentation part Description of safety functions - Documentation Part Function table SI functions for each drive Parameterizing the SI functions via TM54F Safety equipment Acceptance tests Acceptance tests Basic Functions Acceptance test for Safe Torque Off (STO) Acceptance test for Safe Stop 1, time controlled (SS1) Acceptance test for "Safe Brake Control" (SBC) Acceptance tests for Extended Functions (with encoder) Acceptance test Safe Torque Off with encoder (Extended Functions) Acceptance test for Safe Stop 1, time and acceleration controlled Acceptance test for Safe Brake Control with encoder (Extended Functions) Acceptance test for Safe Stop 2 (SS2) Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3

17 Table of contents Acceptance test for Safe Operating Stop (SOS) Acceptance tests for Safely Limited Speed with encoder (Extended Functions) Acceptance test for Safe Speed Monitor with encoder (Extended Functions) Acceptance test for Safe Direction with encoder (Extended Functions) Acceptance test for Safely Limited Position Acceptance tests for Extended Functions (without encoder) Acceptance test Safe Torque Off without encoder (Extended Functions) Acceptance test for Safe Stop 1 without encoder (Extended Functions) Acceptance test for Safe Brake Control without encoder (Extended Functions) Acceptance tests for Safely Limited Speed without encoder (Extended Functions) Acceptance test for Safe Speed Monitor without encoder (Extended Functions) Acceptance test for Safe Direction without encoder (Extended Functions) Completion of certificate System features Latest information Certification Safety instructions Probability of failure of the safety functions (PFH value) Response times Residual risk Servicing and maintenance Information pertaining to component replacements Standards and regulations General information Aims Functional safety Safety of machinery in Europe Machinery Directive Harmonized European Standards Standards for implementing safety-related controllers DIN EN ISO (replaces EN 954-1) EN Series of standards EN (VDE 0803) Risk analysis/assessment Risk reduction Residual risk Machine safety in the USA Minimum requirements of the OSHA NRTL listing NFPA ANSI B Machine safety in Japan Equipment regulations Other safety-related issues Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3 15

18 Table of contents Information sheets issued by the Employer's Liability Insurance Association Additional references A Appendix A A.1 List of abbreviations A.2 Document structure Index Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3

19 Change history 1 Essential changes with respect to the manual, Edition 01/2011 New functions in firmware V4.5 In chapter Safely-Limited Position (SLP) Safely-Limited Position (SLP) (Page 53) Safe referencing Safe referencing (Page 236) Safe Position (SP) Transferring safe position values (SP) (Page 238) SS1 (Extended Functions) without OFF3 Safe Stop 1 without OFF3 (Page 197) Motion monitoring without selection Motion monitoring without selection (Page 95) New PROFIsafe telegrams 31, 901 and 902 Activation via PROFIsafe (Page 64) Acceptance tests for SLP etc. added Acceptance tests (Page 291) Control of the Safety functions via onboard terminals on the CU310-2 Transferring the first SLS limit value via PROFIsafe Control of the safety functions (Page 57), Commissioning CU310-2 using STARTER/SCOUT (Page 133) Transferring the first limit value via PROFIsafe (Page 205) Revised descriptions Acceptance test extended with the new control option "Without selection" In chapter Acceptance tests (Page 291) Error correction In chapter Structural changes The previous Chapter 1 has been rearranged to become new Chapter 13 The new Chapter 1 "Change history" has been introduced The previous Chapter 3 has been rearranged to become new Chapter 11 The previous Chapters 4 and 5 have been shifted into the new Chapter 8 "Commissioning the functions" In chapter Standards and regulations (Page 401) This chapter System features (Page 383) Commissioning the functions (Page 173) Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3 17

20 Change history Structural changes General function descriptions have been introduced as new Chapters 3 and 4 The new Chapter 12 "Service and maintenance" has been introduced; Section 7.9 "Information about replacing components" has been shifted into this chapter In chapter Description of Basic Functions (Page 25), Description of the Extended functions (Page 31) Servicing and maintenance (Page 399) 18 Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3

21 General information about SINAMICS Safety 2 Integrated 2.1 Drive products with integrated safety functions PROFIBUS with PROFIsafe profile PROFINET with PROFIsafe profile Fail-safe inputs Fail-safe outputs Certifications EN ISO EN NFPA 79 NRTL listed Applications with fixed speed SIMATIC SIMATIC SIMATIC SIMATIC SINAMICS ET 200S ET 200pro ET 200S ET 200pro G120C Motor starter FC FC Integrated safety functions according to IEC STO Safe Torque Off Yes Yes SS1 Safe Stop Yes - SBC Safe Brake Control SBT Safe Brake Test SLS Safely Limited Speed - - Yes - SSM Safe Speed Monitor SDI Safe Direction SOS Safe Operating Stop SS2 Safe Stop SCA Safe Cam SLP Safely-Limited Position Fail-safe interfaces Yes Yes Yes, with external components Cat. 4 / PL e SIL 3 Yes Yes Yes Yes Yes, with external components - - Cat. 3 / PLd SIL with certified DCC application Applications with variable speed - SINAMICS G120 Yes Yes Yes Yes Yes Yes Yes Yes SINAMICS G120D SINAMICS G130 Yes Yes Yes 4 Yes Yes Yes - Yes SINAMICS G150 High-performance and motion control applications Yes Yes Yes 3 Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes 3, 4 Yes 4 Yes 1 Yes Yes Yes Yes Yes Yes Yes Yes Yes, external components required in certain cases Yes, when using the Yes TM54F Cat. 3 / PLd Cat. 3 / PLd Yes Cat. 3 / PL d SIL 2 SIL 2 Yes SIL Yes Yes Yes SINAMICS S SINAMICS S120 - SINAMICS S150 Yes Yes - Yes Yes Yes Yes Yes - - Yes Yes Yes Yes only for SINAMICS S120 Booksize 3 with Safe Brake Module 4 For Chassis and Cabinet Modules with Safe Brake Adapter Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3 19

22 General information about SINAMICS 2.2 Supported functions 2.2 Supported functions All of the functions available under SINAMICS S120 are listed in this chapter. SINAMICS makes a distinction between Basic Functions and Extended Functions. The safety functions listed here conform to: Safety Integrity Level (SIL) 2 according to DIN EN Category 3 to DIN EN ISO Performance level (PL) d according to DIN EN ISO The safety functions correspond to the functions according to DIN EN The following functions (SI functions) are available: Basic Functions These functions are part of the standard scope of the drive and can be used without requiring an additional license. These functions are always available. These functions do not require an encoder and/or do not place any special requirements on the encoder used. Safe Torque Off (STO) Safe Torque Off is a safety function that prevents the drive from restarting unexpectedly, in accordance with EN STO prevents the supply of energy to the motor which can generate a torque and corresponds to Stop Category 0. Safe Stop 1 (SS1, time controlled) Safe Stop 1 is based on the "Safe Torque Off" function. This means that a Category 1 stop in accordance with EN can be implemented. Safe Brake Control (SBC) Safe Brake Control is used to safely control a holding brake. 1) 2) 20 Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3

23 General information about SINAMICS 2.2 Supported functions Extended Functions These functions require an additional Safety license: Extended Functions with encoder require an encoder with Safety capability (see section "Reliable actual value acquisition with encoder system"). Safe Torque Off (STO) Safe Torque Off is a safety function that prevents the drive from restarting unexpectedly in accordance with EN Safe Stop 1 (SS1, time and acceleration controlled) Safe Stop 1 is based on the "Safe Torque Off" function. This means that a Category 1 stop in accordance with EN can be implemented. Safe Brake Control (SBC) Safe Brake Control is used to safely control a holding brake. 1) 2) Safe Stop 2 (SS2) Safe Stop 2 is used to safely brake the motor with a subsequent transition into the "Safe Operating Stop" state (SOS). This means that a Category 2 stop in accordance with EN can be implemented. Safe Operating Stop (SOS) Safe Operating Stop is used to protect against unintentional movements. The drive is in closed-loop control mode and is not disconnected from the power supply. Safely Limited Speed (SLS) Safely Limited Speed ensures that the drive does not exceed a preset speed limit/velocity. Safe Speed Monitor (SSM) Safe Speed Monitor is used for safely identifying when a speed limit is fallen below in both directions of motion, e.g. to identify zero speed. A fail-safe output signal is available for further processing. Safe Direction (SDI) Safe Direction is used to safely monitor the direction of motion. Safely-Limited Position (SLP) Safely-Limited Position ensures that a freely definable traversing range is not left. 1) Note regarding Power/Motor Modules in chassis format: For the chassis format, SBC is only supported by Power/Motor Modules with order number...3 or higher. A Safe Brake Adapter is needed in addition for this design. 2) Note regarding Power/Motor Modules in blocksize format: blocksize Power Modules additionally require a Safe Brake Relay for this function. Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3 21

24 General information about SINAMICS 2.3 Examples of how the safety functions can be applied 2.3 Examples of how the safety functions can be applied Safety function Application examples STO When an Emergency Stop button is pressed, the drive must be braked as quickly as possible and transitioned into STO SLS SS1 SSM SDI A central Emergency Stop button ensures that several drives cannot unintentionally start. After opening a protective door, the machine operator must enter the machine and in the hazardous zone, operate a horizontal conveyor belt running at a slow speed using an acknowledgment button. A spindle drive, depending on the selection of the cutting tool, must not exceed a specific maximum speed. It is only permissible to open a protective door if the motor torque has been switched off. A protective door must only be opened when a motor is at standstill. A protective door must only be opened if a drive moves in the safe direction (away from the operator). When replacing the pressure cylinders of the plates, the drive must only move in the safe direction of rotation. After a protective device to detect a jammed door responds, a rolling shutter gate may only start to move in one direction. When a crane trolley is at the operating limit switch then it may only start in the opposite direction. Solution Selecting STO in the inverter via terminal strip using an Emergency Stop button. Evaluating the Emergency Stop button in a central control, selecting STO in the inverter viaprofisafe. Selecting SLS in the inverter via terminal block. The inverter limits and monitors the velocity of the horizontal conveyor. Selecting SLS and the corresponding SLS level in the inverter via PROFIsafe. Select SS1 in the inverter via a failsafe input or via PROFIsafe. After pressing the Emergency Stop pushbutton, the drive is braked along the braking ramp and then brought into a torque-free condition. Selecting SSM in the inverter; the inverter safety monitors the speed and releases the process to proceed via PROFIsafe using the status bit "Status SSM". Selecting SDI in the inverter; enable the protective door via status bit (PROFIsafe) of the inverter. Selecting SDI in the inverter. Disabling the hazardous direction of rotation. SLP The drive may not exit the specified position ranges. Selection of SLP in the inverter; inhibits the range that is not permitted 22 Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3

25 General information about SINAMICS 2.4 Drive monitoring with or without encoder 2.4 Drive monitoring with or without encoder If motors without a (safety-capable) encoder are being used, not all functions can be used. Note When "without encoder" is used in this manual, then this always means that either no encoder or no safety-capable encoder is being used. In operation without encoder the speed actual values are calculated from the measured electrical actual values. As a consequence, speed monitoring down to a speed of 0 rpm is also possible for operation without an encoder. Table 2-1 Basic Functions Extended Functions Overview of functions Functions Abbreviation With encoder Without encode r Brief description Safe Torque Off STO Yes Yes Safe torque off Safe Stop 1 SS1 Yes Yes Safe stopping process in accordance with stop category 1 Safe Brake SBC Yes Yes Safe brake control Control Safe Torque Off STO Yes Yes 1) Safe torque off Safe Stop 1 SS1 Yes Yes 1) Safe stop in accordance with stop category 1 Safe Brake SBC Yes Yes 1) Safe brake control Control Safe Stop 2 SS2 Yes No Safe stop in accordance with stop category 2 Safe Operating Stop Safely Limited Speed Safe Speed Monitor Safe Acceleration Monitor SOS Yes No Safe monitoring of the standstill position SLS Yes Yes 1) Safe monitoring of the maximum speed SSM Yes Yes 1) Safe monitoring of the minimum speed SAM Yes Yes 1) Safe monitoring of drive acceleration Safe Brake Ramp SBR Yes 1) Safe brake ramp Safe Direction SDI Yes Yes 1) Safe monitoring of the direction of motion Safely-Limited SLP Yes No Safely-limited position Position 1) The use of the safety function without encoder is possible only for induction motors or synchronous motors from the SIEMOSYN series. Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3 23

26 General information about SINAMICS 2.4 Drive monitoring with or without encoder The configuration of the functions and the selection of monitoring with or without encoder is realized in the Safety screens of the STARTER or SCOUT tools. 24 Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3

27 Description of Basic Functions 3 Note The Basic Functions are functions for safely stopping the drive. You do not require an encoder. This chapter should provide first users with a quick overview of the principle mode of operation of safety functions. The entry into the description of the safety functions is based on the definition according to standard EN and some simple examples for using the function. The description of the functions is simplified, as far as possible to clearly shown essential properties and setting options. More information about the functions can be found in the following Chapters, e.g.: basic functions (Page 173) Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3 25

28 Description of Basic Functions 3.1 Safe Torque Off (STO) 3.1 Safe Torque Off (STO) Definition according to EN : "The STO function prevents energy from being supplied to the motor, which can generate a torque." STO Select STO Examples of how the function can be used Example After an Emergency Stop button has been pressed, the drive must be braked as quickly as possible and transitioned into STO. A central Emergency Stop button ensures that several drives are braked as quickly as possible and transitioned into the STO state. Solution Wire the Emergency Stop button with a failsafe input. Select STO via the fail-safe input. Evaluating an emergency stop pushbutton in a central control. Select STO via PROFIsafe. How does STO function in detail? The converter recognizes the selection ofsto via a fail-safe input or via the safe communicationprofisa fe. The converter then safely switches off the torque of the connected motor. Details and parameterization For further details and information on how to parameterize this function, refer to Chapter "Safe Torque Off (STO) (Page 173)". 26 Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3

29 Description of Basic Functions 3.2 Safe Stop 1 (SS1) 3.2 Safe Stop 1 (SS1) Definition according to EN : "The function SS1 brakes the motor and trips the function STO after a delay time." STO Select SS1 Example of how the function can be used Example It is only permissible to open a protective door if the motor torque has been switched off. Solution Select SS1 in the converter via a terminal or via PROFIsafe. The motor is braked and the converter then goes into the STO state. How does SS1 function in detail? Overview The drive decelerates once "Safe Stop 1" has been selected, and goes into the "Safe Torque Off" state once the delay time has expired. Select SS1 As soon as the converter identifies that SS1 has been selected via a terminal or via safe communication PROFIsafe, the following happens: If the motor has already been switched off when selecting SS1, then the converter safely switches off the motor torque (STO). If the motor is switched on when SS1 is selected, the converter brakes the motor with the AUS3 ramp-down time. Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3 27

30 Description of Basic Functions 3.2 Safe Stop 1 (SS1) Details and parameterization For further details and information on how to parameterize this function, refer to Chapter "Safe Stop 1 (SS1, time controlled) (Page 177)". 28 Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3

31 Description of Basic Functions 3.3 Safe Brake Control (SBC) 3.3 Safe Brake Control (SBC) The "Safe Brake Control" function (SBC) is used to control holding brakes that function according to the closed-circuit principle (e.g. motor holding brake). SBC is (if configured) initiated together with STO. he Motor Module/Safe Brake Relay then carries out the action and activates the outputs for the brake. Brake activation via the brake connection on the Motor Module/Safe Brake Relay involves a safe, two-channel method. Functional features of "Safe Brake Control" SBC is executed when "Safe Torque Off" (STO) is selected. Unlike conventional brake control, SBC is executed via p1215 through two channels. SBC is executed regardless of the brake control or mode set in p1215. SBC is not recommended, however, when 1215 = 0 or 3. When the state changes, electrical faults, such as e.g. a short-circuit in the brake winding or wire breakage can be detected. Two-channel brake control The brake is essentially controlled from the Control Unit. Two signal paths are available for applying the brake. Figure 3-1 Two-channel brake control, blocksize (example) For the "Safe Brake Control" function, the Motor/Power Module assumes a monitoring function to ensure that when the Control Unit fails or malfunctions the brake current is interrupted therefore closing the brake. The brake diagnostics can only reliably detect a malfunction in either of the switches (TB+, TB ) when the status changes, i.e. when the brake is released or applied. If the Motor Module or Control Unit detects a fault, the brake current is switched off and the safe status is reached. Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3 29

32 Description of Basic Functions 3.3 Safe Brake Control (SBC) Details and parameterization For further details and information on how to parameterize this function, refer to Chapter "Safe Brake Control (SBC) (Page 180)". 30 Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3

33 Description of the Extended 4 functions This chapter should provide first users with a quick overview of the principle mode of operation of safety functions. The entry into the description of the safety functions is based on the definition according to standard EN and some simple examples for using the function. The description of the functions is simplified, as far as possible to clearly shown essential properties and setting options. More information about the functions can be found in the following Chapters, e.g.: Extended Functions (Page 189) Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3 31

34 Description of the Extended functions 4.1 Preconditions for the Safety Extended Functions 4.1 Preconditions for the Safety Extended Functions A license is required to use the Extended Functions. Enter the associated license key via the STARTER button "license key". Then activate the license key using Activate. As an alternative, you can enter the parameters into parameter p9920 in the ASCII code. The license key is activated using parameter p9921 = 1. For information on how to generate the license key for the product "SINAMICS Safety Integrated Extended Functions", read the section "Licensing" in the SINAMICS S120 Function Manual. An insufficient license is indicated via the following alarm and LED: A > License not sufficient LED RDY --> Flashes greed/red at 0.5 Hz Control possible via PROFIsafe TM54F Onboard F-DI (CU310-2) Active functions without control An activated current controller in the drive Overview of hardware components that support the Extended Functions: Control Unit CU320-2 Control Unit CU310-2 Motor Modules Booksize Compact Motor Modules Booksize where the order number ends as follows: -xxx3 or higher Motor Modules Chassis where the order number ends as follows: -xxx3 or higher (For this design, Extended Functions are permitted only with sin/cos encoders.) Motor Modules Cabinet where the order number ends as follows: -xxx2 or higher Power Modules Blocksize Control Unit adapter CUA31 with order no.: 6SL3040-0PA00-0AA1 Control Unit adapter CUA32 with order no.: 6SL3040-0PA01-0AA0 For the Safety Functions with encoder: Motors with sin/cos encoder and encoder evaluation with DRIVE-CLiQ interface or via Sensor Module SMC20, SME20/25/120/ Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3

35 Description of the Extended functions 4.2 Safe Torque Off (STO) 4.2 Safe Torque Off (STO) For the control options and the functionality for "Safe Torque Off" (STO), refer to chapter "Description of Basic Functions". Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3 33

36 Description of the Extended functions 4.3 Safe Stop 1 (SS1) 4.3 Safe Stop 1 (SS1) Definition according to EN : "The function SS1 brakes the motor, monitors the magnitude of the motor deceleration, and after a delay time, initiates the STO function." STO Select SS1 Example of how the function can be used Example It is only permissible to open a protective door if the motor torque has been switched off. Solution Select SS1 in the converter via a terminal or via PROFIsafe. When the inverter signals the standstill of the motor via PROFIsafe, enable the protective door. How does SS1 function in detail? Overview Using the SS1 function, the converter brakes the motor and monitors the absolute speed. If the motor speed is low enough or the delay time has expired, the converter safely switches off the motor torque using STO. Select SS1 As soon as the inverter detects the selection of SS1 via a fail-safe input or via safety communication PROFIsafe the following happens: If the motor has already been switched off when selecting SS1, then the converter safely switches off the motor torque (STO). If the motor is switched on when SS1 is selected, the converter brakes the motor with the AUS3 ramp-down time. 34 Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3

37 Description of the Extended functions 4.3 Safe Stop 1 (SS1) Monitoring modes For Extended Functions with encoder, there is only the "acceleration monitoring" mode. For Extended Functions without encoder, you have the choice between two different monitoring modes of the SS1 function. Braking ramp monitoring (only without encoder) Acceleration monitoring (with or without encoder) Using the SBR (Safe Brake Ramp), the inverter monitors whether the motor speed is decreasing. The gradient of the SBR function can be adjusted using the reference velocity and the ramp-downtime. The SBR function only starts after the "delay for braking ramp". The SBR function starts with the speed setpoint, which was present at the instant in time that SS1 was selected. If the converter detects that the motor is at a standstill or the delay time has expired, then it safely switches off the motor torque (STO) The inverter monitors the motor speed using the SAM function (Safe Acceleration Monitor). The converter prevents the motor from reaccelerating by continuously adjusting the monitoring threshold to the decreasing speed. The converter reduces the monitoring threshold until the "Shutdown speed" has been reached. The converter safely switches off the motor torque (STO), if one of the following conditions is fulfilled: The inverter detects that the motor is stationary. The maximum time until shutdown of the torque has expired. Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3 35

38 Description of the Extended functions 4.3 Safe Stop 1 (SS1) Note SS1 without OFF3 If you use "SS1 without OFF3", neither of the two monitoring functions (SBR, SAM) is active. Details and parameterization For further details and information on how to parameterize this function, refer to Chapter "Safe Stop 1 (SS1) (Page 193)". 36 Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3

39 Description of the Extended functions 4.4 Safe Stop 2 (SS2) 4.4 Safe Stop 2 (SS2) Definition according to EN : "The function SS2 brakes the motor, monitors the magnitude of the motor deceleration, and after a delay time, initiates the SOS function." SOS Select SS2 Example of how the function can be used Example A protective door must only be opened if a motor is in the safe standstill state. Solution Select SS2 in the converter via a terminal or via PROFIsafe. After braking, the converter goes into the SOS state. Only then may the protective door be released. The safety function SS2 monitors the load speed and initiates the SOS function if the SS2 delay time has expired. SS2 monitors the absolute value of the speed. If you are operating the motor with closed-loop torque control, the converter switches to the closed-loop speed control mode when SS2 is selected. Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3 37

40 Description of the Extended functions 4.4 Safe Stop 2 (SS2) How does SS2 function in detail? The SS2 safety function operates as follows: The machine control selects the SS2 safety function via a fail-safe input or via PROFIsafe (safe bus communication). If, when selecting SS2, the motor is already at a standstill, after a delay time, the converter activates the Safe Operating Stop function (SOS). If the motor is not at a standstill when selecting SS2, using the SAM function, the converter monitors whether the converter is accelerating again. After a delay time, the converter activates the Safe Operating Stop function (SOS). Braking behavior Figure 4-1 Braking behavior and diagnostics of the safety function SS2 (Safe Stop 2) 38 Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3

41 Description of the Extended functions 4.4 Safe Stop 2 (SS2) Details and parameterization For further details and information on how to parameterize this function, refer to Chapter "Safe Stop 2 (SS2) (Page 199)". Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3 39

42 Description of the Extended functions 4.5 Safe Operating Stop (SOS) 4.5 Safe Operating Stop (SOS) This function serves for fail-safe monitoring of the standstill position of a drive. The protected machine areas can be entered without having to shut down the machine as long as SOS is active. Drive stopping is monitored using an SOS tolerance window. When this function is activated, the current actual position is saved as a comparative position, until SOS is deselected again. Any delay time is cleared after SOS is deselected and the drive can be immediately moved. STOP B is the stop response after the standstill tolerance window has been violated. Note Contrary to SS1 and SS2, SOS does not automatically brake the drive: The control still enters the setpoint. This means that in the user program of the control system, the system must respond to the "SOS selected" bit so that the control system brings the drive to a standstill within the delay time. Note For SIMOTION, the information "SOS selected" is transferred to the user program using the safety data block. Figure 4-2 Zero speed tolerance 40 Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3

43 Description of the Extended functions 4.5 Safe Operating Stop (SOS) Details and parameterization For further details and information on how to parameterize this function, refer to Chapter "Safe Operating Stop (SOS) (Page 201)". Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3 41

44 Description of the Extended functions 4.6 Safely Limited Speed (SLS) 4.6 Safely Limited Speed (SLS) Definition according to EN : "The SLS function prevents the motor from exceeding the specified speed limit." SLS Select SLS Examples of how the function can be used Example After opening a protective door, the machine operator must enter the machine and in the hazardous zone, operate a horizontal conveyor belt running at a slow speed using an acknowledgment button. A spindle drive, depending on the selection of the cutting tool, must not exceed a specific maximum velocity. Solution Select SLS in the inverter via a fail-safe input or PROFIsafe. The inverter limits and monitors the velocity of the horizontal conveyor. Select SLS and the corresponding SLSlevel in the inverter via PROFIsafe. 42 Function Manual, (FHS), 01/2012, 6SL3097-4AR00-0BP3