SINUMERIK 840D sl Safety Integrated / Safety Integrated plus Safe machines with a high productivity. Unrestricted Siemens AG 2018

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1 SINUMERIK 840D sl Safety Integrated / Safety Integrated plus Safe machines with a high productivity Siemens.com/sinumerik

2 Agenda Machinery directive and standards Overview of the SINUMERIK portfolio Safety Integrated concepts for SINUMERIK 840D sl Safety functions Connection of safety-related sensors and actuators Brake test System requirements and software licenses Commissioning Acceptance test Safety functions on machines according to ISO Additional information Page 2

3 Safety Integrated State-of-the-art and in conformance with the relevant directives Standards and regulations relating to safe machines to protect people are becoming increasingly more stringent. The Machinery Directive 2006/42/EC is mandatory when operating machines in the European Union. Machine OEMs must not only design and build "safe" machines, but they must also prove their safety. In classic designs, additional components (contactors, safety relays, etc.) and complex wiring are required to achieve safe machines. In spite of these challenges, reducing costs and increasing productivity and quality are the decisive drivers when it comes to manufacturing and operating safe machines Page 3

4 Machine safety general Machinery Directive 2006/42/EC The Machinery Directive must be transposed into domestic legislation in the Member States This especially addresses manufacturers and importers The Machinery Directive is applicable when placing in the market machines and safety components in the European Economic Area (EEA) "Placing on the market" means: Making available for the first time in the European Community machinery or partly completed machinery with a view to distribution or use, whether for payment or free of charge. The machine is manufactured in Europe or underwent significant changes and modifications in Europe The machine is imported into Europe All machines placed in the market in the European Economic Area (EEA) since December 29, 2009 must meet the requirements of the Machinery Directive (2006/42/EC)! Page 4

5 Machine safety general Machinery Directive 2006/42/EC Machinery imported into these countries must meet the requirements of the European Machinery Directive Page 5

6 How can the requirements of the European Machinery Directive be complied with? Without applying harmonized standards The machinery manufacturer must demonstrate in detail that it has met the requirements of the Machinery Directive. Applying harmonized standards The machinery manufacturer need only demonstrate that it has met the requirements of the harmonized standards. This means increased effort and costs in validating the machinery when compared to applying the harmonized standards. Then the presumption of conformity applies! We recommend that harmonized standards are applied Page 6

7 Machine safety general EN safety standards are hierarchically classified in 3 groups Basic standard (type A standards), e.g.: EN Functional safety of safety-related electrical/electronic/programmable electronic systems EN14121 Safety of machinery risk assessment Group standard (type B standards), e.g.: EN Safety of machinery functional safety of safety-related electrical, electronic and programmable electronic control systems. EN ISO Safety of machinery safety-related parts of controls EN Safety of machinery electrical equipment of machines Technical standards (type C standards), e.g.: EN ISO Machine tools safety of turning machines EN ISO Machine tools, safety machining centers, milling machines, transfer machines TYPE A Basic design Guidelines and basic terminology for machinery B1 Standards General Safety aspects TYPE B B2 Standards Reference to special Protective devices TYPE C Specific safety features for individual machinery groups Page 7

8 EN ISO Safety of machinery safety-related parts of controls Field of application Safety-related parts of control systems, irrespective of the technology Electrical, hydraulic, pneumatic, mechanical,... Based on the previous Standard EN However, a quantitative analysis of the safety function is also required. The probability of failure (PFH) of a safety function must be calculated The probability of failure (PFH) is defined by the Performance Level The Performance Level is calculated based on safety-related parameters The following safety-related parameters are required Category (structural requirement) Performance Level (PL) Mean Time to Dangerous Failure (MTTF D ) Diagnostic Coverage (DC) Common Cause Fault (CCF) Page 8

9 EN ISO Categories Category B Category 1 Category 2 Category 3 Category 4 I L O I L O I L O I1 L1 O1 I1 L1 O1 Single-channel structure. Single-channel structure. TE OTE I2 L2 O2 I2 L2 O2 The occurrence of a fault can result in the loss of the safety function. I = sensor L = logic O = actuator TE = test equipment OTE = output of the TE The occurrence of a fault can result in the loss of the safety function. The probability of a fault occurring is less than in Category B. Well-proven components and well-proven safety principles must be applied Single-channel structure with test channel The safety function must be tested at regular intervals by the machine control system. Two-channel structure When a single fault occurs, the safety function is maintained. Two-channel structure Single faults must be detected at or before the request for the safety function. If this is not possible, it is not permissible that an accumulation of undetected faults results in the loss of the safety function. Page 9

10 EN ISO Risk graph F1 P1 Low risk a Severity of the injury S1 slight (usually reversible) injury S1 S2 F2 F1 P2 P1 P2 P1 P2 P1 b c d Erforderlicher Performance Level PL S2 serious (usually irreversible) injury including death Frequency and/or duration of the exposure to danger F1 infrequent up to more often and/or short exposure F2 frequent up to continuous and/or long exposure Possibility of avoiding the danger P1 possible under certain conditions F2 P2 e P2 hardly possible High risk The Performance Level of each safety function must first be determined with the help of the risk graph Page 10

11 EN ISO Performance Level Performance Level PFH value (Probabillity of dangerous failure per hour) a >/= bis > b >/= 3 x bis > c >/= bis > 3 x d >/= bis e >/= bis For EN ISO 13849, the result of a risk assessment is indicated by the Performance Level for the respective safety function Page 11

12 IEC Functional safety of safety-related electrical, electronic and programmable electronic control systems IEC is a sector-specific standard, positioned below IEC It describes the implementation of safetyrelated electrical control systems of machines, and takes into account the complete lifecycle from the conceptual phase to de-commissioning. The standard is based on the quantitative and qualitative analyses of safety functions. Sector-specific standards should use the basic approaches of IEC 61508, and apply them for the respective area of application. For example machine sector, power plant sector, medical sector,... Standard IEC describes the risk to be minimized and the ability of the control system to minimize this risk in the sense of the Safety Integrated Level (SIL). Three SILs are used in the machine sector, whereby SIL 1 is the lowest and SIL 3 is the highest Safety Integrity Level. Page 12

13 IEC Safety Integrity Level Safety Integrity Level (SIL) (IEC 62061) PFH value (Probabillity of dangerous failure per hour) - >/= bis > >/= 3 x bis > >/= bis > 3 x >/= bis >/= bis For IEC 62061, the result of a risk assessment is indicated by the Safety Integrity Level for the respective safety function. Page 13

14 Relationship between SIL, PL and PFH value The following table shows the relationship between Performance Level, PFH value and Safety Integrated Level: Performance Level (PL) (EN ISO 13849) PFH value (Probabillity of dangerous failure per hour) Safety Integrity Level (SIL) (IEC 62061) a >/= bis > b >/= 3 x bis > c >/= bis > 3 x d >/= bis e >/= bis Page 14

15 Agenda Machinery directive and standards Overview of the SINUMERIK portfolio Safety Integrated concepts for SINUMERIK 840D sl Safety functions Connection of safety-related sensors and actuators Brake test System requirements and software licenses Commissioning Acceptance test Safety functions on machines according to ISO Additional information Page 15

16 Why do we have a new Safety Integrated concept for SINUMERIK 840D sl? Safety Integrated since 1996 Motion monitoring Safety functions are distributed between NCK (SINUMERIK) and drive (SINAMICS) For axes connected via Profisafe safety functions are integrated in the drive (SINAMICS) Safe programmable logic in NCK and PLC Direct connection of safety-related actuators and sensors to the failsafe I/O from the SIMATIC ET200 range No additional hardware relays required Software-based processing of the digital signals from safety-related sensors and actuators Two programs with crosswise data and result comparison Asynchronous subprogram in the NCK Standard STEP 7 program in the PLC Safety Integrated plus from 2017 Motion monitoring Safety functions are integrated in the drive (SINAMICS) Safe programmable logic in the integrated F-PLC Direct connection of safety-related actuators and sensors to the fail-safe I/O from the SIMATIC ET200 range No additional hardware relays required Software-based processing of the digital and analog signals from the safety-related sensors and actuators One failsafe program in the F-PLC Fail-safe program in STEP 7 TIA-Portal Both versions are offered in parallel Safety Integrated is just as safe and reliable in the application as Safety Integrated plus Page 16

17 Safety Integrated plus SINUMERIK Safety in the TIA Portal SINUMERIK 808D Entry-level class Compact class SINUMERIK 828D SINUMERIK 840D sl Premium class Panel-based compact CNC Technologies: Turning and milling Up to 5 axes/spindles 1 machining channel 7.5"/8.4" color display S7-200-based PLC Panel-based compact CNC Technologies: Turning, milling, grinding Up to 10 axes/spindles / 2 auxiliary axes 2 machining channels 10.4"/15.6" color display S7-200-based PLC Drive-based modular CNC Multi-technology CNC Up to 93 axes/spindles Up to 30 machining channels Modular panel concept up to 19" color display SIMATIC S7-300 PLC 317/319-3PN/DP Page 17

18 Agenda Machinery directive and standards Overview of the SINUMERIK portfolio Safety Integrated concepts for SINUMERIK 840D sl Safety functions Connection of safety-related sensors and actuators Brake test System requirements and software licenses Commissioning Acceptance test Safety functions on machines according to ISO Additional information Page 18

19 SINUMERIK Safety Integrated System-integrated and with safe programmable logic NCU SINUMERIK Operate SPL PLC PROFIBUS PROFINET ET 200 fail-safe I/O Motion monitoring for NC axes distributed between NCK and drive Two fail-safe programs Asynchronous subprogram in the NCK SPL NCK SI-Basic Drives DRIVE-CLiQ External SINAMICS drives SINAMICS drives SI-Basic SI-Extended STEP 7 program in the PLC Different safety concepts for axes which are directly assigned to the NCU and external axes. Mmon Mmon Page 19

20 SINUMERIK Safety Integrated plus Drive-based and with a fail-safe PLC NCU NEW F-PLC Motion monitoring for NC axes exclusively in the drive SINUMERIK Operate PLC PROFIBUS PROFINET ET 200 fail-safe I/O External SINAMICS drives SI-Basic SI-Extended One fail-safe program STEP 7 program in the F-PLC Same safety concept for axes which are directly assigned to the NCU and external axes SI-Basic NCK Drives DRIVE-CLiQ SINAMICS drives SI-Extended NEW Page 20

21 SINUMERIK 840D sl hardware concept for Safety Integrated and Safety Integrated plus PROFIBUS or PROFINET PROFIBUS or PROFINET SINUMERIK 840D sl z. B. ET 200SP e.g. CU320-2 SINAMICS S120 Safety Integrated: Motion monitoring in NCK and drive Safe programmable logic in NCK and PLC Safety Integrated plus: Motion monitoring integrated in the drive Safe programmable logic in F-PLC Direct connection of safe actuators and sensors to the fail-safe I/Os from the SIMATIC ET200 range Safety Integrated / Safety Integrated plus: Motion monitoring integrated in the drive Page 21

22 Agenda Machinery directive and standards Overview of the SINUMERIK portfolio Safety Integrated concepts for SINUMERIK 840D sl Safety functions Connection of safety-related sensors and actuators Brake test System requirements and software licenses Commissioning Acceptance test Safety functions on machines according to ISO Additional information Page 22

23 Safety Integrated und Safety Integrated plus Comparison of functions * In the basic scope of SINAMICS included Page 23

24 Safety function Safe Torque Off (STO) Prevents unexpected starting Selecting STO The drive pulses are suppressed The power feed is electronically disconnected The drive is safely in a no-torque condition Applications Always active after Emergency Stop Manually rotating a spindle with the protective door open SINUMERIK Safety Integrated SINUMERIK Safety Integrated plus Page 24

25 Safety function Safe Stop 1 (SS1; Stop B) Safe stopping process Selecting SS1 The drive is brought to a standstill in accordance with stop category 1 (EN ) Braking along an adjustable ramp (OFF3) Transition into STO after an adjustable time Applications Protection of persons Stopping for Emergency Stop SINUMERIK Safety Integrated SINUMERIK Safety Integrated plus Page 25

26 Safety function Safe Brake Control (SBC) Safety controlling a brake Two-channel output at the SINAMICS Motor Module Is initiated in conjunction with STO Brake winding short-circuit and wire breakage are detected Applications Controlling a brake for axes that can fall due to gravity SINUMERIK Safety Integrated SINUMERIK Safety Integrated plus Page 26

27 Safety function Safe Stop 2 (SS2; Stop C) Safe stopping process Selecting SS2 The drive is brought to a standstill in accordance with stop category 2 (EN ) Braking along an adjustable ramp (OFF3) Transition into SOS after an adjustable time or when a configurable speed is fallen below Applications Protection of persons SINUMERIK Safety Integrated SINUMERIK Safety Integrated plus Page 27

28 Safety function Safe Stop 2 (SS2e; Stop D) Interpolatory stopping process Selecting SS2e Braking a drive along a contour During the delay time the speed follows the setpoint provided by the higher-level control system During this delay time it is not permissible that persons are in the hazardous area Transition into SOS after the delay time has elapsed Delay time Applications Machine protection SINUMERIK Safety Integrated SINUMERIK Safety Integrated plus Page 28

29 Safety function Stop E Interpolatory stopping process incl. retraction montion Retraction motion (ESR) Braking a drive path-related During the delay time the speed follows the setpoint provided by the higher-level control system During this delay time it is not permissible that persons are in the hazardous area Transition into SOS after the delay time has elapsed Selecting SS2e Delay time Applications Machine protection SINUMERIK Safety Integrated SINUMERIK Safety Integrated plus Page 29

30 Safety function Safe Operating Stop (SOS) Safe position monitoring Selecting SOS The drive remains in position control It is monitored that the drive remains at standstill The drive can develop the full torque Applications Working in a hazard area with protective doors open Axes with asymmetrical tools are held in position Axes that can fall due to gravity are maintained at a certain position SINUMERIK Safety Integrated SINUMERIK Safety Integrated plus Page 30

31 Safety function Safe Speed Monitor (SSM; n<nx) Safe Speed Monitoring SSM is a signaling function It outputs a safety-related output signal once the speed limit value has been reached Processing the safe output signal in the safe logic Applications The protective door is only released after all of the drives have come to a standstill (zero speed) SINUMERIK Safety Integrated SINUMERIK Safety Integrated plus Page 31

32 Safety function Safely Limited Speed (SLS) Safely Limited Speed Selecting SLS Safety-related monitoring of the load-side speed 4 different speed values per drive can be parameterized Applications Traversing axes or spindle with the protective door open Protection for persons Burst protection, e.g. for grinding wheels and lathe chucks Machine protection SINUMERIK Safety Integrated SINUMERIK Safety Integrated plus Page 32

33 Safety function Safely Limited Speed (SLS) sensorless* Safely limited speed sensorless* Selecting SLS For induction motors Safety-related monitoring of the load-side speed 4 different speed values per drive can be parameterized SLS override possible Applications Monitoring of spindles with high speed Protection for persons and machine Burst protection, e.g. for grinding wheels and lathe chucks Machine protection * sensorless means: using SLS sensorless for motors with non safety-related encoder e.g. for speed-control, or for motors without encoder SINUMERIK Safety Integrated SINUMERIK Safety Integrated plus Page 33

34 Safety function Safely Limited Speed (SLS) override via machine data Safely limited speed Selecting SLS The second and fourth SLS limit value (SLS2 / SLS4) can be influenced by 16 machine data in each case (value range 0% 100%) The speed levels 1 and 3 can also be parameterized and selected in this case. A total of 34 speed levels per axis are available Applications: Burst protection, e.g. for grinding wheels or lathe chucks machine protection SINUMERIK Safety Integrated SINUMERIK Safety Integrated plus Page 34

35 Safety functions Safely Limited Speed (SLS) via PROFIsafe Safely limited speed Selecting SLS The first SLS limit value (SLS1) can be influenced via PROFIsafe Value range (32767 = 100%) Also in this case, speed levels 2, 3 and 4 can be parameterized and selected. Applications Burst protection, e.g. for grinding wheels and lathe chucks Machine protection SINUMERIK Safety Integrated SINUMERIK Safety Integrated plus Page 35

36 Safety function Safe Acceleration Monitor (SAM) / Safe Brake Ramp (SBR) Safe Acceleration Monitor / Safe Brake Ramp Active for SS1 and SS2 The function monitors whether the speed increases while braking STO is immediately triggered once the monitoring responds Applications Monitoring the braking operation SINUMERIK Safety Integrated SINUMERIK Safety Integrated plus Page 36

37 Safety function Safe Cam (SCA) Safe area detection Outputs a safety-related signal The safety-related signal is processed in a fail-safe program 30 safe cam pairs (plus/minus) available for each axis Applications Definition of working and protection areas Safety-related switchover of safety functions SINUMERIK Safety Integrated SINUMERIK Safety Integrated plus Page 37

38 Safety function Safely Limited Position (SLP) Safe traversing range limits Selecting SLP Switching over SLP Two traversing range limits can be parameterized The two limits can be toggled between Adjustable stop response Substitute/replacement for hardware limit switches Applications Traversing range limits for axes SINUMERIK Safety Integrated SINUMERIK Safety Integrated plus Page 38

39 Safety function Safe Position (SP) Transferring safe position values Transferring safe positions to the fail-safe control system Processing the position in a fail-safe program Applications Implementing more than 30 safety-related cams Calculating the actual speed SINUMERIK Safety Integrated SINUMERIK Safety Integrated plus Page 39

40 Safety function Safe Direction (SDI) Safe monitoring of the direction of motion Selecting SDI Using two fail-safe signals, the positive or negative direction can be inhibited. Applications Expensive tools, which may only be used for machining in one direction of rotation Traversing from an end position in the appropriate direction SINUMERIK Safety Integrated SINUMERIK Safety Integrated plus Page 40

41 Agenda Machinery directive and standards Overview of the SINUMERIK portfolio Safety Integrated concepts for SINUMERIK 840D sl Safety functions Connection of safety-related sensors and actuators Brake test System requirements and software licenses Commissioning Acceptance test Safety functions on machines according to ISO Additional information Page 41

42 Connection of safety-related sensors and actuators Safe Programmable Logic Protection against undefined operating states PROFIBUS or PROFINET with PROFIsafe protocol Direct sensor/actuator connection ET200 range Safety related I/Os Data cross-check and comparison of results Cyclically executed, independent of the user program Effective in all operating modes NCK-SPL KDV Selection and feedback of safety functions PLC-SPL Applications Safety functions NCK KDV Safety functions drive Connection of digital input and output modules from the ET 200 range KDV = kreuzweiser Daten- und Ergebnisvergleich SINUMERIK Safety Integrated SINUMERIK Safety Integrated plus Page 42

43 Connection of safety-related sensors and actuators Fail-safe PLCs Protection against undefined operating states Safety logic only has to be programmed once ET200 range safety-related I/Os Profisafe F-I/O PROFIsafe Standard Communication Programming is carried out in the TIA Portal Certified library blocks available No KDV (data cross-check and comparison of results) errors any more F-PLC F-program PLC Applications SINAMICS MOTION Monitoring (CU/MM) SIC/SCC* NCK Connection of digital input and output modules from the ET 200 range Safety-related analog input module from the ET 200M range: SM 336F (input current 0/4 20 ma) *Safety Info Channel / Safety Control Channel SINUMERIK Safety Integrated SINUMERIK Safety Integrated plus Page 43

44 Agenda Machinery directive and standards Overview of the SINUMERIK portfolio Safety Integrated concepts for SINUMERIK 840D sl Safety functions Connection of safety-related sensors and actuators Brake test System requirements and software licenses Commissioning Acceptance test Safety functions on machines according to ISO Additional information Page 44

45 Safety Integrated Brake management Brake management Safe Brake Test (diagnostic function) + Safe Brake Control Automatic test of the holding torque Monitoring of the test torque Monitoring of the axis movement Plus and minus (P/M) switching control Monitoring of the control cables Forced checking procedure as background test Page 45

46 Agenda Machinery directive and standards Overview of the SINUMERIK portfolio Safety Integrated concepts for SINUMERIK 840D sl Safety functions Connection of safety-related sensors and actuators Brake test System requirements and software licenses Commissioning Acceptance test Safety functions on machines according to ISO Additional information Page 46

47 Safety Integrated and Safety Integrated plus Seamless engineering in the TIA Portal SINUMERIK Safety Integrated Engineering system classic TIA Portal STEP 7 V 5.x S7 F Configuration Pack TIA Portal V15 or higher SIMATIC STEP 7 professional SINUMERIK Safety Integrated plus From SINUMERIK SW version 1.3 SP SIMATIC STEP 7 Safety Advanced SINUMERIK Toolbox V15 From SINUMERIK SW version: 4.8 SP2 1) 2) 1) No license required for Safety Integrated 2) License required for Safety Integrated plus Page 47

48 SINUMERIK Safety Integrated Options and article numbers Basic option Axis options Networking option Expansion axes Article number Designation Comment 6FC5800-0AM63-0YB0 6FC5800-0AM64-0YB0 6FC5800-0AS68-0YB0 SI Basic SI Comfort SI High Feature (from SW version 4.5 SP1) incl. 1 axis and 4 SPL inputs and 4 SPL outputs incl. 1 axis and 64 SPL inputs and 64 SPL outputs incl. 1 axis and 192 SPL inputs and 192 SPL outputs 6FC5800-0AC70-0YB0 SI Axis/Spindle Motion monitoring for one axis 6FC5800-0AC60-0YB0 SI Axis/Spindle package Motion monitoring for 15 axes 6FC5800-0AS67-0YB0 6SL3074-0AA10-0AA0 SI Connect (from SW version 4.7 SP1) SINAMICS SI Extended Functions 16 safe connections (basic scope 3 safe connections) License for external PLC axes Page 48

49 SINUMERIK Safety Integrated plus Options and article numbers Article number Designation Comment Basic option 6FC5800-0AS60-0YB0 Safety Integrated plus/ SI Logic Enables F-PLC Axis options 6FC5800-0AK00-0YB0 6FC5800-0AS61-0YB0 Safety Integrated plus/ SI Axis/Spindle Safety Integrated plus/ SI Multi-axis package Motion monitoring for one axis Motion monitoring for all axes Expansion axes 6SL3074-0AA10-0AA0 SINAMICS SI Expansion functions License for external PLC axes Basic option without motion monitoring for one axis No longer any differentiation according to number of safe inputs/outputs Page 49

50 Hardware requirements SINUMERIK Safety Integrated and Safety Integrated plus SINUMERIK Safety Integrated and Safety Integrated plus* are available with the standard hardware of SINUMERIK 840D sl and SINAMICS S120. Via PROFIBUS or PROFINET external axes can be connected, for example, by means of a CU320 *SINUMERIK Safety Integrated plus is available from the following hardware versions: NCU 710.3B PN with PLC DP/PN (6FC5371-0AA30-0AB0) NCU 720.3B PN with PLC DP/PN (6FC5372-0AA30-0AB0) NCU 730.3B PN with PLC DP/PN (6FC5373-0AA30-0AB0) NCU 730.3B PN with PLC DP/PN (6FC5373-0AA31-0AB0) Can be used universally Page 50

51 Agenda Machinery directive and standards Overview of the SINUMERIK portfolio Safety Integrated concepts for SINUMERIK 840D sl Safety functions Connection of safety-related sensors and actuators Brake test System requirements and software licenses Commissioning Acceptance test Safety functions on machines according to ISO Additional information Page 51

52 Commissioning SINUMERIK Safety Integrated For Safety Integrated the functional description is available under the following link: You will find the current functional description for Safety Integrated by entering the search term Safety Integrated. Page 52

53 Agenda Machinery directive and standards Overview of the SINUMERIK portfolio Safety Integrated concepts for SINUMERIK 840D sl Safety functions Connection of safety-related sensors and actuators Brake test System requirements and software licenses Commissioning Acceptance test Safety functions on machines according to ISO Additional information Page 53

54 Simple verification of the effectiveness of the safety functions Integrated acceptance test in SINUMERIK Operate Partially automated test of safety functions Logging of measured data Operator-controlled test sequence Creation of machine-specific templates For testing Individual machines / special machines Machinery parts as partial test Series machines Page 54

55 Agenda Machinery directive and standards Overview of the SINUMERIK portfolio Safety Integrated concepts for SINUMERIK 840D sl Safety functions Connection of safety-related sensors and acuators Brake test System requirements and software licenses Commissioning Acceptance test Safety functions on machines according to ISO Additional information Page 55

56 Risk evaluation/risk assessment The machine manufacturer must ensure that a risk evaluation is made (excerpt from the Machinery Directive 2006/42/EC) Start The risk evaluation should be performed according to EN The risk evaluation comprises the following elements: The risk analysis with the definition of the machine limits The identification of potential hazards The risk estimate The risk analysis supplies the information required for the risk assessment Measures to minimize the risk are made based on the risk assessment Definition of the machine limits Identification of the hazards Risk estimation Risk assessment Risikoanalyse A safety function has to be specified for each identified hazard. The risk analysis must be performed by the machine manufacturer. Was the risk adequately reduced? Yes End No Risk evaluation Risk minimization (see ) Page 56

57 EN ISO Definition of the Performance Level F1 P1 Low risk a Severity of the injury S1 slight (usually reversible) injury S1 S2 F2 F1 P2 P1 P2 P1 P2 P1 b c d Erforderlicher Performance Level PL S2 serious (usually irreversible) injury including death Frequency and/or duration of the exposure to danger F1 infrequent up to more often and/or short exposure F2 frequent up to continuous and/or long exposure Possibility of avoiding the danger P1 possible under certain conditions F2 P2 e P2 hardly possible High risk A safety function with the associated Performance Level has to be specified for each identified hazard. Page 57

58 Structure of a safety function Detecting Sensors and operating devices: Commands, mode, status of the machine and protective devices Evaluating Signal evaluation, safe logic: Detection of the hazardous situation and determination of the correct response Reacting Actuators: Execution of the correct response Buttons and sensors Relay or control Contactors, signaling units, power controllers, etc. Page 58

59 Example for calculating the "Emergency Stop" safety function Task: For a lathe with two axes and one spindle, when pressing the Emergency Stop pushbutton, all drives are to be stopped with SS1. Block diagram Detecting Evaluating Reacting HT8 Emergency Stop pushbutton NCU 720.3B ET200 SP F-DI Motor Modules Encoder interface I1 L1 L2 C1 C2 C3 R1 R2 R3 PFH 1,01 x PFH 6,60 x PFH 1,00 x Spindle X axis Z axis Spindle X axis Z axis PFH PFH PFH PFH PFH PFH 1,00 x ,00 x ,00 x ,00 x ,00 x ,00 x The total PFH value of the safety function is obtained from the sum of the individual PFH values. In this particular example, 2.88 x This corresponds to a Performance Level d Page 59

60 Example for calculating the "Emergency Stop" safety function for SINUMERIK Safety Integrated plus Task: For a lathe with two axes and one spindle, when pressing the Emergency Stop pushbutton, all drives are to be stopped with SS1 Block diagram Detecting Evaluating Reacting HT8 Emergency Stop pushbutton NCU 720.3B ET200 SP F-DI Motor Modules Encoder interface I1 L1 L2 C1 C2 C3 R1 R2 R3 PFH 1,01 x PFH 1,40 x PFH 1,00 x Spindle X axis Z axis Spindle X axis Z axis PFH PFH PFH PFH PFH PFH 1,00 x ,00 x ,00 x ,00 x ,00 x ,00 x The total PFH value of the safety function is obtained from the sum of the individual PFH values. In this particular example, 2.36 x This corresponds to a Performance Level d Page 60

61 Tools for calculating the PFH value SIS Safety Evaluation Tool SISTEMA Page 61

62 Agenda Machinery directive and standards Overview of the SINUMERIK portfolio Safety Integrated concepts for SINUMERIK 840D sl Safety functions Connection of safety-related sensors and actuators Brake test System requirements and software licenses Commissioning Acceptance test Safety functions on machines according to ISO Additional information Page 62

63 Additional information You can find a collection of links across a wide range of topics for SINUMERIK Safety Integrated at the following link: Page 63

64 Thank you for your attention! Subject to changes and errors. The information given in this document only contains general descriptions and/or performance features which may not always specifically reflect those described, or which may undergo modification in the course of further development of the products. The requested performance features are binding only when they are expressly agreed upon in the concluded contract. All product designations, product names, etc. may contain trademarks or other rights of Siemens AG, its affiliated companies or third parties. Their unauthorized use may infringe the rights of the respective owner. siemens.com/sinumerik Page 64