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12/3 Function12/3 Drive-integrated safety functions with

SINAMICS S12012/4 Safe Torque Off (STO)12/4 Safe Brake Control (SBC)12/5 Safe Stop 1 (SS1)12/5 Safe Stop 2 (SS2)12/6 Safe Operating Stop (SOS)12/6 Safely Limited Speed (SLS)12/7 Safe Speed Monitor (SSM)12/7 Safe Direction (SDI)12/8 Safely Limited Position (SLP) 12/8 Safe Position (SP)12/9 Basic Functions and Extended Functions12/9 Activation of the integrated safety

functions12/9 PROFIsafe12/10 PROFIsafe communication with

SIMOTION D12/11 Safe speed/position sensing12/11 Single-encoder system12/11 Dual-encoder system12/11 Safe acquisition of actual values without

encoders12/11 Licensing

Safety Integrated

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■ Overview

Legal framework

Machine manufacturers and plant constructors must ensure that their machines or plants cannot cause danger due to malfunc-tions apart from the general risks of electric shock, heat or radiation.

In Europe, for example, compliance with the machinery directive is required by law by the EC occupational health and safety directive. In order to ensure the conformity with this directive, it is recommended that the corresponding harmonized European standards are applied. This initiates the assumption of confor-mity and gives manufacturers and operators the legal security in terms of compliance with both national regulations and the EU directive. With the CE marking, the manufacturer of a machine documents the compliance with all applicable directives and regulations in the free movement of goods.

Safety-related standards

Functional safety is specified in various standards. EN ISO 12100, for example, is concerned with the risk assess-ment and risk reduction of machines. IEC 61508 specifies the basic requirements for electronic and programmable safety-related systems. EN 62061 (only applicable for electrical and electronic control systems) and EN ISO 13849-1, which replaces the now withdrawn EN 954-1, define the functional and safety-related requirements of control systems with relevance to safety.

The above-mentioned standards define different safety require-ments that the machine has to satisfy in accordance with the risk, frequency of a dangerous situation, probability of occurrence and the opportunities for recognizing impending danger.• EN ISO 13849-1: Performance Level PL a … e• EN 62061: Safety Integrity Level SIL 1 … 3

Trend toward integrated safety systems

The trend toward greater complexity and increasing modularity of machines have caused the safety functions to move away from the classical central safety functions (for example, deacti-vation of the complete machine using a main switch) and into the machine control system and the drives. This is often accompa-nied by a significant increase in productivity because the changeover times are shortened and during this changeover, depending on the type of machine, some subcomponents can even continue to manufacture.

Integrated safety functions act much faster than those of a con-ventional design. The safety of a machine is increased further with Safety Integrated. Furthermore, safety measures controlled by integrated safety systems are perceived as less interfering by the operator of the machine due to the custom actions, so the motivation to consciously bypass safety functions is significantly reduced.

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■ Function

Drive-integrated safety functions with SINAMICS S120

SINAMICS S120 is characterized by a number of integrated safety functions. In combination with the sensor technology and safety control required for the safety function, they ensure that highly-effective protection for persons and machines is imple-mented in a practice-oriented manner.

They comply with the following requirements:• Performance Level (PL) d and Category 3 according to

EN ISO 13849-1• Safety Integrity Level (SIL) 2 according to IEC 61508

In addition, the Safety Integrated functions of the SINAMICS S120 are generally certified by independent institutes. A list of certified components is available on request from your local Siemens sales office.

The Safety Integrated functions are completely integrated into the drive system. They are implemented electronically and there-fore offer short response times in comparison to solutions with externally implemented monitoring functions.

The motion control system SIMOTION provides support for SINAMICS drives that can execute safety-related monitoring functions (SOS, SLS, SDI) or stop reactions (STO, SS1, SS2). This support ensures that limit violations are prevented at the drive end in that SIMOTION controls (with SLS) the drive through the application, for example, within the permissible velocity range (with SLS) or brings it to a standstill (with SOS).

The functions SS1, SS2, SOS, SLS and SDI are activated and deactivated and their status is displayed with specific techno-logical alarms and system variables on the axis.

The drive software from SINAMICS S120 is integrated into the SIMOTION D motion control system. The safety functions inte-grated into the drive can therefore also be used in combination with SIMOTION D.

The integrated safety functions that are currently available for the SINAMICS S120 drive system are described in the following. Their functional safety satisfies the requirements defined in the international standard IEC 61800-5-2 for variable-speed drive systems.

The safety functions integrated into the SINAMICS S120 drive system can be grouped into three classes:• Functions for stopping a drive safely:

- Safe Torque Off (STO)- Safe Brake Control (SBC)- Safe Stop 1 (SS1)- Safe Stop 2 (SS2)- Safe Operating Stop (SOS)

• Functions for safely monitoring the motion of a drive:- Safely Limited Speed (SLS)- Safe Speed Monitor (SSM)- Safe Direction (SDI)

• Functions for safely monitoring the position of a drive:- Safely Limited Position (SLP)- Safe Position (SP) – this function is not defined in

IEC 61800-5-2

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■ Function

Safe Torque Off (STO)

The STO function is the most common and basic drive-inte-grated safety function. It ensures that no torque-generating energy can continue to affect a motor and prevents unintentional start-ups.

Effect

This function is a mechanism that prevents the drive from restart-ing unexpectedly, in accordance with EN 60204-1, Section 5.4. The STO function disables the drive pulses (corresponds to Stop Category 0 according to EN 60204-1). The drive is reliably torque-free. This state is monitored internally in the drive.

Application

STO has the immediate effect that the drive cannot supply any more torque-generating energy. STO can be used wherever the drive will reach a standstill in a sufficiently short time based on the load or when coasting down of the drive will not have any relevance for safety.

Customer benefits

The advantage of the integrated STO safety function compared to standard safety technology using electromechanical switch-gear is the elimination of separate components and the effort that would be required to wire and service them. Because of the rapid electronic switching times, the function offers a shorter reaction time than a conventional solution comprising electro-mechanical components.

Safe Brake Control (SBC)

The SBC function permits the safe control of a holding brake. SBC is always activated in parallel with STO.

Effect

A holding brake which is active in a de-energized state is con-trolled and monitored using safe two-channel technology. Due to the two-channel control, the brake may still be operated in the event of an insulation fault in the control cable. Errors of this kind are detected early by means of test pulses.

Notes:

Safe Brake Control does not detect mechanical faults in the brake itself, such as worn brake linings. For Motor Modules in booksize format, the terminals for the motor brake are integrated. In the case of blocksize format an additional Safe Brake Relay is required, and in the case of chassis format an additional Safe Brake Adapter is necessary.

Application

The SBC function is used in conjunction with the functions STO or SS1 to prevent the movement of an axis in the torque-free state, e.g. because of gravity.

Customer benefits

Again, the function saves the use of external hardware and the associated wiring.

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Safe Stop 1 (SS1)

The SS1 function causes a motor to stop rapidly and safely and switches the motor to torque-free mode after the standstill by activating STO.

Effect

The SS1 function can safely stop the drive in accordance with EN 60204-1, Stop Category 1. When the SS1 function is se-lected, the drive brakes autonomously along a quick-stop ramp and automatically activates the Safe Torque Off and Safe Brake Control functions (if configured) when the parameterized safety delay time expires.

In firmware version V4.5 and higher, an additional variant of SS1 is available (SS1E). In this case, when SS1 is selected, auto-matic braking of the drive does not start, but the safe delay time starts to elapse instead. The higher-level controller remains in control of the setpoint which must bring the drive to a standstill within this time.

Application

The SS1 function is used when in the event of a safety-relevant incident the drive must stop as quickly as possible with a sub-sequent transition into the STO state. It is thus used to bring large centrifugal masses to a stop as quickly as possible for the safety of the operating personnel, or to brake motors at high speeds as quickly as possible. Typical application examples are saws, grinding machine spindles, centrifuges and stacker cranes.

Customer benefits

The targeted stopping of a drive by means of SS1 reduces the risk of danger, increases the productivity of a machine, and allows safety clearances in a machine to be reduced. This results from active stopping of the drive as opposed to sole use of the STO function.

Safe Stop 2 (SS2)

The SS2 function shuts down a motor quickly and safely and then monitors the standstill position.

Effect

The SS2 function can safely stop the drive in accordance with EN 60204-1, Stop Category 2. When the SS2 function is se-lected, the drive brakes autonomously along a quick-stop ramp. In contrast to SS1, the automatic speed control remains opera-tional afterwards, i.e. the motor can supply the full torque re-quired to maintain zero speed. Standstill is safely monitored (SOS – Safe Operating Stop function).

Application

As with SS1, the SS2 function ensures the quickest possible deceleration of the motor. However, the motor power is not switched off, but prevented by a control system from leaving the standstill position even if affected by external forces.

Customer benefits

The SS2 function ensures a rapid axis stop. Because the control remains active, after the safety function is deselected, produc-tive operation can continue without referencing. This ensures short setup and standstill times and high productivity.

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Safe Operating Stop (SOS)

With the SOS function, the stopped drive is kept in position and monitored by drive control.

Effect

The SOS function represents safe standstill monitoring. The drive control remains in operation. The motor can therefore deliver the full torque to hold the current position. The actual position is reliably monitored. In contrast to safety functions SS1 and SS2, the speed setpoint is not influenced automatically by the drive.

Application

SOS is an ideal solution for applications for which the machine or parts of the machine must be at a safe standstill in certain steps, but the drive must also supply a holding torque. The speed control continues to operate and ensures that the drive remains in its current position despite opposing torques. SOS monitors the current standstill position. When SOS is selected, in contrast to SS1 and SS2, the drive does not influence the speed setpoint autonomously. Conversely, before SOS is activated the higher-level control has the option of ramping down the affected axes in a coordinated manner in the network within a delay time that can be set. This can be used to prevent any damage to the machine or product.

Customer benefits

No mechanical components are necessary to keep the axis in position despite any counterforce that might appear. Due to the short switching times and the fact that the drive control always remains active, setup and downtimes are reduced. Recalibra-tion of the axis after exiting the SOS function is not necessary. The axis can immediately be moved again after deactivation of the SOS function.

Safely Limited Speed (SLS)

The SLS function ensures that the drive does not exceed a preset speed limit.

Effect

The SLS function monitors the drive against a parameterized speed limit. Four different limit values can be selected. As in the case of SOS, the speed setpoint is not automatically influenced. After SLS has been selected, the higher-level control must bring the drive down below the selected speed limit within a parame-terizable time. If the speed limit is exceeded, a configurable drive-integrated fault reaction is instigated.

In firmware version V4.5 and higher, a factor can be applied to SLS limit 1 that is transferred over PROFIsafe in 16-bit resolution. This allows an almost unlimited number of limits to be specified.

Application

The SLS function is used if people are in the danger zone of a machine and their safety can only be guaranteed by reduced speed. Typical application cases include those in which an operator must enter the danger zone of the machine for the pur-poses of maintenance or setting up, such as a winder for which the material has to be fed in manually by the operator. To prevent injury to the operator, the roller may only spin at a safe reduced speed. SLS is often also used as part of a two-stage safety con-cept. While a person is in a less critical zone, the SLS function is activated, and the drives are only stopped in a smaller area with higher potential risk. SLS can be used not only for operator pro-tection, but also for machinery protection, e.g. if a maximum speed must not be exceeded.

Customer benefits

The SLS function can contribute to a significant reduction in downtime, or greatly simplify or even accelerate setup. The overall effect achieved is a higher availability of the machine. Moreover, external components such as speed monitors can be omitted.

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■ Function

Safe Speed Monitor (SSM)

The SSM function warns when a drive is working below an adjustable speed limit. As long as it remains below the threshold, the function outputs a safety-related signal.

Effect

If a speed value drops below a parameterized limit, a safety-related signal is generated. This can be processed, for example, in a safety controller to respond to the event by programming, depending on the situation.

Application

With the SSM function, in the simplest case, a safety door can be released if the speed drops below a non-critical level.

Customer benefits

Unlike SLS, there is no drive-independent fault reaction when the speed limit is exceeded. The safe feedback can be evaluated in a safety control unit, allowing the user to respond appropriately to the situation.

Safe Direction (SDI)

The SDI function ensures that the drive can only move in the selected direction.

Effect

A deviation from the currently monitored direction of motion is reliably detected and the configured autonomous fault response of the drive is initiated. It is possible to monitor one or two directions of motion optionally.

Application

The SDI function is used if the drive is allowed to move in only one direction. A typical application is to make a danger area ac-cessible to the operator, provided the machine is moving in the safe direction, i.e. away from the operator. In this status, the op-erator can safely feed material into or remove it from the working area.

Customer benefits

The function does away with the use of external components such as speed monitors and the associated wiring expense. The release of a danger zone while the machine is moving away from the operator also raises productivity. Without the SDI function, the machine would have to be stopped safely while material was fed in or removed.

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Safely Limited Position (SLP)

The SLP function monitors the axis to ensure that it remains within the permissible traversing range.

Effect

When SLP is activated, the traversing range limited by the con-figured software limit switch is safely monitored. It is possible to switch between two limit switch pairs. If the permitted traversing range is exited, a configurable fault reaction is instigated. SLP can only be used when the axis has been safely referenced.

Application

SLP is used for applications in which machine operators have to enter a protection area, e.g. for feeding in and removing material. Safe monitoring of the axis position ensures that the axis cannot move into the protection area released for operators, placing them in danger.

Customer benefits

SLP can be used for highly-effective protection area monitoring. The function does away with the use of external components such as hardware limit switches and the associated wiring ex-pense. Due to the short reaction time following a limit overshoot, safety clearances can be reduced.

Safe Position (SP)

The SP function transfers the actual position values determined safely in the drive over safe PROFIsafe communication to a safety control.

Effect

In contrast to the SLP function that monitors the current actual position value against a limit and, in the case of an overshoot, activates a drive-integrated fault reaction, SP transfers the current actual position values to the safety control. Position monitoring is implemented in the safety program of the control. Extended PROFIsafe telegrams are available for transferring the position values. The position values can be transferred in 16-bit or 32-bit resolution, as required. A time stamp is also transferred with the position values.

Application

The monitoring function has to be implemented in the safety control, so this offers extensive possibilities. For example, a safe cam controller can be implemented in this manner. Depending on the performance capability of the control, multi-dimensional position or speed monitoring functions can be implemented.

SP will only output valid, absolute actual position values if the axis has been safely referenced. A time stamp is transferred with the actual position values to enable safe speed values to be cal-culated in the safety control. The axis does not have to be safely referenced for safe speed values to be calculated.

Customer benefits

Position monitoring or speed monitoring is implemented in the safety program of the control, so the user has the flexibility for implementing tailor-made safety functions. The reaction to a limit overshoot must also be specified in the safety program. This means a higher initial programming outlay, but it does offer the opportunity for initiating different fault reactions.

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■ Function

Basic Functions and Extended Functions

The Safety Integrated functions of the SINAMICS S120 drive system are grouped into Basic Functions and Extended Func-tions.

The Basic Functions are included in the standard scope of supply.

The Extended Functions can only be enabled via a license.• Basic Functions

- Safe Torque Off (STO)- Safe Brake Control (SBC)- Safe Stop 1 (SS1)

• Extended Functions- Safe Stop 1 (SS1) with SBR or SAM- Safe Stop 2 (SS2) with SAM- Safe Operating Stop (SOS)- Safely Limited Speed (SLS)- Safe Speed Monitor (SSM)- Safe Direction (SDI)- Safely Limited Position (SLP)- Safe Position (SP)

With Extended Functions Safe Stop 1 (SS1) and Safe Stop 2 (SS2) with SAM, safe acceleration monitoring (SAM) is per-formed during braking to ensure that any faults during braking will be detected. If Safe Stop 1 is used as an encoderless function, safe brake ramp (SBR) can be configured as an alter-native.

The Basic Functions – activated via on-board terminals on the device or via PROFIsafe – do not require an encoder.

Activation of the integrated safety functions

The safety functions integrated into SINAMICS S120 can be activated as follows:• Basic Functions:

- Over terminals on the CU320-2 or SIMOTION D4x5-2 Control Unit and on the power unit (STO, SBC, SS1 only)

- Over the safety-related digital inputs of CU310-2 or SIMOTION D410-2

- Over PROFIBUS or PROFINET with PROFIsafe profile• Extended Functions:

- Over the safety-related digital inputs of the TM54F Terminal Module

- Over the safety-related digital inputs of CU310-2 or SIMOTION D410-2

- Over PROFIBUS or PROFINET with PROFIsafe profile- The SLS and SDI functions can also be parameterized to be

permanently activated

PROFIsafe

PROFIsafe is an open communications standard that supports standard and safety-related communication over the same communications cable (wired or wireless). A second, separate bus system is therefore not necessary. To ensure safe communi-cation, the transmitted message frames are continuously moni-tored. Possible errors, such as lost or repeated messages or those received in the wrong order are avoided in that safety-related messages are numbered consecutively, their arrival is monitored within a defined period, and an identifier for the sender and receiver of a message is transferred. A CRC (cyclic redundancy check) data security mechanism is also used.

SINAMICS S120 supports the PROFIsafe profile based on PROFIBUS as well as on PROFINET.

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■ Function

PROFIsafe communication with SIMOTION D

A typical communication topology between a safety control and the drives integrated in SIMOTION D is shown in the diagram below based on the example of PROFINET. This topology is also possible with PROFIBUS as the basis.

In this case, the safety control must be configured as a PROFINET controller or PROFIBUS master respectively. SIMOTION D is an I-Device or I-Slave here. SIMOTION D transfers the PROFIsafe telegrams to the drives using the F-Proxy mechanism.

Safety Integrated solution based on the example of SIMOTION D4x5-2: Control of the safety functions via PROFINET with PROFIsafe

Safety program

Light curtain Laser scanner Position switch

Emergency stop

PROFINETI-Devices

SIMOTION D4x5-2(I-Device)

SIMATIC ET 200S (I-Device) with F-I/O

SIMOTIONCX32-2

SIMATIC S7-300 F-CPU(Controller)

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■ Function

Safe speed/position sensing

Incremental encoders or absolute encoders can be used for safe sensing of the position values on a drive. Safe actual value sensing relies on redundant evaluation of the incremental channels A/B that supply sin/cos signals of 1 Vpp. Only encoders of the type whose A/B track signals are created and processed using purely analog techniques can be used.

The encoder signals can be read via SMC20, SME20/25 or SME120/125 Sensor Modules (for further information, see the chapter SINAMICS S120 drive system).

As an alternative, motors with an integrated DRIVE-CLiQ inter-face can be used. The speed or position actual values are generated directly in the motor as safe values and are trans-ferred to the Control Unit over safe communication via DRIVE-CLiQ.

The encoder must be mechanically attached in such a manner that the encoder shaft is unable to unplug or slide off. For notes on this, see IEC 61800-5-2: 2007, Table D.16.

A list of Siemens motors that fulfill the electrical and mechanical requirements is available at:

http://support.automation.siemens.com/WW/view/en/33512621

The following can be used for safe speed/position sensing:• Single-encoder systems or• Dual-encoder systems

Single-encoder system

Example: Single-encoder system

In a single-encoder system, the motor encoder is used exclusively for safe actual value sensing.

Dual-encoder system

Example: Dual-encoder system on a spindle

The safe actual values for a drive are provided by two separate encoders. The actual values are transferred to the Control Unit over DRIVE-CLiQ. When motors without a DRIVE-CLiQ connec-tion are used, a Sensor Module (SMC20/SME20/25/120/125) must be implemented. Each measuring system requires a separate DRIVE-CLiQ connection.

Safe acquisition of actual values without encoders

The Extended Functions Safe Stop 1 (SS1) with SAM/SBR, Safely Limited Speed (SLS), Safe Speed Monitor (SSM) and Safe Direc-tion (SDI) are also available for use without encoders (initially only in the Booksize or Blocksize performance range and in combination with induction motors and SIEMOSYN motors). An encoder that is used for the purposes of motor control has no significance for the safety function here.

The Safety Integrated Function Manual contains additional information about the encoderless safety functions.

The Extended Functions Safe Stop 2 (SS2), Safe Operating Stop (SOS), Safely Limited Position (SLP) and Safe Position (SP) always require a safe encoder system.

Licensing

The Safety Integrated Basic Functions do not require a license.

In the case of Safety Integrated Extended Functions, however, a license is required for every axis using these functions. It is of no consequence here which safety functions are used and how many.

The required licenses can be optionally ordered with the CompactFlash card:

For the order numbers of the CompactFlash cards, see chapter SINAMICS S120 drive system and SIMOTION D.

Notes:

Up to 6 safety axes with Extended Functions are possible in vec-tor or servo control on one CU320-2, D4x5-2 or CX32-2. Up to 11 axes with Safety Integrated Extended Functions are possible in V/f control mode.

The CU310-2 and CU410-2 Control Units have been designed to control only single axes. Only one license is therefore required for the Safety Integrated Extended Functions (short code F01).

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■ Function

An overview of the Safety Integrated functions of SINAMICS S120 and their boundary conditions is given in the following table:

Function Activation Underlying function Reaction to limit overshoot

External setpoint input effective

Encoder required

License required

STO • EP terminals on the power unit or CUA31/CUA32 and on the Control Unit

• F-DI on TM54F• F-DI on CU310-2 or

D410-2• PROFIsafe

SBC (if activated) – No No 1) No 2)

SBC • With STO (directly or following expiry of the delay with SS1)

– – – No No

SS1 • EP terminals on the power unit or CUA31/CUA32 and on the Control Unit

• PROFIsafe

STO following expiry of the parameterized delay, SBC (if activated)

– Parame-terizable

No No

SS1 with SAM/SBR

• F-DI on TM54F• F-DI on CU310-2 or

D410-2• PROFIsafe

Safe acceleration monitoring (SAM) or safe brake ramp (SBR) during braking. STO and SBC (if activated) following expiry of the parameterized delay or undershooting of the minimum speed limit

STO Parame-terizable

No Yes (per safety axis)

SS2 • F-DI on TM54F• F-DI on CU310-2 or

D410-2• PROFIsafe

Safe acceleration monitoring (SAM) during braking. Following expiry of the parameterized delay SOS

SS1 → STO No Yes Yes (per safety axis)

SLSsensorless

• F-DI on TM54F• F-DI on CU310-2 or

D410-2• PROFIsafe• Continuously activated

– SS1, STO(parameterizable)

Yes No Yes (per safety axis)

SLS • F-DI on TM54F• F-DI on CU310-2 or

D410-2• PROFIsafe

– STO, SS1, SS2 or SOS (parameterizable)

Yes Yes Yes (per safety axis)

SOS • F-DI on TM54F• F-DI on CU310-2 or

D410-2• PROFIsafe

– SS1 → STO Yes Yes Yes (per safety axis)

SSM • Always active, if configured

– Message only Yes No Yes (per safety axis)

SDI • F-DI on TM54F• F-DI on CU310-2 or

D410-2• PROFIsafe• Continuously activated

– STO, SS1, SS2, SOS (parameterizable)

Yes No Yes (per safety axis)

SLP • F-DI on TM54F• F-DI on CU310-2 • PROFIsafe

– STO, SS1, SS2, SOS (parameterizable)

Yes Yes Yes (per safety axis)

SP Always active, if configured

– – Yes Yes Yes (per safety axis)

1) The activation option using terminals on TM54F currently requires an encoder.

2) The activation option using terminals on TM54F currently requires a license.

© Siemens AG 2013