SINAMICS G120 SINAMICS G120C

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1 SINAMICS G120 SINAMICS G120C frequency inverter SINAMICS G120 frequency inverter with the Control Units CU240E-2 CU240E-2 F CU240E-2 DP CU240E-2 DP-F Safety Integrated Function Manual SINAMICS Answers for industry.

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3 Safety Integrated Function Manual, SINAMICS G120 and G120C SINAMICS SINAMICS G120 Safety Integrated Function Manual, SINAMICS G120 and G120C Function Manual Change history Introduction 1 Description 2 Interfaces 3 Commissioning 4 Servicing and maintenance 5 Alarms, faults and system messages 6 System properties 7 A Appendix Edition 01/2011, Firmware V4.4 01/2011, FW 4.4 A5E B AB

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 corresponding information is not taken into account. If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage. Qualified Personnel The product/system described in this documentation may be operated only by personnel qualified for the specific task in accordance with the relevant documentation for the specific task, in particular its warning notices and safety instructions. Qualified personnel are those who, based on their training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems. Proper use of Siemens products Note the following: WARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems. The permissible ambient conditions must be adhered to. The information in the relevant documentation must be observed. Trademarks All names identified by are registered trademarks of the Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner. Disclaimer of Liability We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions. Siemens AG Industry Sector Postfach NÜRNBERG GERMANY A5E B AB P 03/2011 Copyright Siemens AG Technical data subject to change

5 Change history Most essential changes to the manual, Edition 07/2010 New functions in firmware V4.4 The SINAMICS G120C frequency inverter has been included in the manual. New safety functions: SDI (Safe Direction) SSM (Safe Speed Monitor) Safety function SS1 (Safe Stop 1) has an additional mode: "SS1 with delay time". Safety function SLS (Safely Limited Speed) has an additional mode: "SLS with delay time". From firmware V4.4, torque control is permitted in conjunction with the safety functions SS1, SLS, SDI and SSM. In chapter Description (Page 13) Servicing and maintenance (Page 179) Description (Page 13) Commissioning (Page 105) Description (Page 13) Commissioning (Page 105) Preconditions and constraints (Page 17) Revised descriptions The designations of the control words and status words in the PROFIsafe telegram have been adapted to the PROFIsafe specification: In chapter Activation via PROFIsafe (Page 94) Control word 0 and status word 0 have been renamed to be control word 1 and status word 1 Control word 2 and status word 2 have been renamed to be control word 5 and status word 5 In the commissioning guidelines, basic commissioning has been added before commissioning the safety functions. Commissioning (Page 105) Error correction The meaning of the "Internal Event" bit (status word 1, bit 7 in the PROFIsafe telegram) has been corrected: 0 fault-free operation 1 fault In chapter Activation via PROFIsafe (Page 94) Function Manual, 01/2011, FW 4.4, A5E B AB 3

6 Change history 4 Function Manual, 01/2011, FW 4.4, A5E B AB

7 Table of contents Change history Introduction About this manual Guide through this manual Description Examples of how the safety functions can be applied Preconditions and constraints General conditions Permissible and prohibited applications Impermissible functions Safe Torque Off, STO Safe Stop 1, SS Basic principle of operation Monitoring modes of SS Braking ramp monitoring Acceleration monitoring Switching off the motor when SS1 is active Safely Limited Speed, SLS Monitoring modes of SLS Braking ramp monitoring Selecting SLS when the motor is switched on Switching between monitoring thresholds Acceleration monitoring Selecting SLS when the motor is switched on Switching between monitoring thresholds Switching off the motor when SLS is active Switching the motor off and on again when SLS is active Safe Direction (SDI) Selecting and deselecting SDI Switching off the motor when SDI is active Switching the motor off and on again when SDI is active Safe Speed Monitor, SSM Switching off the motor when SSM is active Switching the motor off and on again when SSM is active Interaction of the safety functions Overview Selecting STO when SS1 is active Selecting STO when SLS is active Selecting STO when SDI is active Selecting STO when SSM is active...60 Function Manual, 01/2011, FW 4.4, A5E B AB 5

8 Table of contents Selecting SS1 when SLS is active Selecting SS1 when SDI is active Selecting SS1 when SSM is active Selecting SDI when SLS is active Selecting SLS when SDI is active Selecting SLS when SSM is active Selecting SDI when SSM is active Password Checksum Forced dormant error detection (test stop) Interfaces Overview Activation via F-DI Fail-safe digital inputs F-DI signal filtering Wiring examples Connecting sensors Connecting pre-processing devices Activation via PROFIsafe Communication via PROFIsafe Telegram types Control word 1 and status word 1 (Basic Safety) Control word 1 and status word 1 (Extended Safety) Control word 5 and status word Configuring communication in STEP 7 (telegram 30) Configuring communication in STEP 7 (telegram 900) Further steps Example: Interface to the S7 safety program Commissioning Commissioning guidelines Commissioning tool Resetting the safety function parameters to the factory setting Selecting the commissioning method Basic Safety Activate STO via F-DI Defining the commissioning method Setting STO Activate settings Multiple assignment of the DI Further steps Activating STO via PROFIsafe Defining the commissioning method Setting STO Activate settings Further steps Activating STO via PROFIsafe and F-DI Function Manual, 01/2011, FW 4.4, A5E B AB

9 Table of contents Defining the commissioning method Setting STO Activate settings Multiple assignment of the DI Further steps Extended Safety Extended Safety with activation via F-DI Defining the commissioning method Configuring activation via FDI Configuring safety functions Setting forced dormant error detection Setting the gear ratio and tolerance Encoderless actual value sensing Enabling safety functions Setting STO Setting SS Setting SLS Setting SDI Activate settings Multiple assignment of the DI Further steps Extended Safety with activation via PROFIsafe Defining the commissioning method Setting forced dormant error detection and the PROFIsafe address Setting the gear ratio and tolerance Encoderless actual value sensing Enabling safety functions Setting STO Setting SS Setting SLS Setting SSM Setting SDI Defining the F-DI status Activate settings Starting communication via PROFIsafe Further steps Extended Safety with activation via PROFIsafe and F-DI Defining the commissioning method Setting forced dormant error detection and the PROFIsafe address Setting the gear ratio and tolerance Encoderless actual value sensing Enabling safety functions Setting STO Setting SS Setting SLS Setting SSM Setting SDI Defining the F-DI status Activate settings Starting communication via PROFIsafe Multiple assignment of the DI Further steps Function Manual, 01/2011, FW 4.4, A5E B AB 7

10 Table of contents 4.7 Offline commissioning Offline parameterization Downloading parameters Further steps Series commissioning Acceptance test - Completion of commissioning Prerequisites and authorized persons Complete acceptance test Reduced acceptance test Documentation Function test Safe Torque Off, STO (Basic Safety) Safe Torque Off, STO (Extended Safety) Safe Stop 1, SS Safely Limited Speed, SLS Safe Direction (SDI) Safe Speed Monitor (SSM) Completion of certificate Servicing and maintenance Replacing components of the modular SINAMICS G120 inverter Overview of replacing converter components Replacing the Control Unit Replacing the Power Module Replacing the SINAMICS G120C inverter Overview of how to replace an inverter Replacing the inverter Alarms, faults and system messages Operating states indicated on LEDs Reaction of the safety functions to faults Cause of fault Acknowledging with a fail-safe signal or with a power on reset STOP reactions Response of Safe Torque Off (STO) to faults Response of Safe Stop 1 (SS1) to faults Reaction of Safely Limited Speed (SLS) to faults Response of Safe Direction (SDI) to faults Response of Safe Speed monitoring (SSM) to faults Alarms and faults System properties Response times Certification Probability of failure of the safety functions (PFH value) A Appendix A.1 Standards and specifications A.1.1 General information Function Manual, 01/2011, FW 4.4, A5E B AB

11 Table of contents A Aims A Functional safety A.1.2 Safety of machinery in Europe A Machinery Directive A Harmonized European Standards A Standards for implementing safety-related controllers A EN ISO (previously EN 954-1) A EN A Series of standards EN (VDE 0803) A Risk analysis/assessment A Risk reduction A Residual risk A.1.3 Machine safety in the USA A Minimum requirements of the OSHA A NRTL listing A NFPA A ANSI B A.1.4 Machine safety in Japan A.1.5 Equipment regulations A.1.6 Other safety-related issues A Additional references A Information sheets issued by the Employer's Liability Insurance Association A.2 Additional information on the inverter A.2.1 Manuals for your inverter A.2.2 Configuring support A.2.3 Product Support A.3 Mistakes and improvements Index Function Manual, 01/2011, FW 4.4, A5E B AB 9

12 Table of contents 10 Function Manual, 01/2011, FW 4.4, A5E B AB

13 Introduction About this manual Who requires this manual and why? This manual is aimed primarily at machine and plant manfacturers, commissioning engineers, and service personnel. It describes the integrated safety functions of the SINAMICS G120 inverter and enables the target groups specified to parameterize and commission the integrated safety functions of the inverter correctly. What is described in this manual? This manual covers all the information, procedures and operations required for the following scenarios: Activating the safety functions via fail-safe digital inputs or PROFIsafe. Commissioning the safety functions. Performing diagnostics for the safety functions. The appendix contains an overview of the applicable regulations and standards for using the safety functions. What other information do you need? This manual alone is not sufficient for installing or commissioning the standard inverter functions. An overview of the documentation available and the associated applications is provided in the sectionmanuals for your inverter (Page 229). Function Manual, 01/2011, FW 4.4, A5E B AB 11

14 Introduction 1.2 Guide through this manual 1.2 Guide through this manual Chapter In this chapter, you will find answers to the following questions: Description (Page 13) What safety functions does my inverter have? In which applications are the safety functions of my inverter not permitted? How must I select and deselect the safety function? How do the inverter and motor respond when the safety function is active? How do the safety functions mutually influence one another? Interfaces (Page 75) How many fail-safe inputs does my inverter have? How do I have to wire up the fail-safe inputs of my inverter? What do I have to observe if the wiring extends beyond the control cabinet? How do I configure the communication of my inverter via PROFIsafe? How are the control words and status words assigned in PROFIsafe? Commissioning (Page 105) What approach to commissioning should I take? What tool do I need for commissioning? How do I transfer the parameters of the safety functions to other inverters? How do I reset my inverter to the factory setting? How do I check the safety functions after commissioning? What safety function settings must I document? Servicing and maintenance (Page 179) Alarms, faults and system messages (Page 187) System properties (Page 209) When do I have to recommission the safety functions of my inverter after I have replaced defective components? What do I have to check after making a replacement? What is the meaning of the signal states of the LED on my inverter? How do the inverter and motor respond to faults when the safety function is active? How do I acknowledge safety function faults? What is the meaning of the alarms and faults, which are assigned to the safety functions? How long does it take for my drive to respond when selecting a safety function? How long does it take for my drive to respond when the safety function is active and the motor malfunctions? What are the probabilities of failure of the safety functions of my inverter? According to which standards are the safety functions of my inverter certified? Appendix (Page 211) As machine manufacturer or company operating a machine, what standards and regulations must I observe? Where can I find more information on my inverter? 12 Function Manual, 01/2011, FW 4.4, A5E B AB

15 Description 2 Applications with fixed speed Applications with variable speed SIMATIC ET 200S Motorstarter SIMATIC ET 200pro Motorstarter SIMATIC ET 200S FC SIMATIC ET 200pro FC SINAMICS G120C SINAMICS G120 SINAMICS G120D SINAMICS G130 Integrated safety functions (to IEC ) STO Yes Safe Torque Off SS1 Safe Stop 1 SBC Safe Brake Control SBT Safe Brake Test SLS Safely-Limited Speed SSM Safe Speed Monitor SDI Safe Direction SOS Safe Operating Stop SS2 Safe Stop 2 SCA Safe Cam SLP Safely-Limited Position Fail-safe communication PROFIBUS with PROFIsafe profile PROFINET with PROFIsafe profile Safety Local via F-DI Certification EN EN ISO EN NFPA 79 NRTL listed Yes Yes Yes, with external components Cat. 4 Cat. 4 / PL e SIL 3 Yes Yes Yes Yes Yes Yes Yes, with external components Yes Yes Yes Yes Yes Cat. 3 Cat. 3 / PLd SIL 2 Yes Yes Yes Yes SINAMICS G150 Yes High-performance and motion control applications Numeric control in machine tools SINAMICS S110 SINAMICS S120 SINAMICS S150 SINUMERIK 840D sl SINUMERIK 840D powerline Yes Yes Yes Yes Yes Yes Yes 1 Yes Yes Yes Yes Yes Yes - - Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes, external components required in certain cases Yes Cat. 3 Cat. 3 / PL d SIL 2 Yes Yes 2 Cat. 3 Cat. 3 / PL d SIL 2 Yes Yes 1 with certified DCC application 2 only for SINAMICS S120 Booksize Figure 2-1 Overview of products for drive technology with integrated safety functions Function Manual, 01/2011, FW 4.4, A5E B AB 13

16 Description Safety functions in the SINAMICS G120 and SINAMICS G120C Table 2-1 Safety functions Abbreviation acc. to EN STO Description (de/en) acc. to EN Sicher abgeschaltetes Moment Safe Torque Off SS1 Sicherer Stopp 1 Safe Stop 1 SLS SSM SDI SBC 1) Sicher begrenzte Geschwindigkeit Safely-Limited Speed Sichere Geschwindigkeitsüberwachung Safe Speed Monitor Sichere Bewegungsrichtung Safe Direction Sichere Bremsenansteuerung 1) Safe Brake Control 1) Function in the inverter The STO function prevents the supply of energy to the motor which can generate a torque. The SS1 function brakes the motor, monitors the deceleration level of the motor within defined limits and initiates the STO function if the motor speed falls below a defined limit value. An encoder to detect the motor speed is not required. The SLS function prevents the motor exceeding the defined velocity/speed limit. An encoder to detect the motor speed is not required. The SSM function supplies a safe output signal, to indicate whether the motor speed is below a defined limit. An encoder for measuring the motor speed is not required. The SDI function prevents the motor shaft from rotating in the wrong direction. An encoder for measuring the motor speed is not required The SBC function supplies a safe output signal to control an external brake. 1) Available for SINAMICS G120 with Control Unit CU240E-2 CU240E-2 DP CU240E-2 F CU240E-2 DP-F CU240S DP-F 1) CU240S PN F 1) CU240E-2 F CU240E-2 DP-F CU240S DP-F 1) CU240S PN-F 1) CU240E-2 F CU240E-2 DP-F CU240S DP-F 1) CU240S PN-F 1) CU240E-2 DP-F - CU240E-2 F CU240E-2 DP-F CU240S DP-F 1) CU240S PN-F 1) Available with SINAMICS G120C G120C G120C DP G120C CAN ) The SBC safety function and the Control Units CU240S DP-F and CU240S PN-F are not described in this manual. 14 Function Manual, 01/2011, FW 4.4, A5E B AB

17 Description Table 2-2 Fail-safe communication Communication PROFIsafe via PROFIBUS Available for SINAMICS G120 with Control Unit CU240E-2 DP CU240E-2 DP-F CU240S DP-F 1) PROFIsafe via PROFINET 1) CU240S PN-F 1) - Available with SINAMICS G120C G120C DP 1) PROFIsafe communication via PROFINET and the Control Units CU240S DP-F and CU240S PN- F are not described in this manual. Table 2-3 Certifications of the safety functions Standard Available for SINAMICS G120 with Control Unit EN 954-1) Kat. 3 1) CU240S DP-F 1) CU240S PN-F 1) EN ISO Kat. 3 / PL d CU240E-2 CU240E-2 DP CU240E-2 F CU240E-2 DP-F CU240S DP-F 1) CU240S PN-F 1) EN SIL 2 CU240E-2 CU240E-2 DP CU240E-2 F CU240E-2 DP-F CU240S DP-F 1) CU240S PN-F 1) Available with SINAMICS G120C G120C G120C DP G120C CAN G120C G120C DP G120C CAN 1) The Control Units CU240S DP-F and CU240S PN-F are not described in this manual. Information on the safety functions of the Control Units CU240S DP-F and CU240S PN-F can be found in thefunction Manual: SINAMICS G120, SINAMICS G120D, SIMATIC ET200S FC, SIMATIC ET200pro FC ( Function Manual, 01/2011, FW 4.4, A5E B AB 15

18 Description 2.1 Examples of how the safety functions can be applied 2.1 Examples of how the safety functions can be applied Safety function Application examples STO When the emergency stop button is pressed, a stationary motor must not start unintentionally. SLS SS1 A central emergency stop button is designed to prevent more than one drive from starting unintentionally. 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 a pushbutton. A spindle drive, depending on the selection of the cutting tool, must not exceed a specific maximum speed. A protective door must only be opened when a motor is at standstill. 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. Selecting SS1 in the inverter; enable the protective door via status bit "Power removed" (PROFIsafe) of the inverter. SSM A centrifuge may only filled below a minimum velocity. Selecting SSM in the inverter; the inverter safety monitors the speed of the centrifuge and releases the process to proceed via PROFIsafe using the status bit "Status SSM ". SDI 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. 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. 16 Function Manual, 01/2011, FW 4.4, A5E B AB

19 Description 2.2 Preconditions and constraints 2.2 Preconditions and constraints General conditions Prerequisites for using fail-safe functions 1. The machine risk assessment (e.g. in compliance with EN ISO 1050, "Safety of machinery - Principles of risk assessment") allows inverter safety functions to be used in accordance with SIL 2 or PL d. 2. The closed-loop speed control of the inverter must function properly. Each fail-safe drive train must be set up in such a way that all the operating procedures performed by the driven machine can be properly monitored and that the inverter operates below its limit values (for current, temperature, voltage, etc.). The drive train comprises an inverter, motor, brake and driven machine. The performance and parameters of the inverter must be compatible with both the connected motor and the application in question. 3. Once the machine has been successfully commissioned, you must review the typical operating conditions and operate the machine close to the permissible limit values. The fail-safe inverter must not malfunction during this test. Permissible control modes for using fail-safe functions When the above-mentioned conditions are fulfilled, all of the fail-safe functions can be used for both V/f control and vector control. Permissible motors for using fail-safe functions When the above-mentioned conditions are fulfilled, all of the fail-safe functions can be used for induction motors from SIEMENS and other manufacturers. Synchronous motors are not permitted. Function Manual, 01/2011, FW 4.4, A5E B AB 17

20 Description 2.2 Preconditions and constraints Permissible and prohibited applications The safety function STO may be used without any restrictions in all applications. WARNING Suspended loads If the motor can be accelerated by the mechanical system of the connected machine part after the motor has been switched off, encoderless safety functions SS1, SLS, SSM and SDI must not be used. Whether or not a mechanical brake is installed is irrelevant here. Examples: 1. For the hoisting gear of a crane, the suspended load can accelerate the motor as soon as the motor is switched off. In this case, encoderless safety functions SS1, SLS, SSM and SDI are not permissible. Even if the mechanical brake of the hoisting gear is applied after the motor has been switched off, this is of no significance regarding the fact that safety functions SS1, SLS, SSM and SDI are prohibited in this application. 2. A horizontal conveyor is always braked to a standstill due to friction as soon as the motor is switched off. In this case, encoderless safety functions SS1, SLS, SSM and SDI can be used without any restrictions. WARNING PM240 FSGX Power Module Encoderless safety functions SS1, SLS, SSM and SDI must not be used in conjunction with the PM240 FSGX Power Module. 18 Function Manual, 01/2011, FW 4.4, A5E B AB

21 Description 2.2 Preconditions and constraints Impermissible functions NOTICE With some inverter functions the motor speed fluctuates significantly. If a safety function is simultaneously active, then this can result in a malfunction of the safety function and the inverter initiates a STOP F. As long as one or several of the safety functions SS1, SLS, SSM or SDI are active, then you must not use the following inverter functions: Motor identification Flying restart DC braking Compound braking Further, if SS1, SLS, SSM or SDI is active, you must not switch over the control mode, neither using p1300 nor by switching over the drive data sets (DDS switchover). More detailed information on the abovementioned inverter functions can be found in the operating instructions. Function Manual, 01/2011, FW 4.4, A5E B AB 19

22 Description 2.3 Safe Torque Off, STO 2.3 Safe Torque Off, STO STO functions as follows: As soon as the machine control selects the STO safety function via a fail-safe input or via PROFIsafe safety-relevant communication, the inverter safely switches off the motor torque. To switch the motor on again, you have to first deselect STO and then enter an ON command again. Figure 2-2 Dynamic response of STO (Safe Torque Off) Diagnostics Bit r and bit 0 in the PROFIsafe status word 0 indicate the status of the motor. Further information The behavior of the motor when several safety functions are simultaneously selected is described in Section: Interaction of the safety functions (Page 56). The behavior of the inverter when an internal fault is detected or in the event of a discrepancy at a fail-safe digital input can be found in Section: Response of Safe Torque Off (STO) to faults (Page 194). 20 Function Manual, 01/2011, FW 4.4, A5E B AB

23 Description 2.4 Safe Stop 1, SS1 2.4 Safe Stop 1, SS Basic principle of operation The safety function SS1 monitors the load speed and triggers the STO function, if the load speed falls below a limit value. SS1 monitors the speed but not the direction of rotation. If you operate the motor with torque control, the inverter switches to the closed-loop speed control mode when SS1 is selected Monitoring modes of SS1 You can select between two different monitoring modes of the SS1 function. Figure 2-3 The two monitoring modes of the SS1 function Your selection also influences the monitoring mode of the SLS function. Braking ramp monitoring (p9306 = 1) After selecting SS1, the inverter monitors braking with the SBR function (Safe Brake Ramp). You define the braking ramp gradient during commissioning, i.e. it is independent of the actual speed characteristic. Select this monitoring mode if your motor, after selecting SS1, should always brake with the same ramp (e.g. OFF3). Function Manual, 01/2011, FW 4.4, A5E B AB 21

24 Description 2.4 Safe Stop 1, SS1 Acceleration monitoring (p9306 = 3) The inverter adapts the monitoring using the SAM (Safe Acceleration Monitor) function to the actual speed, as long as the load does not accelerate. Select this monitoring mode if the motor, after SS1 has been selected, must not brake with a fixed ramp, e.g. if motor speeds in a drive group are dependent on one another Braking ramp monitoring The SS1 safety function operates as follows: The machine control selects the SS1 safety function via a fail-safe input or via PROFIsafe (safe bus communication). If the motor has already been switched off when selecting SS1, then the inverter safely switches off the motor torque (STO). If the motor is switched on when SS1 is selected, using the SBR function, the inverter monitors whether the speed of the load decreases. Note Normally, the inverter brakes the motor with the OFF3 ramp-down time (parameter p1135). If you do not want that the inverter automatically brakes the motor when SS1 is selected, then you must disconnect the interconnection between the "SS1" function and the ramp-function generator of the inverter: p1051 = and p1052 = If the motor does not automatically brake the inverter, then the machine control must ensure that the motor speed lies below the monitoring threshold. The inverter uses the values set for the reference speed and SS1 monitoring time parameters for this purpose. The SBR function does not start until a definable time (SS1 delay) has elapsed. To begin with, the inverter monitors the speed setpoint that applied when SS1 was selected. The inverter safely switches off the motor torque (STO), if one of the following conditions is fulfilled: The load speed reaches the "standstill monitoring threshold". The standstill monitoring function of the motor (parameters p1226 and p1227) responds. 22 Function Manual, 01/2011, FW 4.4, A5E B AB

25 Description 2.4 Safe Stop 1, SS1 Braking behavior Figure 2-4 Braking behavior and diagnostics of the safety function SS1 (Safe Stop 1) Switch on the motor To switch the motor on again, you have to first deactivate SS1 and then issue the ON command again. Function Manual, 01/2011, FW 4.4, A5E B AB 23

26 Description 2.4 Safe Stop 1, SS Acceleration monitoring The SS1 safety function operates as follows: The machine control selects the SS1 safety function via a fail-safe input or via PROFIsafe (safe bus communication). If the motor has already been switched off when selecting SS1, then the inverter safely switches off the motor torque (STO). If the motor is switched on when selecting SS1, the inverter monitors the motor speed using the SAM function (Safe Acceleration Monitor). Note Normally, the inverter brakes the motor with the OFF3 ramp-down time (parameter p1135). If you do not want that the inverter automatically brakes the motor when SS1 is selected, then you must disconnect the interconnection between the "SS1" function and the ramp-function generator of the inverter: p1051 = and p1052 = If the motor does not automatically brake the inverter, then the machine control must ensure that the motor speed lies below the monitoring threshold in sufficient time. As long as the speed is less, the inverter continually adds the tolerance to the actual speed so that monitoring tracks the speed. If the speed is temporarily higher, then the monitoring remains at the last value. The inverter reduces the monitoring threshold until the "Shutdown speed SS1" has been reached. The inverter safely switches off the motor torque (STO), if one of the following conditions is fulfilled: The load speed reaches the "standstill monitoring threshold". The standstill monitoring function of the motor (parameters p9560 or p1226 and p1227) responds. The delay time has expired. 24 Function Manual, 01/2011, FW 4.4, A5E B AB

27 Description 2.4 Safe Stop 1, SS1 Braking behavior Figure 2-5 Braking behavior and diagnostics of the safety function SS1 (Safe Stop 1) Switch on the motor To switch the motor on again, you have to first deactivate SS1 and then issue the ON command again. Function Manual, 01/2011, FW 4.4, A5E B AB 25

28 Description 2.4 Safe Stop 1, SS Switching off the motor when SS1 is active If you switch the motor off with the OFF1 or OFF3 command while the SS1 safety function is active, for example when limit switches are reached, this does not affect how the motor behaves. SS1 remains active and the inverter brakes the motor with the OFF3 ramp-down time until the standstill detection threshold is reached. If you switch off the motor with the OFF2 command when the SS1 safety function is active, then the inverter immediately safely switches off the motor torque (STO). The motor then coasts to a standstill. Figure 2-6 OFF2 command when the SS1 safety function is active (example: SS1 mode 1) To switch the motor on again, you must proceed as follows: Deselect the SS1 safety function. Select the OFF2 command. Switch off the motor with the ON/OFF1 command and then switch on again. 26 Function Manual, 01/2011, FW 4.4, A5E B AB

29 Description 2.4 Safe Stop 1, SS1 Further information The behavior of the motor when several safety functions are simultaneously selected is described in Section: Interaction of the safety functions (Page 56). The behavior of the inverter when an internal fault is detected or in the event of a discrepancy at a fail-safe digital input can be found in Section: Response of Safe Stop 1 (SS1) to faults (Page 197). Function Manual, 01/2011, FW 4.4, A5E B AB 27

30 Description 2.5 Safely Limited Speed, SLS 2.5 Safely Limited Speed, SLS With the SLS safety function, the inverter prevents the motor from exceeding the fixed speed limit. SLS monitors the absolute load speed but not the direction of rotation. Figure 2-7 Basic principle of operation of SLS If you use the PROFIsafe interface to select SLS, you can parameterize the SLS monitoring function with up to four different speed levels and toggle between these levels Monitoring modes of SLS You can select between two different monitoring modes of the SLS function. Figure 2-8 The two monitoring modes of the SLS function Your selection also influences the monitoring mode of the SS1 function. 28 Function Manual, 01/2011, FW 4.4, A5E B AB

31 Description 2.5 Safely Limited Speed, SLS Braking ramp monitoring (p9306 = 1) The inverter not only monitors the selected speed level (SLS level), but also the braking of the load, e.g. after switching over to a lower speed level. Advantages: The inverter already detects during braking, as to whether the load speed decreases too slowly. Generally, the inverter signals when the lower speed level is reached earlier than when using the delay time as monitoring method. Acceleration monitoring (p9306 = 3) The inverter only monitors the selected speed level, but not the braking of the load. When changing over to a lower speed level, the inverter begins to brake the load; however, it only switches over its monitoring to the lower speed after an adjustable delay time. Advantage: Commissioning is simplified, because instead of monitoring the braking, you only have to parameterize the delay time. Function Manual, 01/2011, FW 4.4, A5E B AB 29

32 Description 2.5 Safely Limited Speed, SLS Braking ramp monitoring Selecting SLS when the motor is switched on The machine control selects the SLS safety function via a fail-safe input or via PROFIsafe (safe bus communication). If the motor is switched off when SLS is selected, then you have 5 seconds to switch on the motor. Further information can be found in the section Switching the motor off and on again when SLS is active (Page 40). If the motor is switched on when SLS is selected, the motor behaves differently depending on the absolute value of the load speed. These two scenarios are described below. Scenario 1: The absolute value of the load speed is below the monitoring threshold. The motor speed continues to follow the setpoint as long as the load speed does not exceed the "speed limit for SLS". The inverter does not start monitoring the load speed until a definable time (SS1 delay) has elapsed. The delay is the same as that for the SS1 function. When you deselect SLS, the motor continues following its speed setpoint. Figure 2-9 Selecting and deselecting the SLS safety function at low speeds 30 Function Manual, 01/2011, FW 4.4, A5E B AB

33 Description 2.5 Safely Limited Speed, SLS Scenario 2: The absolute value of the load speed is higher than the monitoring threshold. After a definable "SS1 delay" has elapsed, the inverter uses the SBR (Safe Brake Ramp) function to determine whether the load speed has decreased. The delay is the same as that for the SS1 function. Note Normally, the inverter brakes the motor when selecting SLS with the OFF3 ramp-down time (parameter p1135). If you do not want that the inverter automatically brakes the motor, then you must disconnect the interconnection between the "SLS" function and the ramp-function generator of the inverter: p1051 = and p1052 = If the motor does not automatically brake the inverter, then the machine control must ensure that the motor speed lies below the monitoring threshold in sufficient time. The inverter switches from SBR monitoring to "SLS monitoring" as soon as one of the following two conditions is fulfilled: The SBR ramp has reached the "SLS monitoring" value. The load speed has decreased to the "SLS monitoring" value and the "SS1 delay" has elapsed. This case is illustrated in the diagram below. When you deselect SLS, the motor continues following its speed setpoint. Figure 2-10 Selecting and deselecting the SLS safety function at high speeds Function Manual, 01/2011, FW 4.4, A5E B AB 31

34 Description 2.5 Safely Limited Speed, SLS Switching between monitoring thresholds When SLS is active, you can switch between four different levels. Note Switching between the SLS levels is only possible via PROFIsafe. PROFIsafe control word 1 Selected SLS level Bit 10 Bit Level 1 p9531[0] 0 1 Level 2 p9531[1] 1 0 Level 3 p9531[2] 1 1 Level 4 p9531[3] Behavior of SLS when the monitoring thresholds are switched The drive behaves as follows when you switch from a higher to a lower monitoring threshold: Once the delay time (SS1 delay) has elapsed, the inverter monitors the motor speed using the function SBR (Safe Safe Brake Ramp ). The inverter switches from SBR monitoring to "SLS monitoring" as soon as one of the following two conditions is fulfilled: The SBR ramp has reached the "SLS monitoring" value. The load speed has decreased to the "SLS monitoring" value and the "SS1 delay" has elapsed. This case is illustrated in the diagram below. When you switch from one of the lower monitoring limits to a higher monitoring limit, then the inverter immediately monitors the speed with the higher SLS level. 32 Function Manual, 01/2011, FW 4.4, A5E B AB

35 Description 2.5 Safely Limited Speed, SLS Figure 2-11 Switching between different monitoring thresholds PROFIsafe status word 1 Active SLS level Bit 10 Bit Level 1 p9531[0] 0 1 Level 2 p9531[1] 1 0 Level 3 p9531[2] 1 1 Level 4 p9531[3] Function Manual, 01/2011, FW 4.4, A5E B AB 33

36 Description 2.5 Safely Limited Speed, SLS Acceleration monitoring Selecting SLS when the motor is switched on The machine control selects the SLS safety function via a fail-safe input or via PROFIsafe (safe bus communication). If the motor is switched off when SLS is selected, then the control has 5 seconds to switch on the motor. Further information can be found in the section Switching the motor off and on again when SLS is active (Page 40). If the motor is switched on when SLS is selected, the motor behaves differently depending on the absolute value of the load speed. These two scenarios are described below. Scenario 1: The absolute value of the load speed is below the monitoring threshold. The motor speed continues to follow the setpoint as long as the load speed does not exceed the "speed limit for SLS". The inverter monitors the load speed after a settable delay. When you deselect SLS, the motor continues following its speed setpoint. Figure 2-12 Selecting and deselecting the SLS safety function at low speeds 34 Function Manual, 01/2011, FW 4.4, A5E B AB

37 Description 2.5 Safely Limited Speed, SLS Scenario 2: The absolute value of the load speed is higher than the monitoring threshold. The inverter monitors the load speed after a settable delay. Note Normally, the inverter brakes the motor when selecting SLS with the OFF3 ramp-down time (parameter p1135). If you do not want that the inverter automatically brakes the motor, then you must disconnect the interconnection between the "SLS" function and the ramp-function generator of the inverter: p1051 = and p1052 = If the motor does not automatically brake the inverter, then the machine control must ensure that the motor speed lies below the monitoring threshold in sufficient time. Figure 2-13 Selecting and deselecting the SLS safety function at high speeds Function Manual, 01/2011, FW 4.4, A5E B AB 35

38 Description 2.5 Safely Limited Speed, SLS Switching between monitoring thresholds When SLS is active, you can switch between four different levels. Note Switching between the SLS levels is only possible via PROFIsafe. PROFIsafe control word 1 Selected SLS level Bit 10 Bit Level 1 p9531[0] 0 1 Level 2 p9531[1] 1 0 Level 3 p9531[2] 1 1 Level 4 p9531[3] Behavior of SLS when switching over the monitoring If you switch from a higher to a lower SLSlevel, then the inverter only monitors the speed with the lower SLS level after the delay time has expired. If you switch from a lower to a higher SLS level, then the inverter immediately monitors the speed with the higher SLS level. 36 Function Manual, 01/2011, FW 4.4, A5E B AB

39 Description 2.5 Safely Limited Speed, SLS Figure 2-14 Switching between different monitoring thresholds PROFIsafe status word 1 Active SLS level Bit 10 Bit Level 1 p9531[0] 0 1 Level 2 p9531[1] 1 0 Level 3 p9531[2] 1 1 Level 4 p9531[3] Function Manual, 01/2011, FW 4.4, A5E B AB 37

40 Description 2.5 Safely Limited Speed, SLS Switching off the motor when SLS is active Switching off the motor with OFF1, OFF2 or OFF3 If you switch off the motor with OFF1 or OFF3, the inverter safely switches off the motor torque (STO) when the standstill monitoring is reached. The motor then coasts to a standstill. Figure 2-15 OFF1 command when the SLS safety function is active 38 Function Manual, 01/2011, FW 4.4, A5E B AB

41 Description 2.5 Safely Limited Speed, SLS If you switch off the motor with the OFF2 command, then the inverter immediately safely switches off the motor torque (STO). Figure 2-16 OFF2 command when the SLS safety function is active You must proceed as follows in order to switch on the motor again after the SLS function has been deselected: Deselect SLS. If you switched off the motor with one of the OFF2 or OFF3 commands, then deselect the corresponding command. Switch off the motor with the ON/OFF1 command and then switch on again. Function Manual, 01/2011, FW 4.4, A5E B AB 39

42 Description 2.5 Safely Limited Speed, SLS Switching the motor off and on again when SLS is active If you switch the motor off with the OFF1 or OFF3 command while the SLS safety function is active, for example when limit switches are reached, the inverter brakes the motor with the OFF1 or OFF3 ramp-down time. While braking, the inverter monitors the motor speed to determine whether the permissible limit has been exceeded. Proceed as follows to switch the motor off and on again when SLS is active: Switch the motor off when SLS is active. When the motor has come to a standstill, select STO. Deselect STO before switching the motor on again. Switch on the motor within 5 seconds (ON command). Figure 2-17 Switching the motor off and on (ON/OFF 1) when SLS is active 40 Function Manual, 01/2011, FW 4.4, A5E B AB

43 Description 2.5 Safely Limited Speed, SLS If you do not switch on the motor within 5 seconds, then the inverter again goes into the STO state and no longer responds to the ON command. To switch the motor on again, proceed as follows: Select STO. Deselect STO again. Switch on the motor within 5 seconds (ON command). Further information The behavior of the motor when several safety functions are simultaneously selected is described in Section: Interaction of the safety functions (Page 56). The behavior of the inverter when an internal fault is detected or in the event of a discrepancy at a fail-safe digital input can be found in Section: Reaction of Safely Limited Speed (SLS) to faults (Page 199). Function Manual, 01/2011, FW 4.4, A5E B AB 41

44 Description 2.6 Safe Direction (SDI) 2.6 Safe Direction (SDI) Using the safety function SDI, the inverter prevents that the motor shaft rotates in the wrong direction. Figure 2-18 Basic principle of operation of SDI Selecting and deselecting SDI If you select SDI, then the inverter only permits the selected motor direction of rotation after the delay time expires. Note If the motor rotates in the wrong direction when SDI is selected, then the inverter normally brakes the motor with the OFF3 ramp-down time (parameter p1135). If you do not want that the inverter automatically brakes the motor, then you must disconnect the interconnection between the "SDI" function and the ramp-function generator of the inverter: p1051 = and p1052 = If the motor does not automatically brake the inverter, then the machine control must ensure that the motor speed lies below the monitoring threshold in sufficient time. The inverter tolerates brief movement in the monitored direction of rotation, by converting the motor speed into a distance (position). With the tolerance p9564, you specify the maximum permissible position. 42 Function Manual, 01/2011, FW 4.4, A5E B AB

45 Description 2.6 Safe Direction (SDI) Figure 2-19 Time response and diagnostics of the safety function SDI (Safe direction) Function Manual, 01/2011, FW 4.4, A5E B AB 43

46 Description 2.6 Safe Direction (SDI) Switching off the motor when SDI is active Switching off the motor with OFF1, OFF2 or OFF3 If you switch off the motor with OFF1 or OFF3, the inverter switches off the motor. Depending on the selected setting, the inverter safely switches off the motor torque (STO) when the standstill monitoring is reached. Figure 2-20 OFF1 command when the SDI safety function is active 44 Function Manual, 01/2011, FW 4.4, A5E B AB

47 Description 2.6 Safe Direction (SDI) If you switch the motor off with the OFF2 command when the SDI safety function is active, the inverter immediately switches off the motor (STO). Depending on the selected setting, the inverter immediately safely switches off the motor torque (STO). Figure 2-21 OFF2 command when the SDI safety function is active You must proceed as follows in order to switch on the motor again after the SDI function has been deselected: Deselect the SDI safety function. If you switched off the motor with one of the OFF2 or OFF3 commands, then deselect the corresponding command. Switch off the motor with the ON/OFF1 command and then switch on again. Function Manual, 01/2011, FW 4.4, A5E B AB 45

48 Description 2.6 Safe Direction (SDI) Switching the motor off and on again when SDI is active If you switch the motor off with the OFF1 or OFF3 command while the SDI safety function is active, for example when limit switches are reached, the inverter brakes the motor with the OFF1 or OFF3 ramp-down time. Also while braking, the inverter monitors the direction of rotation. The behavior of SSM after the motor has been switched off can be defined in two different ways. The feedback signal "SDI active" becomes inactive when the pulses are inhibited (p = 1) If you switch off the motor when SDI is active, then the inverter interrupts the speed monitoring and sets the "Status SDI" to "0". The function SDI becomes active again as soon as you switch on the motor again. Figure 2-22 Switching the motor off and on when SDI is active, interrupts the feedback signal from SDI 46 Function Manual, 01/2011, FW 4.4, A5E B AB

49 Description 2.6 Safe Direction (SDI) The feedback signal "SDI active" remains active when the pulses are inhibited (p = 0) In order to ensure that the motor comes to a standstill after switching off, you must set parameters p / p to 0. In this case, after the motor is switched off, the inverter interrupts the SDI function, but by specifying STO, safely prevents the motor from accelerating. Proceed as follows to switch the motor off and on again when SDI is active: Select STO after the motor has been switched off. Deselect STO again before you switch on the motor. Switch on the motor within 5 seconds (ON command). Figure 2-23 Switching the motor off and on when SDI is active Function Manual, 01/2011, FW 4.4, A5E B AB 47

50 Description 2.6 Safe Direction (SDI) If you do not switch on the motor within 5 seconds, then the inverter again goes into the STO state and no longer responds to the ON command. To switch the motor on again, proceed as follows: Select STO. Deselect STO again. Switch on the motor within 5 seconds (ON command). Further information The behavior of the motor when several safety functions are simultaneously selected is described in Section: Interaction of the safety functions (Page 56). The behavior of the inverter when an internal fault is detected or in the event of a discrepancy at a fail-safe digital input can be found in Section: Response of Safe Direction (SDI) to faults (Page 201). 48 Function Manual, 01/2011, FW 4.4, A5E B AB

51 Description 2.7 Safe Speed Monitor, SSM 2.7 Safe Speed Monitor, SSM The safety function SSM cannot be selected or deselected using external control signals. SSM is active if all of the following conditions are met: You have enabled the safety function SSM with hysteresis. For the SSM function, you have set a monitoring velocity of > 0. The motor is switched on. Principle of operation When the motor is switched on, the inverter compares the load speed with the velocity limit (p9546 / p9346). Figure 2-24 Time response and diagnostics of the safety function SSM (Safe Speed Monitor) Function Manual, 01/2011, FW 4.4, A5E B AB 49

52 Description 2.7 Safe Speed Monitor, SSM Signal filter The signal filters smoothes the speed measured by the inverter. Figure 2-25 Mode of operation of the filter of the SSM function Use the filter if you wish to monitor speeds that lie just below the velocity limit. 50 Function Manual, 01/2011, FW 4.4, A5E B AB

53 Description 2.7 Safe Speed Monitor, SSM Switching off the motor when SSM is active Switching off the motor with OFF1, OFF2 or OFF3 If you switch off the motor with OFF1 or OFF3, the inverter brakes the motor and switches it off when standstill monitoring threshold is reached. You can set the behavior of the inverter after switching-off the motor in two different ways: 1. Checkback signal "SSM active" for pulse inhibit remains active With this setting, the inverter safely switches off the motor torque (STO) when standstill monitoring is reached. The inverter ensures that the motor speed remains below the SSM monitoring. The "SSM active" signal therefore also remains active when the motor is switched off. 2. Checkback signal "SSM active" for pulse inhibit becomes inactive With this setting the inverter switches off the motor torque, but not safely. The motor speed is not safely below the SSM monitoring threshold. Therefore, the inverter sets the "SSM active" signal to inactive when the motor is switched off.. Figure 2-26 OFF1 command when the SSM safety function is active Function Manual, 01/2011, FW 4.4, A5E B AB 51

54 Description 2.7 Safe Speed Monitor, SSM If you switch off the motor with OFF2, the inverter immediately switches off the motor. Depending on the selected setting, the inverter safely switches off the motor torque (STO). Figure 2-27 OFF2 command when the SSM safety function is active You must proceed as follows in order to switch on the motor again after the SSM function has been deselected: Deselect the SSM safety function. If you switched off the motor with one of the OFF2 or OFF3 commands, then deselect the corresponding command. Switch off the motor with the ON/OFF1 command and then switch on again. 52 Function Manual, 01/2011, FW 4.4, A5E B AB

55 Description 2.7 Safe Speed Monitor, SSM Switching the motor off and on again when SSM is active If you switch off the motor with the SSM safety function active, using the OFF1 or OFF3 command, e.g. when the limit switches are reached, then the inverter brakes the motor with the OFF1 or OFF3 ramp-down time. Also while braking, the inverter monitors the motors speed. The behavior of SSM when the motor is being switched off, can be defined in two different ways. The feedback signal "SSM active" for pulse inhibit becomes inactive (p = 1) If you switch off the motor when SSM is active, then the inverter interrupts the speed monitoring and sets the "Status SSM" to "0". The function SSM becomes active again as soon as you switch on the motor again. Figure 2-28 Switching the motor off and on again with SSM active, interruption of SSM Function Manual, 01/2011, FW 4.4, A5E B AB 53

56 Description 2.7 Safe Speed Monitor, SSM The feedback signal "SSM active" remains active when the pulses are inhibited (p = 0) In order to ensure that the motor is at a standstill after switching off, you must set parameter p = 0. In this case, after the motor is switched off, the inverter interrupts the SSM function, but by specifying STO, prevents the motor from accelerating. Proceed as follows to switch the motor off and on again when SSM is active: Select STO after the motor has been switched off. Deselect STO again before you switch on the motor. Switch on the motor within 5 seconds (ON command). Figure 2-29 Switching the motor off and on when SSM is active If you do not switch on the motor within 5 seconds, then the inverter again goes into the STO state and no longer responds to the ON command. To switch the motor on again, proceed as follows: Select STO. Deselect STO again. Switch on the motor within 5 seconds (ON command). 54 Function Manual, 01/2011, FW 4.4, A5E B AB

57 Description 2.7 Safe Speed Monitor, SSM Further information The behavior of the motor when several safety functions are simultaneously selected is described in Section: Interaction of the safety functions (Page 56). The behavior of the inverter when an internal fault is detected or in the event of a discrepancy at a fail-safe digital input can be found in Section: Response of Safe Speed monitoring (SSM) to faults (Page 203). Function Manual, 01/2011, FW 4.4, A5E B AB 55

58 Description 2.8 Interaction of the safety functions 2.8 Interaction of the safety functions Overview The table below lists the notes regarding the behavior of your drive if you select more than one safety function at the same time. Some cases do not affect the behavior of your drive. If, for example, the safety function STO is active, the motor torque remains switched off regardless of which inverter function you also select. Table 2-4 Interaction between two safety functions Active safety With safety function 1 active, additionally control safety function 2: function 1 STO SS1 SLS SDI STO --- No effect No effect No effect SS1 Selecting STO when --- No effect No effect SS1 is active (Page 57) SLS Selecting STO when SLS is active (Page 58) Selecting SS1 when SLS is active (Page 61) --- Selecting SDI when SLS is active (Page 67) SDI SSM Selecting STO when SDI is active (Page 59) Selecting STO when SSM is active (Page 60) Selecting SS1 when SDI is active (Page 63) Selecting SS1 when SSM is active (Page 65) Selecting SLS when SDI is active (Page 68) Selecting SLS when SSM is active (Page 69) --- Selecting SDI when SSM is active (Page 70) 56 Function Manual, 01/2011, FW 4.4, A5E B AB

59 Description 2.8 Interaction of the safety functions Selecting STO when SS1 is active If you select the safety function STO when SS1 is already active, the inverter cuts off the motor torque immediately. The motor then coasts to a standstill. Figure 2-30 Selecting STO when SS1 is active (as example: SS1 in mode 2) To switch the motor on again, you must proceed as follows: Issue the OFF1 command. Deselect the STO and SS1 safety functions. Switch on the motor (ON command). Function Manual, 01/2011, FW 4.4, A5E B AB 57

60 Description 2.8 Interaction of the safety functions Selecting STO when SLS is active If you select the safety function STO when SLS is already active, the inverter safely and immediately switches off the motor torque. Figure 2-31 Selecting STO when SLS is active You can switch the motor on again in one of two ways: Proceed as follows if you want to deselect SLS: Issue the OFF1 command. Deselect the STO and SLS safety functions. Switch on the motor (ON command). Proceed as follows if SLS is to remain active when the motor is switched on: Issue the OFF1 command. Deselect the STO safety functions. Switch on the motor within 5 seconds (ON command). Further information can be found in the section Switching the motor off and on again when SLS is active (Page 40). 58 Function Manual, 01/2011, FW 4.4, A5E B AB

61 Description 2.8 Interaction of the safety functions Selecting STO when SDI is active If you select the safety function STO when SDI is already active, the inverter safely and immediately switches off the motor torque. Figure 2-32 Selecting STO when SDI is active You can switch the motor on again in one of two ways: Proceed as follows if you want to deselect SDI: Issue the OFF1 command. Deselect the STO and SDI safety functions. Switch on the motor (ON command). Proceed as follows if SDI is to remain active when the motor is switched on: Issue the OFF1 command. Deselect the STO safety functions. Switch on the motor within 5 seconds (ON command). Further information can be found in the section Switching the motor off and on again when SDI is active (Page 46). Function Manual, 01/2011, FW 4.4, A5E B AB 59

62 Description 2.8 Interaction of the safety functions Selecting STO when SSM is active If you select the safety function STO when SSM is already active, the inverter safely and immediately switches off the motor torque. Figure 2-33 Selecting STO when SSM is active How you switch the motor on again, depends on how you have parameterized the safety function SSM: When the pulses are inhibited, feedback signal "SSM active" becomes inactive Proceed as follows: Issue the OFF1 command. Deselect the STO safety function. Switch on the motor (ON command). When the pulses are inhibited, feedback signal "SSM active" remains active Proceed as follows: Issue the OFF1 command. Deselect the STO safety function. Switch on the motor within 5 seconds (ON command). Further information can be found in the section Switching the motor off and on again when SSM is active (Page 53). 60 Function Manual, 01/2011, FW 4.4, A5E B AB

63 Description 2.8 Interaction of the safety functions Selecting SS1 when SLS is active If you select the safety function SS1 when SLS is already active, the inverter brakes the motor with the OFF3 ramp-down time and monitors the braking operation. When the standstill monitoring threshold is reached, the inverter safely switches off the motor torque. Figure 2-34 Selecting safety function SS1 (as an example SS1 in mode 1) when SLS is active Function Manual, 01/2011, FW 4.4, A5E B AB 61

64 Description 2.8 Interaction of the safety functions You can switch the motor on again in one of two ways: Proceed as follows if you want to deselect SLS: Issue the OFF1 command. Deselect the SS1 and SLS safety functions. Switch on the motor (ON command). Proceed as follows if SLS is to remain active when the motor is switched on: Issue the OFF1 command. Deselect the SS1 safety functions. Switch on the motor within 5 seconds (ON command). Further information can be found in the section Switching the motor off and on again when SLS is active (Page 40). 62 Function Manual, 01/2011, FW 4.4, A5E B AB

65 Description 2.8 Interaction of the safety functions Selecting SS1 when SDI is active If you select the safety function SS1 when SDI is already active, the inverter brakes the motor with the OFF3 ramp-down time and monitors the braking operation. When the standstill monitoring threshold is reached, the inverter safely switches off the motor torque. Figure 2-35 Selecting SS1 when SDI is active Function Manual, 01/2011, FW 4.4, A5E B AB 63

66 Description 2.8 Interaction of the safety functions You can switch the motor on again in one of two ways: Proceed as follows if you want to deselect SDI: Issue the OFF1 command. Deselect the SS1 and SDI safety functions. Switch on the motor (ON command). Proceed as follows if SDI is to remain active when the motor is switched on: Issue the OFF1 command. Deselect the SS1 safety functions. Switch on the motor within 5 seconds (ON command). Further information can be found in the section Switching the motor off and on again when SDI is active (Page 46). 64 Function Manual, 01/2011, FW 4.4, A5E B AB

67 Description 2.8 Interaction of the safety functions Selecting SS1 when SSM is active If you select the safety function SS1 when the SSM safety function is already active, the inverter brakes the motor with the OFF3 ramp-down time and monitors the braking operation. When the standstill monitoring threshold is reached, the inverter safely switches off the motor torque. Figure 2-36 Selecting SS1 when SSM is active Function Manual, 01/2011, FW 4.4, A5E B AB 65

68 Description 2.8 Interaction of the safety functions How you switch the motor on again, depends on how you have parameterized the safety function SSM: When the pulses are inhibited, feedback signal "SSM active" becomes inactive. Proceed as follows: Issue the OFF1 command. Deselect the SS1 safety function. Switch on the motor (ON command). When the pulses are inhibited, feedback signal "SSM active" remains active. Proceed as follows: Issue the OFF1 command. Deselect the SS1 safety function. Switch on the motor within 5 seconds (ON command). Further information can be found in the section Switching the motor off and on again when SSM is active (Page 53). 66 Function Manual, 01/2011, FW 4.4, A5E B AB

69 Description 2.8 Interaction of the safety functions Selecting SDI when SLS is active If you select SDI when SLS is active, the inverter brakes the load for the case that the load is rotating in the prohibited direction. Figure 2-37 Selecting safety function SDI when SLS is active Function Manual, 01/2011, FW 4.4, A5E B AB 67

70 Description 2.8 Interaction of the safety functions Selecting SLS when SDI is active If you select SLS when SDI is active, the inverter brakes the load for the case that the load speed is too high. Figure 2-38 Selecting safety function SLS when SDI is active 68 Function Manual, 01/2011, FW 4.4, A5E B AB

71 Description 2.8 Interaction of the safety functions Selecting SLS when SSM is active If you select SLS when SSM is active, the inverter brakes the load for the case that the load speed is too high. Figure 2-39 Selecting safety function SLS when SSM is active Function Manual, 01/2011, FW 4.4, A5E B AB 69

72 Description 2.8 Interaction of the safety functions Selecting SDI when SSM is active If you select SDI when SSM is active, the inverter brakes the load for the case that the load is rotating in the prohibited direction. Figure 2-40 Selecting safety function SDI when SSM is active 70 Function Manual, 01/2011, FW 4.4, A5E B AB

73 Description 2.9 Password 2.9 Password The safety functions are protected against unauthorized changes by a password. Note If you want to change the parameters of the safety functions, but do not know the password, please contact customer support. The factory setting for the password is "0". During commissioning, choose your password from the permissible range 1 FFFF FFFF Checksum Each parameter of the safety functions is available twice. This redundancy is a basic precondition so that after commissioning, the inverter can monitor the parameters for any unwanted changes (Cyclic Redundancy Check, CRC). During commissioning, you set only one of the two redundant parameters at a time. After completing the commissioning of the safety functions, you duplicate all parameter values using a copy function. Function Manual, 01/2011, FW 4.4, A5E B AB 71

74 Description 2.11 Forced dormant error detection (test stop) 2.11 Forced dormant error detection (test stop) Description To fulfill the requirements of standards EN 954-1, ISO and IEC regarding timely error detection, the inverter must regularly test its safety-relevant circuits to ensure that they function correctly - this must be performed at least once every year. The inverter monitors the regular test of its safety-relevant circuits, which monitor the speed of the motor and which switch off the motor torque. Figure 2-41 Monitoring the regular forced dormant error detection in the inverter Table 2-5 Forced dormant error detection monitoring Extended Safety r9765 contains the remaining monitoring time. The inverter signals that the monitoring time has come to an end with alarm A Basic Safety r9660 contains the remaining monitoring time. The inverter signals that the monitoring time has come to an end with alarm A Setting forced dormant error detection If you only use "Basic Safety", you must take the following steps during commissioning: Set monitoring time p9659 to a value to match your application. Evaluate alarm A01699 in your higher-level controller, by, for example, interconnecting r with a digital output or a bit in the status word of the field bus. The "Basic-Safety circuits" are an integral part of the "Extended-Safety circuits". If you use "Extended-Safety", you must take the following steps during commissioning: Set monitoring time p9559 to a value to match your application. Set the monitoring time p9659 to the maximum value. Evaluate alarm A01697 in your higher-level controller, for example by interconnecting the output of the time monitoring (r9723.0) with a digital output or a bit in the status word of the field bus. 72 Function Manual, 01/2011, FW 4.4, A5E B AB

75 Description 2.11 Forced dormant error detection (test stop) Execute the forced dormant error detection If the inverter outputs alarm A01699 or A01697, you must initiate forced dormant error detection at the next opportunity. These alarms do not affect the operation of your machine. Before the forced dormant error detection you must stop the drive. Table 2-6 Initiating the forced dormant error detection Extended Safety You define the signal with which the inverter tests its circuits for speed monitoring. If you select the forced dormant error detection, the inverter will check the circuits of both Extended Safety and Basic Safety. Basic Safety The inverter checks its circuits used to switch off the torque if one of the following conditions exists: After the power supply has been switched on (power on reset). Each time after the STO.function has been selected. In the event of forced dormant error detection of Extended Safety. Examples for the times when forced dormant error detection is performed When the drives are at a standstill after the system has been switched on. When the protective door is opened. At defined intervals (e.g. every 8 hours). In automatic mode (time and event dependent). Function Manual, 01/2011, FW 4.4, A5E B AB 73

76 Description 2.11 Forced dormant error detection (test stop) 74 Function Manual, 01/2011, FW 4.4, A5E B AB

77 Interfaces Overview Depending on the design of inverter, fail-safe digital inputs (F-DI) or the safe bus communication PROFIsafe is available as interface of the safety functions. Frequency inverter Integrated safety functions Interfaces SINAMICS G120C STO 1 F-DI SINAMICS G120C DP STO 1 F-DI PROFIsafe SINAMICS G120C CAN STO 1 F-DI SINAMICS G120 with Control Unit CU240E2 STO 1 F-DI SINAMICS G120 with Control Unit CU240E-2 DP STO 1 F-DI PROFIsafe SINAMICS G120 with Control Unit CU240E-2 F STO, SS1, SLS, SDI, SSM 3 F-DI SINAMICS G120 with Control Unit CU240E-2 DP-F STO, SS1, SLS, SDI, SSM 3 F-DI PROFIsafe Function Manual, 01/2011, FW 4.4, A5E B AB 75

78 Interfaces 3.2 Activation via F-DI 3.2 Activation via F-DI Fail-safe digital inputs In the factory setting of the inverter, the fail-safe digital inputs are not assigned to the integrated safety functions. It is only at the parameterization stage that you define, for example, whether digital inputs DI4 and DI5 are to be used for standard functions or whether a fail-safe dual-channel input is to be created by merging. Assignment of the fail-safe digital inputs Table 3-1 SINAMICS G120C and for SINAMICS G120 with Control Units CU240E-2 and CU240E- 2 DP Terminal strip Digital input Fail-safe digital input Terminal 16 DI 4 Terminal 17 DI 5 F-DI 0 Table 3-2 SINAMICS G120 with Control Units CU240E-2 F and CU240E-2 DP-F Terminal strip Digital input Fail-safe digital inputs Terminal 5 DI 0 Terminal 6 DI 1 Terminal 7 DI 2 Terminal 8 DI 3 Terminal 16 DI 4 Terminal 17 DI 5 Basic Safety Extended Safety - F-DI 0 F-DI 1 F-DI 0 F-DI 2 Safety-related signals, e.g. the switching state of a sensor, must be wired on two channels with a fail-safe digital input. The inverter evaluates the signal on two separate signal paths. 76 Function Manual, 01/2011, FW 4.4, A5E B AB

79 Interfaces 3.2 Activation via F-DI F-DI signal filtering The inverter checks the consistency of the fail-safe digital input signals. Consistent signals at both inputs always assume the same signal state (high or low). Discrepancy With electromechanical sensors (e.g. emergency stop buttons or door switches), the two sensor contacts never switch at exactly the same time and are therefore temporarily inconsistent (discrepancy). A long-term discrepancy points toward a fault in the wiring of a fail-safe input, e.g. a wire break. An adjustable filter in the inverter prevents faults caused by temporary discrepancy. Within the filter's tolerance time, the inverter suppresses the discrepancy monitoring of the fail-safe inputs. Figure 3-1 Filter for suppressing discrepancy monitoring Table 3-3 Parameters for the discrepancy monitoring tolerance time Basic Safety Extended Safety Activation via F-DI Activation both via F-DI and PROFIsafe p9650, p9850 p10002, p10102 p9650, p9850 The filter does not increase the inverter response time. The inverter selects its safety function as soon as one of the two F-DI signals changes its state from high to low. The way in which the inverter responds to a discrepancy depends on the active safety function. Further information can be found in the section Cause of fault (Page 190). Function Manual, 01/2011, FW 4.4, A5E B AB 77

80 Interfaces 3.2 Activation via F-DI Bit pattern test of fail-safe outputs and contact bounces of sensors The inverter normally responds immediately to signal changes in its fail-safe inputs. This is not required in the following cases: 1. When you interconnect a fail-safe input of the inverter with an electromechanical sensor, contact bounce may result in signal changes occurring, to which the inverter responds. 2. Several control modules test their fail-safe outputs using bit pattern tests (on/off tests), in order to identify faults due to either short or cross circuiting. When you interconnect a failsafe input of the inverter with a fail-safe output of a control module, the inverter responds to these test signals. A signal change during a bit pattern test usually lasts: Bright test: 1 ms Dark test: 4 ms Figure 3-2 Inverter response to a bit pattern test When the signal for STO control in "Basic Safety" is not "stable", the inverter responds to this by means of a fault. (Definition of a stable signal: Following a change to the F-DI input signals, the inverter triggers an internal monitoring time. Up until the end of the time interval 5 x p9650, both input signals must have a constant signal level. A constant signal level is a high or a low state, for a period of at least p9650). 78 Function Manual, 01/2011, FW 4.4, A5E B AB

81 Interfaces 3.2 Activation via F-DI An adjustable signal filter in the inverter suppresses temporary signal changes using bit pattern test or contact bounce. Figure 3-3 Filter for suppressing temporary signal changes Table 3-4 Parameters for debounce time Basic Safety Extended Safety Activation via F-DI Activation both via F-DI and PROFIsafe p9651, p9851 p10017, p10117 p9651, p9851 Note The filter increases the inverter response time. The inverter only selects its safety function after the debounce time has elapsed. Note Debounce times for standard and safety functions The debounce time p0724 for "standard" digital inputs has no influence over the fail-safe input signals. Conversely, the same applies: The F-DI debounce time does not affect the signals of the "standard" inputs. If you use an input as a standard input, set the debounce time at p0724. If you use an input as a fail-safe input, set the debounce time as described above. Function Manual, 01/2011, FW 4.4, A5E B AB 79

82 Interfaces 3.2 Activation via F-DI Wiring examples On the following pages, you will find examples of interconnecting the fail-safe digital inputs in accordance with PL d to EN and SIL 2 to IEC Connecting sensors The fail-safe inputs of the converter are designed for connecting sensors with two NC contacts. It is not possible to directly connect sensors with two NO contacts and antivalent contacts (1 NO contact and 1 NC contact). Permitted sensors The fail-safe digital inputs are configured for both directly connecting safety sensors, e.g. emergency stop control devices or light curtains, as well as for connecting pre-processing safety relays, e.g. fail-safe controls. 80 Function Manual, 01/2011, FW 4.4, A5E B AB

83 Interfaces 3.2 Activation via F-DI Electromechanical sensor The inverter provides the supply voltage Connect the 24 V supply of the inverter to the sensors and connect the reference potentials of the inputs used to GND. Figure 3-4 Connecting an electromechanical sensor to the inverter power supply External power supply Connect the external power supply to the sensors and connect the reference potentials of the inputs used to the reference potential of the external power supply. Figure 3-5 Connecting an electromechanical sensor to an external power supply Function Manual, 01/2011, FW 4.4, A5E B AB 81

84 Interfaces 3.2 Activation via F-DI Series-connected electromechanical sensors You may connect emergency stop control devices in series because it is not possible for these devices to fail and be actuated at the same time. According to IEC (SIL) and ISO (PL), position switches of protective doors may also connected in series. Exception: If several protective doors are regularly opened at the same time, it is not possible for faults to be detected, which means that the position switches must not be connected in series. The inverter provides the supply voltage Connect the 24 V supply of the inverter to the sensors and connect the reference potentials of the inputs used to GND. Figure 3-6 Connecting electromechanical sensors to the inverter power supply in series 82 Function Manual, 01/2011, FW 4.4, A5E B AB

85 Interfaces 3.2 Activation via F-DI External power supply Connect the external power supply to the sensors and connect the reference potentials of the inputs used to the reference potential of the external power supply. Figure 3-7 Connecting electromechanical sensors to an external power supply in series Function Manual, 01/2011, FW 4.4, A5E B AB 83

86 Interfaces 3.2 Activation via F-DI Activating several inverters simultaneously You may activate the safety functions of several inverters simultaneously with one or several series-connected safety sensors. Inverter delivers supply voltage Connect the 24 V supply of the inverter to the sensors and connect the reference potentials of the inputs used to GND. Figure 3-8 Simultaneous activation of several inverters with inverter power supply External power supply Connect the external power supply to the sensors and connect the reference potentials of the inputs used to the reference potential of the external power supply. Figure 3-9 Simultaneous activation of several inverters with external power supply 84 Function Manual, 01/2011, FW 4.4, A5E B AB

87 Interfaces 3.2 Activation via F-DI Electronic sensor In this example, you select one of the safety functions with a safety light curtain. The diagram only shows how the sensor and inverter are interconnected. Information providing full details of how the sensor is wired can be found in the product-specific documentation: Light curtains and arrays ( Figure 3-10 Connecting an electronic sensor Connecting pre-processing devices If you use safety relays with electronic enabling circuits, the relays must feature outputs that switch to P potential. The safety relay switches the 24 V supply line to the inverter but not the ground return line. Safety relays with relay enabling circuits are only permitted if they have an internal dualchannel configuration. The following pages describe a number of typical circuits for various types of safety relay. Exactly how these are interconnected depends on whether the safety relay and the inverter are housed in the same or separate control cabinets. Function Manual, 01/2011, FW 4.4, A5E B AB 85

88 Interfaces 3.2 Activation via F-DI 3TK28 safety relay The typical circuits described on the following pages are based on safety relays with relay enabling circuits. Safety relays with semiconductor enabling circuits can also be used. The diagrams only show how the safety relay and inverter are interconnected. Information providing full details of how the safety relay is wired can be found in the product-specific documentation: SIRIUS 3TK28 safety relays ( Components in the same control cabinet A control cabinet that has been set up and wired correctly does not contain any damaged wiring or cross circuits. For this reason, you may interconnect a safety relay and inverter in the same control cabinet by means of a single-channel wiring arrangement. The two terminals of the fail-safe input must be connected to each other on the inverter. Figure 3-11 Interconnecting the inverter and safety relay within the same control cabinet 86 Function Manual, 01/2011, FW 4.4, A5E B AB

89 Interfaces 3.2 Activation via F-DI Components in separate control cabinets If the components are located in separate control cabinets, the wiring between the safety relay and fail-safe digital inputs on the inverter must be installed such that it is protected against cross and short-circuits. Transfer the two signals for activating a safety function via wires in separate lines. In the example, the signals for terminal 5 and 7 are transferred via the first line. The signals for terminal 6 and 8 are then transferred via the second line. Figure 3-12 Interconnecting the inverter and safety relay in separate control cabinets Function Manual, 01/2011, FW 4.4, A5E B AB 87

90 Interfaces 3.2 Activation via F-DI 3RK3 Modular Safety System You can use both the fail-safe outputs in the MSS Basic central unit of the 3RK3 Modular Safety System as well as the outputs in the EM 2/4F-DI 2F-DO expansion module to activate the F-DIs of the inverter. The fail-safe relay outputs of the EM 2/4F-DI 1/2F-RO expansion module must not be used because these only have a single-channel configuration. The diagrams only show how the 3RK3 Modular Safety System and inverter are interconnected. Information providing full details of how the 3RK3 Modular Safety System are wired can be found in the product-specific documentation: SIRIUS 3RK3 Modular Safety System ( Components in the same control cabinet A control cabinet that has been set up and wired correctly does not contain any damaged wiring or cross circuits. You may interconnect the Modular Safety System and inverter within the same control cabinet by means of a single-channel wiring arrangement. The two terminals of the fail-safe input must be connected to each other on the inverter. Figure 3-13 Interconnecting the inverter and Modular Safety System within the same control cabinet 88 Function Manual, 01/2011, FW 4.4, A5E B AB

91 Interfaces 3.2 Activation via F-DI Components in separate control cabinets If the components are located in separate control cabinets, the wiring between the Modular Safety System and the F-DIs on the inverter must be installed such that it is protected against cross and short-circuits. Transfer the two signals for activating a safety function via wires in separate lines. In the example, the signals for terminal 5 and 7 are transferred via the first line. The signals for terminal 6 and 8 are then transferred via the second line. If you want to use the fail-safe outputs of the 3RK3 central unit for transferring signals via two channels, inverter discrepancy monitoring must be adapted to the different switching times of the electronic output and relay contact. Figure 3-14 Interconnecting the inverter and Modular Safety System in separate control cabinets Function Manual, 01/2011, FW 4.4, A5E B AB 89

92 Interfaces 3.2 Activation via F-DI S7-300 I/O modules Fail-safe outputs that switch to P potential are required for activating the fail-safe digital inputs of the SINAMICS G120. From the S7-300 range, the SM326 DO 10 x 24 V / 2 A PP I/O module fulfills this requirement. The diagrams only show how the I/O module and inverter are interconnected. Information providing full details of how the I/O module is wired can be found in the product-specific documentation: S7-300 ( Components in the same control cabinet A control cabinet that has been set up and wired correctly does not contain any damaged wiring or cross circuits. You may interconnect the SM326 I/O module and inverter within the same control cabinet by means of a single-channel wiring arrangement. The two terminals of the fail-safe input must be connected to each other on the inverter. Figure 3-15 Interconnecting the inverter and SM326 I/O module within the same control cabinet 90 Function Manual, 01/2011, FW 4.4, A5E B AB

93 Interfaces 3.2 Activation via F-DI Components in separate control cabinets If the components are located in separate control cabinets, the wiring between the SM326 I/O module and the F-DIs on the inverter must be installed such that it is protected against cross and short-circuits. Transfer the two signals for activating a safety function via wires in separate lines. In the example, the signals for terminal 5 and 7 are transferred via the first line. The signals for terminal 6 and 8 are then transferred via the second line. Figure 3-16 Interconnecting the inverter and SM326 I/O module in separate control cabinets Function Manual, 01/2011, FW 4.4, A5E B AB 91

94 Interfaces 3.2 Activation via F-DI ET 200S I/O modules Fail-safe outputs that switch to P potential are required for activating the fail-safe digital inputs of the SINAMICS G120. Out of the ET 200S system range, only the fail-safe relay module EM 1 F-RO DC 24 V / AC V / 5 A fulfills this requirement. The fail-safe relay module is activated via a fail-safe ET 200S output module. The diagrams only show how the I/O modules and inverter are interconnected. Information providing full details of how the I/O modules is wired can be found in the product-specific documentation: ET 200S ( Components in the same control cabinet A control cabinet that has been set up and wired correctly does not contain any damaged wiring or cross circuits. For this reason, you may interconnect the I/O modules and inverter in a control cabinet by means of a single-channel wiring arrangement. The two terminals of the fail-safe input must be connected to each other on the inverter. Figure 3-17 Interconnecting the inverter and I/O modules within the same control cabinet 92 Function Manual, 01/2011, FW 4.4, A5E B AB

95 Interfaces 3.2 Activation via F-DI Components in separate control cabinets If the components are located in separate control cabinets, the wiring between the I/O modules and the F-DIs on the inverter must be installed such that it is protected against cross and short-circuits. Transfer the two signals for activating a safety function via wires in separate lines. In the example, the signals for terminal 5 and 7 are transferred via the first line. The signals for terminal 6 and 8 are then transferred via the second line. Figure 3-18 Interconnecting the inverter and I/O modules in separate control cabinets Function Manual, 01/2011, FW 4.4, A5E B AB 93

96 Interfaces 3.3 Activation via PROFIsafe 3.3 Activation via PROFIsafe Communication via PROFIsafe If you want to use the PROFIsafe telegram, you must connect the inverter to a fieldbus with a central F-CPU. PROFIsafe communication is not possible between the inverter and an I-slave (F-CPU configured as a slave on the fieldbus). 94 Function Manual, 01/2011, FW 4.4, A5E B AB

97 Interfaces 3.3 Activation via PROFIsafe Telegram types Two telegrams are available for the data exchange via PROFIsafe between the inverter and the higher-level controller: Table 3-5 Telegram types Telegram type Process data (PZD) - control and status words PZD1 PZD2 Optional with: Available for SINAMICS G120 with the following Control Units Available with SINAMICS G120C Telegram 30 PZD 1/1 STW1 --- ZSW1 --- Basic Safety and Extended Safety CU240E-2 CU240E-2 DP CU240E-2 F CU240E-2 DP-F G120C DP Telegram 900 STW1 STW5 PZD 2/2 ZSW1 ZSW5 Extended Safety CU240E-2 DP-F --- STW: Control word; ZSW: Status word The higher-level controller triggers the safety functions in the inverter via the control word. The inverter uses the status word to report the status of the safety functions to the controller. The section Selecting the commissioning method (Page 108) contains information to help you decide whether you must operate your inverter with "Basic Safety" or "Extended Safety". Function Manual, 01/2011, FW 4.4, A5E B AB 95

98 Interfaces 3.3 Activation via PROFIsafe Control word 1 and status word 1 (Basic Safety) Table 3-6 Control word 1 (bit ) Bit Meaning Comment 0 STO 1 6 Reserved 7 Internal event ack 8 15 Reserved 1 STO is deselected 0 STO is selected 1 Acknowledge serious safety function faults with a signal change Do not acknowledge faults Table 3-7 Status word 1 (bit ) Bit Meaning Comment 0 Power removed 1 6 Reserved 7 Internal Event 8 15 Reserved 1 STO is active 0 STO is not active 1 The inverter has detected a severe safety function fault and stops the motor. 0 Fault-free operation 96 Function Manual, 01/2011, FW 4.4, A5E B AB

99 Interfaces 3.3 Activation via PROFIsafe Control word 1 and status word 1 (Extended Safety) Table 3-8 Control word 1 (bit ) Bit Meaning Comment 0 STO 1 SS1 2, 3 Reserved 4 SLS 5, 6 Reserved 7 Internal event ack 8 Reserved 9 SLS-level, bit 0 10 SLS-level, bit 1 11 Reserved 12 SDI Positive 13 SDI Negative 14, 15 Reserved 1 STO is deselected 0 STO is selected 1 SS1 is deselected 0 SS1 is selected 1 SLS is deselected 0 SLS is selected 1 Acknowledge serious safety function faults with a signal change Do not acknowledge faults Selection of the SLS level level 1 level 2 level 3 level 4 Bit 10 Bit 9 1 SDI with positive direction of rotation is deselected 0 SDI with positive direction of rotation is selected 1 SDI with negative direction of rotation is deselected 0 SDI with negative direction of rotation is selected Function Manual, 01/2011, FW 4.4, A5E B AB 97

100 Interfaces 3.3 Activation via PROFIsafe Table 3-9 Status word 1 (bit ) Bit Meaning Comment 0 Power removed 1 SS1 active 2, 3 Reserved 4 SLS active 5, 6 Reserved 7 Internal Event 8 Reserved 9 SLS-level, bit 0 10 SLS-level, bit 1 11 Reserved 12 SDI Positive active 13 SDI Negative active 14 Reserved 15 Status SSM 1 STO is active 0 STO is not active 1 SS1 is active 0 SS1 is not active 1 SLS is active 0 SLS is not active 1 The inverter has detected a severe safety function fault and stops the motor. 0 Fault-free operation Active SLS level level 1 level 2 level 3 level 4 Bit 10 Bit 9 1 SDI positive direction of rotation is active 0 SDI positive direction of rotation is not active 1 SDI negative direction of rotation is active 0 SDI negative direction of rotation is not active 1 Speed is within the SSM limit value 0 Speed is outside the SSM limit value Function Manual, 01/2011, FW 4.4, A5E B AB

101 Interfaces 3.3 Activation via PROFIsafe Control word 5 and status word 5 Telegram 900 of the PROFIsafe profile also contains control and status word 5. The inverter uses status word 5 to transfer the status of the fail-safe digital inputs to the controller. Table 3-10 Control word 5 (bit ) Bit Meaning Comment 0 15 Reserved Assign the value 0 to the reserved bits. Table 3-11 Status word 5 (bit ) Bit Meaning Comment Reserved Status of fail-safe inputs - 0 LOW signal (0 V present) at terminals 5 and 6 1 HIGH signal (24 V present) at terminals 5 and 6 0 LOW signal (0 V present) at terminals 7 and 8 1 HIGH signal (24 V present) at terminals 7 and 8 0 LOW signal (0 V present) at terminals 16 and 17 1 HIGH signal (24 V present) at terminals 16 and 17 Reserved - An overview of the fail-safe inputs can be found in the section Fail-safe digital inputs (Page 76). The status bit of a fail-safe input in status word 5 is always 0 if one of the following two conditions is fulfilled: The relevant fail-safe input is not used. The inverter has deactivated the relevant fail-safe input due to a discrepancy. Function Manual, 01/2011, FW 4.4, A5E B AB 99

102 Interfaces 3.3 Activation via PROFIsafe Configuring communication in STEP 7 (telegram 30) Hardware configuration In STEP 7, the inverter is integrated in PROFIsafe communication via HW Config. Configure your SIMATIC CPU (e.g. a CPU315F-2 PN/DP) with a PROFIBUS network. Insert the inverter in the PROFIBUS network via its GSD. Assign the PROFIsafe telegram to the first slot of the frequency inverter. Assign standard telegram 1, for example, to the other slots of the inverter. The operating instructions contain further information on the telegrams and slot sequence. 100 Function Manual, 01/2011, FW 4.4, A5E B AB

103 Interfaces 3.3 Activation via PROFIsafe Double-click the PROFIsafe telegram to open the properties dialog and set the input and output range to address 14, for example: Then choose the "PROFIsafe" tab page: 1 F_Dest_Add: Set a unique PROFIsafe address for the inverter. 2 F_WD_Time: Set a value which is larger than the cycle time of your safety program. If your safety program is called every 150 ms, for example, in OB35, set the value of F_WD_Time to 200. Save and compile your project and download the data to your SIMATIC CPU. Close HW Config. Function Manual, 01/2011, FW 4.4, A5E B AB 101

104 Interfaces 3.3 Activation via PROFIsafe Configuring communication in STEP 7 (telegram 900) If you want to evaluate the status of the fail-safe inputs in the higher-level controller directly, choose PROFIsafe telegram 900. The inverter writes the signals of its F-DIs to status word 2. Only inverters with Control Unit CU240E-2 DP-F support telegram 900. Hardware configuration The basic procedure is described in the section Configuring communication in STEP 7 (telegram 30) (Page 100). Instead of telegram 30, select telegram 900: Further steps Once you have completed the controller side, configure PROFIsafe communication in the inverter. This is described in the chapter Commissioning (Page 105). 102 Function Manual, 01/2011, FW 4.4, A5E B AB

105 Interfaces 3.3 Activation via PROFIsafe Example: Interface to the S7 safety program When you configure the hardware in STEP 7, you assign the control word and status word in the PROFIsafe profile of the inverter to specific output and input addresses of the SIMATIC controller. In the section Configuring communication in STEP 7 (telegram 30) (Page 100), start address 14, for example, was assigned. This results in the following assignments between the I/O addresses and inverter signals for this example: Table 3-12 Control word 1 I/O address Meaning Comment A14.0 STO A14.1 SS1 A14.4 SLS A14.7 Internal event ACK A15.1 Select SLS level bit 0 A15.2 Select SLS level, bit 1 1 Deselect STO 0 Select STO 1 Deselect SS1 0 Select SS1 1 Deselect SLS 0 Select SLS 1 Acknowledge with signal change No acknowledgement Selection of the SLS level Table 3-13 Status word 1 I/O address Meaning Comment E14.0 Power removed E14.1 SS1 active E14.4 SLS active E14.7 Internal event E15.1 Active SLS level, bit 0 E15.2 Active SLS level, bit 1 1 The motor torque has been switched off safely. 0 The motor torque has not yet been switched off safely. 1 The motor is currently being braked with the SS1 ramp-down time. 0 SS1 ramp-down time is not active. 1 The motor speed is currently below the selected SLS limit value. 0 SLS not active 1 The inverter has detected an internal fault and responded accordingly, e.g. with a STOP A. 0 Fault-free operation Active SLS level A detailed description of the PROFIsafe interface can be found in the section Control word 1 and status word 1 (Extended Safety) (Page 97). Function Manual, 01/2011, FW 4.4, A5E B AB 103

106 Interfaces 3.3 Activation via PROFIsafe 104 Function Manual, 01/2011, FW 4.4, A5E B AB

107 Commissioning Commissioning guidelines The steps for commissioning the safety functions form part of the activities for commissioning the entire drive. Depending on whether you activate the safety functions via fail-safe inputs or connect the inverter to PROFIsafe, we recommend that you use one the following two commissioning procedures. Control the inverter via fail-safe digital inputs (F-DI) Information on the commissioning steps can be found in the following sections or manuals: 1 Manuals for your control, e.g. Step-7 manuals. 2 Operating instructions and Fail-safe digital inputs (Page 76) 3 Operating instructions 4 Selecting the commissioning method (Page 108) 5 Operating instructions 6 Acceptance test - Completion of commissioning (Page 164) You can find an overview of all of the manuals for your inverter in section Manuals for your inverter (Page 229). Function Manual, 01/2011, FW 4.4, A5E B AB 105

108 Commissioning 4.2 Commissioning tool Control the inverter via PROFIsafe (and, where appropriate, via F-DI) Information on the commissioning steps can be found in the following sections or manuals: 1 STEP 7 manuals 2 Operating Instructions Fail-safe digital inputs (Page 76), Activation via PROFIsafe (Page 94), and STEP 7 manuals 3 Operating instructions 4 Selecting the commissioning method (Page 108) 5 Operating instructions 6 Acceptance test - Completion of commissioning (Page 164) You can find an overview of all of the manuals for your inverter in section Manuals for your inverter (Page 229). 4.2 Commissioning tool We strongly recommend that you commission the safety functions using the STARTER PC tool. Table 4-1 STARTER commissioning tool (PC software) Download Order number STARTER PC Connection Kit ( The kit contains a STARTER DVD and USB /en/ /130000) cable 6SL3255-0AA00-2CA0 106 Function Manual, 01/2011, FW 4.4, A5E B AB

109 Commissioning 4.3 Resetting the safety function parameters to the factory setting Commissioning: Online or offline With STARTER, you can work offline (without a connection to the inverter) as well as online. We recommend that you commission the safety functions online. This manual provides a detailed description of the online commissioning procedure. The section Offline commissioning (Page 161) describes the important points to remember when commissioning the safety functions offline. You can find additional information on using STARTER in the operating instructions of your inverter. 4.3 Resetting the safety function parameters to the factory setting Proceed as follows if you wish to reset the safety function parameters to the factory setting, without influencing the standard parameters: Go online with STARTER. Open the screen form of the safety functions. Click on the "Restore Safety factory settings" button. Enter the password,for the safety functions. Confirm that the parameters have been saved (RAM to ROM). Go offline with STARTER. Switch off the converter supply voltage. Wait until all LEDs on the converter go dark. Now switch on the converter power supply again (power on reset). Function Manual, 01/2011, FW 4.4, A5E B AB 107

110 Commissioning 4.4 Selecting the commissioning method 4.4 Selecting the commissioning method When you start commissioning, you must choose the commissioning method that best suits your application. The following overview lists the alternatives and the outcome of using a particular method. 108 Function Manual, 01/2011, FW 4.4, A5E B AB

111 Commissioning 4.4 Selecting the commissioning method 1 Decide whether you use "Basic Safety" or "Extended Safety". If you only use STO as safety function of the inverter, then select "Basic Safety". In all other cases, select "Extended Safety". 2 Select one of the three alternatives corresponding to your particular application: F-DI, PROFIsafe or both interfaces. Outcome of commissioning See section... 3 Select STO via F-DI. Activate STO via F-DI. (Page 110). Acknowledge safety faults via standard DI after selecting and deselecting STO. 4 Select STO via PROFIsafe. Activating STO via PROFIsafe (Page 114). Evaluate the state of STO via PROFIsafe. Acknowledge safety faults via PROFIsafe. 5 Select STO via F-DI as well as also via PROFIsafe. Activating STO via PROFIsafe and F-DI Evaluate the state of STO via PROFIsafe. (Page 117). Acknowledge safety faults: via PROFIsafe via standard DI after selecting and deselecting STO 6 Select safety functions via F-DI. Extended Safety with activation via F-DI Only one monitoring limit of SLS can be used (SLS level 0). (Page 121). Acknowledge safety faults: via F-DI via standard DI after selecting and deselecting STO 7 Select safety functions via PROFIsafe. Extended Safety with activation via Evaluate the state of the safety functions via PROFIsafe. PROFIsafe (Page 134). All four monitoring limits of SLS can be used (SLS levels 0 3) Acknowledge safety faults via PROFIsafe. Evaluate the state of the fail-safe inputs via PROFIsafe. 8 Select safety functions via PROFIsafe. Extended Safety with activation via Select STO additionally via F-DI. PROFIsafe and F-DI (Page 147). Evaluate the state of the safety functions via PROFIsafe. All four monitoring limits of SLS can be used (SLS levels 0 3) Acknowledge safety faults: via F-DI via standard DI after selecting and deselecting STO Evaluate the state of the fail-safe inputs via PROFIsafe. 9 Check the safety functions and generate the acceptance report. Acceptance test - Completion of commissioning (Page 164). Function Manual, 01/2011, FW 4.4, A5E B AB 109

112 Commissioning 4.5 Basic Safety 4.5 Basic Safety Activate STO via F-DI Procedure Go online with STARTER. In STARTER, call up the screens displaying the fail-safe functions and click on "Change settings": Defining the commissioning method Select "STO via terminal". If you require the status signal "STO active" in your higher-level controller, interconnect it accordingly. Click the button to call up the advanced settings for STO. 110 Function Manual, 01/2011, FW 4.4, A5E B AB

113 Commissioning 4.5 Basic Safety Setting STO You can adapt the STO function according to your requirements in the following screen. Set the following in the above screen: 1 2 F-DI input filter (debounce time) and monitoring for simultaneous operation (discrepancy): The method of functioning of the two filters is described in the section entitled F-DI signal filtering (Page 77). 3 4 Time interval for forced dormant error detection: Information regarding forced dormant error detection can be found in the Forced dormant error detection (test stop) (Page 72) section. Close the screen Activate settings Click "Copy parameters" and then click "Activate settings": You are prompted to allocate a password if the password = 0 (factory setting). If you try to set a password that is not permissible, the old password will not be changed. Further information can be found in the section Password (Page 71). Confirm the prompt for saving your settings (copy RAM to ROM). Switch off the inverter supply voltage. Wait until all LEDs on the inverter go dark. Now switch on the inverter supply voltage again. Your settings only become effective after this power-on reset. Function Manual, 01/2011, FW 4.4, A5E B AB 111

114 Commissioning 4.5 Basic Safety Multiple assignment of the DI Check whether the digital inputs used as fail-safe input are also assigned a further function. NOTICE Both, the assignment of digital inputs with the selection of a safety function or with a "standard" function can lead to an unexpected behavior of the motor. Remove multiple assignments of the digital inputs: Figure 4-1 Example: automatic assignment of digital inputs DI 4 and DI 5 with STO Figure 4-2 Remove pre-assignment of digital inputs DI 4 and DI 5 When you use the data set changeover CDS, you must delete the multiple assignment of the digital inputs for all CDS. 112 Function Manual, 01/2011, FW 4.4, A5E B AB

115 Commissioning 4.5 Basic Safety Further steps Commission the standard inverter functions by following the operating instructions. The link to the operating instructions can be found in the section Manuals for your inverter (Page 229). Perform an acceptance test for the safety functions: Document your settings in an acceptance report. Check whether the safety functions are functioning correctly in your application. The instructions for the acceptance test can be found in the section Acceptance test - Completion of commissioning (Page 164). Function Manual, 01/2011, FW 4.4, A5E B AB 113

116 Commissioning 4.5 Basic Safety Activating STO via PROFIsafe Procedure Go online with STARTER. In STARTER, call up the screens displaying the fail-safe functions and click on "Change settings": Defining the commissioning method 1 Set "STO via PROFIsafe". 2 If you require the status signal "STO active" in your higher-level controller, interconnect it accordingly. 3 Enter the same PROFIsafe address as a hexadecimal value that you defined in the hardware configuration (F_Dest_Add). See section: Configuring communication in STEP 7 (telegram 30) (Page 100). 4 Click the button to set the STO. 114 Function Manual, 01/2011, FW 4.4, A5E B AB

117 Commissioning 4.5 Basic Safety Setting STO Define the time interval for forced dormant error detection and connect the appropriate message to any signal: Information on forced dormant error detection can be found in the section Forced dormant error detection (test stop) (Page 72) Activate settings Click "Copy parameters" and then click "Activate settings": You are prompted to allocate a password if the password = 0 (factory setting). If you try to set a password that is not permissible, the old password will not be changed. Further information can be found in the section Password (Page 71). Confirm the prompt for saving your settings (copy RAM to ROM). Switch off the inverter supply voltage. Wait until all LEDs on the inverter go dark. Now switch on the inverter supply voltage again. Your settings only become effective after this power-on reset. Function Manual, 01/2011, FW 4.4, A5E B AB 115

118 Commissioning 4.5 Basic Safety When you connect the inverter to the central controller via the fieldbus for the first time, the central controller sends the PROFIsafe configuration to the inverter. Once the configuration data has been received, the inverter interconnects its internal signals with the PROFIsafe telegram. Note Monitoring PROFIsafe communication The inverter monitors communication with the central controller. The inverter does not start monitoring communication until the configuration data has been received from the central controller Further steps Commission the standard inverter functions by following the operating instructions. The link to the operating instructions can be found in the section Manuals for your inverter (Page 229). Perform an acceptance test for the safety functions: Document your settings in an acceptance report. Check whether the safety functions are functioning correctly in your application. The instructions for the acceptance test can be found in the section Acceptance test - Completion of commissioning (Page 164). 116 Function Manual, 01/2011, FW 4.4, A5E B AB

119 Commissioning 4.5 Basic Safety Activating STO via PROFIsafe and F-DI Procedure Go online with STARTER. In STARTER, call up the screens displaying the fail-safe functions and click on "Change settings": Defining the commissioning method 1 Set "STO via PROFIsafe and Terminal". 2 If you require the status signal "STO active" in your higher-level controller, interconnect it accordingly. 3 Enter the same PROFIsafe address as a hexadecimal value that you defined in the hardware configuration (F_Dest_Add). See section: Configuring communication in STEP 7 (telegram 30) (Page 100). 4 Click the button to set the STO. Function Manual, 01/2011, FW 4.4, A5E B AB 117

120 Commissioning 4.5 Basic Safety Setting STO You can adapt the STO function according to your requirements in the following screen. Set the following in the above screen: 1 2 F-DI input filter (debounce time) and monitoring for simultaneous operation (discrepancy): The method of functioning of the two filters is described in the section entitled F-DI signal filtering (Page 77). 3 4 Time interval for forced dormant error detection: Information regarding forced dormant error detection can be found in the Forced dormant error detection (test stop) (Page 72) section. Close the screen Activate settings Click "Copy parameters" and then click "Activate settings": You are prompted to allocate a password if the password = 0 (factory setting). If you try to set a password that is not permissible, the old password will not be changed. Further information can be found in the section Password (Page 71). Confirm the prompt for saving your settings (copy RAM to ROM). Switch off the inverter supply voltage. Wait until all LEDs on the inverter go dark. Now switch on the inverter supply voltage again. Your settings only become effective after this power-on reset. 118 Function Manual, 01/2011, FW 4.4, A5E B AB

121 Commissioning 4.5 Basic Safety When you connect the inverter to the central controller via the fieldbus for the first time, the central controller sends the PROFIsafe configuration to the inverter. Once the configuration data has been received, the inverter interconnects its internal signals with the PROFIsafe telegram. Note Monitoring PROFIsafe communication The inverter monitors communication with the central controller. The inverter does not start monitoring communication until the configuration data has been received from the central controller Multiple assignment of the DI Check whether the digital inputs used as fail-safe input are also assigned a further function. NOTICE Both, the assignment of digital inputs with the selection of a safety function or with a "standard" function can lead to an unexpected behavior of the motor. Remove multiple assignments of the digital inputs: Figure 4-3 Example: automatic assignment of digital inputs DI 4 and DI 5 with STO Function Manual, 01/2011, FW 4.4, A5E B AB 119

122 Commissioning 4.5 Basic Safety Figure 4-4 Remove pre-assignment of digital inputs DI 4 and DI 5 When you use the data set changeover CDS, you must delete the multiple assignment of the digital inputs for all CDS Further steps Commission the standard inverter functions by following the operating instructions. The link to the operating instructions can be found in the section Manuals for your inverter (Page 229). Perform an acceptance test for the safety functions: Document your settings in an acceptance report. Check whether the safety functions are functioning correctly in your application. The instructions for the acceptance test can be found in the section Acceptance test - Completion of commissioning (Page 164). 120 Function Manual, 01/2011, FW 4.4, A5E B AB

123 Commissioning 4.6 Extended Safety 4.6 Extended Safety Extended Safety with activation via F-DI Procedure Go online with STARTER. In STARTER, call up the screens displaying the fail-safe functions and click on "Change settings": Defining the commissioning method 1 Select "Motion monitoring via terminals". Function Manual, 01/2011, FW 4.4, A5E B AB 121

124 Commissioning 4.6 Extended Safety 2 If you use one of the safety functions SS1 or SLS, then you must select the monitoring mode of these functions. More detailed information on the modes can be found in the following sections: Monitoring modes of SS1 (Page 21) Monitoring modes of SLS (Page 28) 3 Click on the button for configuring the fail-safe inputs and outputs Configuring activation via FDI Click the "Drive" button. 1 In the following screen form, you assign the fail-safe inputs to the safety functions. If you do not want to use a particular safety function, set the relevant input to "(255) Statically inactive". 122 Function Manual, 01/2011, FW 4.4, A5E B AB

125 Commissioning 4.6 Extended Safety Click the "Configuration" button: Set the following: 2 3 F-DI input filter (debounce time) and monitoring for simultaneous operation (discrepancy): A functional description of the two filters is provided in the section F-DI signal filtering (Page 77). 4 Acknowledging safety faults: Choose a free F-DI to acknowledge the safety faults. If there are no free F-DIs available, you have to acknowledge the safety function faults using a different method (see Acknowledging with a fail-safe signal or with a power on reset (Page 191)) Configuring safety functions Click the "Configuration" button. Function Manual, 01/2011, FW 4.4, A5E B AB 123

126 Commissioning 4.6 Extended Safety Setting forced dormant error detection Select the values compatible with your application. 1 This signal triggers a forced dormant error detection and resets the timer. Interconnect this signal with a binector of your choice, for example a digital input or a control bit in the field bus. 2 You must conduct a forced dormant error detection for this signal. Interconnect this binector with a signal of your choice, for example a digital input or a status bit in the field bus. 3 Time interval for forced dormant error detection. Further information can be found in the section Forced dormant error detection (test stop) (Page 72). If you only want to use STO, close this screen and go to the section Enabling safety functions (Page 126). In all other cases, go to the next section Setting the gear ratio and tolerance 124 Function Manual, 01/2011, FW 4.4, A5E B AB

127 Commissioning 4.6 Extended Safety If you only use STO, then the settings in this screen form have no significance. In all other cases, set the following: 1 Actual value tolerance: In most cases you do not have to change this value. For the "flying restart" function, if the inverter responds with message C01711 or C30711, increase this value step-bystep until the message to longer occurs. Note: If you increase this value, the speed monitoring of the inverter becomes less sensitive to limit violations. 2 3 Gear ratio: Enter your machine's data in accordance with the following table. 2 Number of load revolutions 3 Number of motor revolutions Without gear 1 Number of pole pairs Gear with speed ratio Load/motor = L/M L M number of pole pairs Example: Gear with speed ratio Load/motor = 1/3 1 3 number of pole pairs Table 4-2 Determine the number of pole pairs (r0313) Motor speed under no-load conditions at 50 Hz Motor speed under no-load conditions at 60 Hz Number of pole pairs 3000 rpm 3600 rpm rpm 1800 rpm rpm 1200 rpm rpm 900 rpm 4 Close the screen for the gear ratio. Close the screen form for forced dormant error detection. Function Manual, 01/2011, FW 4.4, A5E B AB 125

128 Commissioning 4.6 Extended Safety Encoderless actual value sensing If you only use STO, then the settings in this screen form have no significance. In all other cases, set the following: 1 Delay time, actual value sensing: In most cases you do not have to change this value. If you switch on the motor with the safety functions active (SLS, SDI or SSM) and the inverter responds when switching on with a safety fault message, increase this value in the range 50 % 100% of the motor excitation build-up time (p0346). 2 Minimum current actual value sensing: Leave this value at the factory setting (10 %). 3 Voltage tolerance, acceleration: In most cases you do not have to change this parameter. During acceleration with very short ramp-up and ramp-down times, if the inverter responds with a safety function fault, increase this value step-by-step by approx. 10%. Close the screen form. Close the screen form for forced dormant error detection Enabling safety functions 1 Enable the safety functions via the drop-down menu: 126 Function Manual, 01/2011, FW 4.4, A5E B AB

129 Commissioning 4.6 Extended Safety The rest of the procedure depends on which safety functions you use: 2 The safety function "Safe Torque Off" (STO) must always be selected. The settings are described in the section. Setting STO (Page 127). 3 If you use the safety function "Safe Stop 1" (SS1), follow the instructions in Section: Setting SS1 (Page 128). 4 If you use the safety function "Safely Limited Speed" (SLS), follow the instructions in the section. Setting SLS (Page 130). 5 The safety function SSM only makes sense for a connection via PROFIsafe, as you can only evaluate the SSM feedback signal via PROFIsafe. 6 If you use the safety function "safe direction of movement" (SDI), follow the instructions in Section: Setting SDI (Page 130) Setting STO Configure the following settings in this screen form: 1 Forced dormant error detection of the switch-off signal paths You define the monitoring of the forced checking procedure in another screen form (Setting forced dormant error detection (Page 124)). Set this time to the maximum value (9000 hours). 2 If you need this signal in your control, connect it to any digital output of your choice or to a status word on the fieldbus. 3 Setting is not required Close the screen form. If you do not use any other safety function, go directly to Section Activate settings (Page 131). Function Manual, 01/2011, FW 4.4, A5E B AB 127

130 Commissioning 4.6 Extended Safety Setting SS1 The appearance of the SS1 screen form depends on which mode you set when selecting the safety functions. SS1 with braking ramp monitoring The function is described in Section: Braking ramp monitoring (Page 22). Set the following in this screen form: 1 Shutdown speed (standstill monitoring) 2 Delay time: If the OFF3 ramp-down time (p1135) is less than 10 seconds, leave the delay time set to the factory setting. If SS1 switches to the fault status during the function test, increase this value until the motor brakes normally. If the OFF3 ramp-down time is set to several minutes, you must extend the delay time to a number of seconds in order to avoid any unwanted interruptions caused by SS1. 3 Monitoring time Monitoring time OFF3 ramp-down time (p1135). If the monitoring time and OFF3 ramp-down time are identical, the deceleration ramp and monitoring curve run parallel to each other. Longer monitoring times result in flatter monitoring curves. 4 Reference speed: Reference speed = rated speed of the motor (p1082) gear ratio Gear ratio = load / motor revolutions Example: p1082 = 1500 rpm, gear ratio = 1 / 3 reference speed = 500 rpm 128 Function Manual, 01/2011, FW 4.4, A5E B AB

131 Commissioning 4.6 Extended Safety Close the screen form. If you do not use any other safety function, go directly to Section Activate settings (Page 131). SS1 with acceleration monitoring The function is described in Section: Acceleration monitoring (Page 24). Set the following in this screen form: 1 Delay time After this time the inverter safely switches off the motor torque - regardless of the actual speed. 2 Shutdown speed (standstill monitoring) 3 Velocity tolerance Tolerance for the SAM monitoring 4 Shutdown of velocity Lower speed limit for the SAM monitoring Close the screen form. If you do not use any other safety function, go directly to Section Activate settings (Page 131). Function Manual, 01/2011, FW 4.4, A5E B AB 129

132 Commissioning 4.6 Extended Safety Setting SLS The principle of operation of SLS is provided in section Safely Limited Speed, SLS (Page 28). Set the following: 1 The delay time is only displayed if you selected "acceleration monitoring" at the start of commissioning. The selected delay time must be greater than the time that the motor requires when SLS is selected for braking with maximum load from the maximum speed down to the SLS speed. 2 Setpoint speed limit as a % of the monitoring threshold. This parameter defines the upper speed limit when SLS is active. 3 Monitoring threshold. Enter the load-side speed to be monitored. The inverter calculates the maximum motor speed on the basis of this parameter and the gear ratio. 4 Reaction when the monitoring responds. See also section: STOP reactions (Page 192). Close the screen form Setting SDI The principle of operation of SDI is provided in section Safe Direction (SDI) (Page 42). 130 Function Manual, 01/2011, FW 4.4, A5E B AB

133 Commissioning 4.6 Extended Safety Set the following in this screen form: 1 Enable the function 2 Delay time between selecting SDI and the active SDI: The delay time must be greater than the time that the motor requires, when SDI is selected, for braking with the maximum load from the maximum speed down to standstill. 3 Tolerance for the permissible motion in the monitored direction (Unit: degree) 4 Reaction when the monitoring responds See also section: STOP reactions (Page 192) 5 Behavior when the motor is switched off Also see section: Switching off the motor when SDI is active (Page 44) 6 7 If you interconnect the monitoring with speed limits p1051 and p1052, the inverter limits the speed when SDI is active Activate settings Click "Copy parameters" and then click "Activate settings": You are prompted to allocate a password if the password = 0 (factory setting). If you try to set a password that is not permissible, the old password will not be changed. Further information can be found in the section Password (Page 71). Confirm the prompt for saving your settings (copy RAM to ROM). Switch off the inverter supply voltage. Wait until all LEDs on the inverter go dark. Now switch on the inverter supply voltage again. Your settings only become effective after this power-on reset. Function Manual, 01/2011, FW 4.4, A5E B AB 131

134 Commissioning 4.6 Extended Safety Multiple assignment of the DI Check whether the digital inputs used as fail-safe input are also assigned a further function. NOTICE Both, the assignment of digital inputs with the selection of a safety function or with a "standard" function can lead to an unexpected behavior of the motor. Remove multiple assignments of the digital inputs: Figure 4-5 Example: automatic assignment of digital inputs DI 4 and DI 5 with STO Figure 4-6 Remove pre-assignment of digital inputs DI 4 and DI 5 When you use the data set changeover CDS, you must delete the multiple assignment of the digital inputs for all CDS. 132 Function Manual, 01/2011, FW 4.4, A5E B AB

135 Commissioning 4.6 Extended Safety Further steps Commission the standard inverter functions by following the operating instructions. The link to the operating instructions can be found in the section Manuals for your inverter (Page 229). Perform an acceptance test for the safety functions: Document your settings in an acceptance report. Check whether the safety functions are functioning correctly in your application. The instructions for the acceptance test can be found in the section Acceptance test - Completion of commissioning (Page 164). Function Manual, 01/2011, FW 4.4, A5E B AB 133

136 Commissioning 4.6 Extended Safety Extended Safety with activation via PROFIsafe Procedure Go online with STARTER. In STARTER, call up the screens displaying the fail-safe functions and click on "Change settings": Defining the commissioning method 1 Set "Motion monitoring via PROFIsafe". 2 If you use one of the safety functions SS1 or SLS, then you must select the monitoring mode of these functions. More detailed information on the modes can be found in the following sections: Monitoring modes of SS1 (Page 21) Monitoring modes of SLS (Page 28) 3 Click on the "Configuration" button. 134 Function Manual, 01/2011, FW 4.4, A5E B AB

137 Commissioning 4.6 Extended Safety Setting forced dormant error detection and the PROFIsafe address Select the values compatible with your application. 1 This signal triggers a forced dormant error detection and resets the timer. Interconnect this signal with a binector of your choice, for example a digital input or a control bit in the field bus. 2 You must conduct a forced dormant error detection for this signal. Interconnect this binector with a signal of your choice, for example a digital input or a status bit in the field bus. 3 Time interval for forced dormant error detection. Further information can be found in the section Forced dormant error detection (test stop) (Page 72). 4 PROFIsafe address Enter the same PROFIsafe address as a hexadecimal value, that you defined in the hardware configuration (F_Dest_Add). See sectionconfiguring communication in STEP 7 (telegram 30) (Page 100). If you only want to use STO, close this screen and go to the section Enabling safety functions (Page 138). In all other cases, go to the next section. Function Manual, 01/2011, FW 4.4, A5E B AB 135

138 Commissioning 4.6 Extended Safety Setting the gear ratio and tolerance If you only use STO, then the settings in this screen form have no significance. In all other cases, set the following: 1 Actual value tolerance: In most cases you do not have to change this value. For the "flying restart" function, if the inverter responds with message C01711 or C30711, increase this value step-bystep until the message to longer occurs. Note: If you increase this value, the speed monitoring of the inverter becomes less sensitive to limit violations. 2 3 Gear ratio: Enter your machine's data in accordance with the following table. 2 Number of load revolutions 3 Number of motor revolutions Without gear 1 Number of pole pairs Gear with speed ratio Load/motor = L/M L M number of pole pairs Example: Gear with speed ratio Load/motor = 1/3 1 3 number of pole pairs Table 4-3 Determine the number of pole pairs (r0313) Motor speed under no-load conditions at 50 Hz Motor speed under no-load conditions at 60 Hz Number of pole pairs 3000 rpm 3600 rpm rpm 1800 rpm rpm 1200 rpm rpm 900 rpm 4 Close the screen for the gear ratio. Close the screen form for forced dormant error detection. 136 Function Manual, 01/2011, FW 4.4, A5E B AB

139 Commissioning 4.6 Extended Safety Encoderless actual value sensing If you only use STO, then the settings in this screen form have no significance. In all other cases, set the following: 1 Delay time, actual value sensing: In most cases you do not have to change this value. If you switch on the motor with the safety functions active (SLS, SDI or SSM) and the inverter responds when switching on with a safety fault message, increase this value in the range 50 % 100% of the motor excitation build-up time (p0346). 2 Minimum current actual value sensing: Leave this value at the factory setting (10 %). 3 Voltage tolerance, acceleration: In most cases you do not have to change this parameter. During acceleration with very short ramp-up and ramp-down times, if the inverter responds with a safety function fault, increase this value step-by-step by approx. 10%. Close the screen form. Close the screen form for forced dormant error detection. Function Manual, 01/2011, FW 4.4, A5E B AB 137

140 Commissioning 4.6 Extended Safety Enabling safety functions 1 Enable the safety functions via the drop-down menu: The rest of the procedure depends on which safety functions you use: 2 The safety function "Safe Torque Off" (STO) must always be selected. The settings are described in the section. Setting STO (Page 139). 3 If you use the safety function "Safe Stop 1" (SS1), follow the instructions in section: Setting SS1 (Page 140). 4 If you use the safety function "Safely Limited Speed" (SLS), follow the instructions in the section. Setting SLS (Page 142). 5 If you use the safety function "safe speed monitoring" (SSM), follow the instructions in section: Setting SSM (Page 143). 6 If you use the safety function "safe direction of movement" (SDI), follow the instructions in section: Setting SDI (Page 144). 138 Function Manual, 01/2011, FW 4.4, A5E B AB

141 Commissioning 4.6 Extended Safety Setting STO Configure the following settings in this screen form: 1 Forced dormant error detection of the switch-off signal paths You define the monitoring of the forced checking procedure in another screen form (Forced dormant error detection (test stop) (Page 72)). Set this time to the maximum value (9000 hours). 2 If you need this signal in your control, connect it to any digital output of your choice or to a status word on the fieldbus. 3 Setting is not required Close the screen form. If you do not use any other safety function, go directly to Section Activate settings (Page 145). Function Manual, 01/2011, FW 4.4, A5E B AB 139

142 Commissioning 4.6 Extended Safety Setting SS1 The appearance of the SS1 screen form depends on which mode you set when selecting the safety functions. SS1 with braking ramp monitoring The function is described in Section: Braking ramp monitoring (Page 22). Set the following in this screen form: 1 Shutdown speed (standstill monitoring) 2 Delay time: If the OFF3 ramp-down time (p1135) is less than 10 seconds, leave the delay time set to the factory setting. If SS1 switches to the fault status during the function test, increase this value until the motor brakes normally. If the OFF3 ramp-down time is set to several minutes, you must extend the delay time to a number of seconds in order to avoid any unwanted interruptions caused by SS1. 3 Monitoring time Monitoring time OFF3 ramp-down time (p1135). If the monitoring time and OFF3 ramp-down time are identical, the deceleration ramp and monitoring curve run parallel to each other. Longer monitoring times result in flatter monitoring curves. 4 Reference speed: Reference speed = rated speed of the motor (p1082) gear ratio Gear ratio = load / motor revolutions Example: p1082 = 1500 rpm, gear ratio = 1 / 3 reference speed = 500 rpm 140 Function Manual, 01/2011, FW 4.4, A5E B AB

143 Commissioning 4.6 Extended Safety Close the screen form. If you do not use any other safety function, go directly to Section Activate settings (Page 145). SS1 with acceleration monitoring The function is described in Section: Acceleration monitoring (Page 24). Set the following in this screen form: 1 Delay time After this time the inverter safely switches off the motor torque - regardless of the actual speed. 2 Shutdown speed (standstill monitoring) 3 Velocity tolerance Tolerance for the SAM monitoring 4 Shutdown of velocity Lower speed limit for the SAM monitoring Close the screen form. If you do not use any other safety function, go directly to Section Activate settings (Page 145). Function Manual, 01/2011, FW 4.4, A5E B AB 141

144 Commissioning 4.6 Extended Safety Setting SLS The principle of operation of SLS is provided in section Safely Limited Speed, SLS (Page 28). Set the following: 1 The delay time is only displayed if you selected "acceleration monitoring" at the start of commissioning. The selected delay time must be greater than the time that the motor requires when SLS is selected for braking with maximum load from the maximum speed down to the lowest SLS level. 2 Setpoint speed limit as a % of the monitoring threshold. This parameter defines the upper speed limit when SLS is active. 3 Monitoring threshold. Enter the load-side speed to be monitored. The inverter calculates the maximum motor speed on the basis of this parameter and the gear ratio. 4 Reaction when the monitoring responds. See also section: STOP reactions (Page 192). Close the screen form. 142 Function Manual, 01/2011, FW 4.4, A5E B AB

145 Commissioning 4.6 Extended Safety Setting SSM The principle of operation of SSM is provided in section Safe Speed Monitor, SSM (Page 49). Set the following in this screen form: 1 Enable the function with hysteresis 2 Filter time Smoothes the signal for monitoring. Set the filter if you wish to monitor speeds that lie just below the velocity limit. 3 Hysteresis 4 Speed limit Set the speed to be monitored 5 Behavior when the motor is switched off See section: Switching off the motor when SSM is active (Page 51) Note Switching on the motor after commissioning SSM The SSM function is active immediately after commissioning has been completed. To switch on the motor after the commissioning of SSM has been completed, observe the procedure in section Switching the motor off and on again when SSM is active (Page 53). Function Manual, 01/2011, FW 4.4, A5E B AB 143

146 Commissioning 4.6 Extended Safety Setting SDI The principle of operation of SDI is provided in section Safe Direction (SDI) (Page 42). Set the following in this screen form: 1 Enable the function 2 Delay time between selecting SDI and the active SDI: The delay time must be greater than the time that the motor requires, when SDI is selected, for braking with the maximum load from the maximum speed down to standstill. 3 Tolerance for the permissible motion in the monitored direction (Unit: degree) 4 Reaction when the monitoring responds See also section: STOP reactions (Page 192) 5 Behavior when the motor is switched off Also see section: Switching off the motor when SDI is active (Page 44) 6 7 If you interconnect the monitoring with speed limits p1051 and p1052, the inverter limits the speed when SDI is active Defining the F-DI status If you do not want to transfer the status of the fail-safe inputs via PROFIsafe, go straight to the section Activate settings (Page 145). If you want to transfer the status of the fail-safe digital inputs via PROFIsafe, you first have to configure the relevant PROFIsafe telegram; see the section Configuring communication in STEP 7 (telegram 900) (Page 102). In STARTER, you then have to specify which F-DI- Status you want to transfer via PROFIsafe. 144 Function Manual, 01/2011, FW 4.4, A5E B AB

147 Commissioning 4.6 Extended Safety Click the "Safety Inputs" button. Specify which F-DI-Status you want to transfer via PROFIsafe: Note The F-DI status is transferred irrespective of whether you use the F-DI to activate a failsafe function Activate settings Click "Copy parameters" and then click "Activate settings": You are prompted to allocate a password if the password = 0 (factory setting). If you try to set a password that is not permissible, the old password will not be changed. Further information can be found in the section Password (Page 71). Confirm the prompt for saving your settings (copy RAM to ROM). Switch off the inverter supply voltage. Wait until all LEDs on the inverter go dark. Now switch on the inverter supply voltage again. Your settings only become effective after this power-on reset. Function Manual, 01/2011, FW 4.4, A5E B AB 145

148 Commissioning 4.6 Extended Safety Starting communication via PROFIsafe When you connect the inverter to the central controller via the fieldbus for the first time, the central controller sends the PROFIsafe configuration to the inverter. Once the configuration data has been received, the inverter interconnects its internal signals with the PROFIsafe telegram. Note Monitoring PROFIsafe communication The inverter monitors communication with the central controller. The inverter does not start monitoring communication until the configuration data has been received from the central controller Further steps Commission the standard inverter functions by following the operating instructions. The link to the operating instructions can be found in the section Manuals for your inverter (Page 229). Perform an acceptance test for the safety functions: Document your settings in an acceptance report. Check whether the safety functions are functioning correctly in your application. The instructions for the acceptance test can be found in the section Acceptance test - Completion of commissioning (Page 164). 146 Function Manual, 01/2011, FW 4.4, A5E B AB

149 Commissioning 4.6 Extended Safety Extended Safety with activation via PROFIsafe and F-DI Procedure Go online with STARTER. In STARTER, call up the screens displaying the fail-safe functions and click on "Change settings": Defining the commissioning method 1 Set "Motion monitoring via PROFIsafe and terminals". 2 If you use one of the safety functions SS1 or SLS, then you must select the monitoring mode of these functions. More detailed information on the modes can be found in the following sections: Monitoring modes of SS1 (Page 21) Monitoring modes of SLS (Page 28) 3 Click on the "Configuration" button. Function Manual, 01/2011, FW 4.4, A5E B AB 147

150 Commissioning 4.6 Extended Safety Setting forced dormant error detection and the PROFIsafe address Select the values compatible with your application. 1 This signal triggers a forced dormant error detection and resets the timer. Interconnect this signal with a binector of your choice, for example a digital input or a control bit in the field bus. 2 You must conduct a forced dormant error detection for this signal. Interconnect this binector with a signal of your choice, for example a digital input or a status bit in the field bus. 3 Time interval for forced dormant error detection. Further information can be found in the section Forced dormant error detection (test stop) (Page 72). 4 PROFIsafe address Enter the same PROFIsafe address as a hexadecimal value, that you defined in the hardware configuration (F_Dest_Add). See sectionconfiguring communication in STEP 7 (telegram 30) (Page 100). If you only want to use STO, close this screen and go to the section Enabling safety functions (Page 151). In all other cases, go to the next section Setting the gear ratio and tolerance 148 Function Manual, 01/2011, FW 4.4, A5E B AB

151 Commissioning 4.6 Extended Safety If you only use STO, then the settings in this screen form have no significance. In all other cases, set the following: 1 Actual value tolerance: In most cases you do not have to change this value. For the "flying restart" function, if the inverter responds with message C01711 or C30711, increase this value step-bystep until the message to longer occurs. Note: If you increase this value, the speed monitoring of the inverter becomes less sensitive to limit violations. 2 3 Gear ratio: Enter your machine's data in accordance with the following table. 2 Number of load revolutions 3 Number of motor revolutions Without gear 1 Number of pole pairs Gear with speed ratio Load/motor = L/M L M number of pole pairs Example: Gear with speed ratio Load/motor = 1/3 1 3 number of pole pairs Table 4-4 Determine the number of pole pairs (r0313) Motor speed under no-load conditions at 50 Hz Motor speed under no-load conditions at 60 Hz Number of pole pairs 3000 rpm 3600 rpm rpm 1800 rpm rpm 1200 rpm rpm 900 rpm 4 Close the screen for the gear ratio. Close the screen form for forced dormant error detection. Function Manual, 01/2011, FW 4.4, A5E B AB 149

152 Commissioning 4.6 Extended Safety Encoderless actual value sensing If you only use STO, then the settings in this screen form have no significance. In all other cases, set the following: 1 Delay time, actual value sensing: In most cases you do not have to change this value. If you switch on the motor with the safety functions active (SLS, SDI or SSM) and the inverter responds when switching on with a safety fault message, increase this value in the range 50 % 100% of the motor excitation build-up time (p0346). 2 Minimum current actual value sensing: Leave this value at the factory setting (10 %). 3 Voltage tolerance, acceleration: In most cases you do not have to change this parameter. During acceleration with very short ramp-up and ramp-down times, if the inverter responds with a safety function fault, increase this value step-by-step by approx. 10%. Close the screen form. Close the screen form for forced dormant error detection. 150 Function Manual, 01/2011, FW 4.4, A5E B AB

153 Commissioning 4.6 Extended Safety Enabling safety functions 1 Enable the safety functions via the drop-down menu: The rest of the procedure depends on which safety functions you use: 2 The safety function "Safe Torque Off" (STO) must always be selected. The settings are described in the section. Setting STO (Page 151). 3 If you use the safety function "Safe Stop 1" (SS1), follow the instructions in section: Setting SS1 (Page 152). 4 If you use the safety function "Safely Limited Speed" (SLS), follow the instructions in the section. Setting SLS (Page 155). 5 If you use the safety function "safe speed monitoring" (SSM), follow the instructions in section: Setting SSM (Page 156). 6 If you use the safety function "safe direction of movement" (SDI), follow the instructions in section: Setting SDI (Page 157) Setting STO If you require the status signal "STO active" in your higher-level controller, interconnect it accordingly. Do not enter any other settings in this screen, instead click on the "STO" button. In the next screen, do not enter any settings here either, instead click on the "STO" button again. Function Manual, 01/2011, FW 4.4, A5E B AB 151

154 Commissioning 4.6 Extended Safety You can adapt the STO function according to your requirements in the following screen. Set the following in the above screen: 1 2 F-DI input filter (debounce time) and monitoring for simultaneous operation (discrepancy): The method of functioning of the two filters is described in section F-DI signal filtering (Page 77). 3 Forced dormant error detection of the switch-off signal paths: You define the monitoring of the forced dormant error detection in another screen form (Setting forced dormant error detection and the PROFIsafe address (Page 148)). Set this time to the maximum value (9000 hours). 4 No setting required Close the screen form. Also, close any other STO screens. If you do not use any other safety function, go directly to Section Activate settings (Page 158) Setting SS1 The appearance of the SS1 screen form depends on which mode you set when selecting the safety functions. 152 Function Manual, 01/2011, FW 4.4, A5E B AB

155 Commissioning 4.6 Extended Safety SS1 with braking ramp monitoring The function is described in Section: Braking ramp monitoring (Page 22). Set the following in this screen form: 1 Shutdown speed (standstill monitoring) 2 Delay time: If the OFF3 ramp-down time (p1135) is less than 10 seconds, leave the delay time set to the factory setting. If SS1 switches to the fault status during the function test, increase this value until the motor brakes normally. If the OFF3 ramp-down time is set to several minutes, you must extend the delay time to a number of seconds in order to avoid any unwanted interruptions caused by SS1. 3 Monitoring time Monitoring time OFF3 ramp-down time (p1135). If the monitoring time and OFF3 ramp-down time are identical, the deceleration ramp and monitoring curve run parallel to each other. Longer monitoring times result in flatter monitoring curves. 4 Reference speed: Reference speed = rated speed of the motor (p1082) gear ratio Gear ratio = load / motor revolutions Example: p1082 = 1500 rpm, gear ratio = 1 / 3 reference speed = 500 rpm Close the screen form. If you do not use any other safety function, go directly to Section Activate settings (Page 158). Function Manual, 01/2011, FW 4.4, A5E B AB 153

156 Commissioning 4.6 Extended Safety SS1 with acceleration monitoring The function is described in Section: Acceleration monitoring (Page 24). Set the following in this screen form: 1 Delay time After this time the inverter safely switches off the motor torque - regardless of the actual speed. 2 Shutdown speed (standstill monitoring) 3 Velocity tolerance Tolerance for the SAM monitoring 4 Shutdown of velocity Lower speed limit for the SAM monitoring Close the screen form. If you do not use any other safety function, go directly to Section Activate settings (Page 158). 154 Function Manual, 01/2011, FW 4.4, A5E B AB

157 Commissioning 4.6 Extended Safety Setting SLS The principle of operation of SLS is provided in section Safely Limited Speed, SLS (Page 28). Set the following: 1 The delay time is only displayed if you selected "acceleration monitoring" at the start of commissioning. The selected delay time must be greater than the time that the motor requires when SLS is selected for braking with maximum load from the maximum speed down to the lowest SLS level. 2 Setpoint speed limit as a % of the monitoring threshold. This parameter defines the upper speed limit when SLS is active. 3 Monitoring threshold. Enter the load-side speed to be monitored. The inverter calculates the maximum motor speed on the basis of this parameter and the gear ratio. 4 Reaction when the monitoring responds. See also section: STOP reactions (Page 192). Close the screen form. Function Manual, 01/2011, FW 4.4, A5E B AB 155

158 Commissioning 4.6 Extended Safety Setting SSM The principle of operation of SSM is provided in section Safe Speed Monitor, SSM (Page 49). Set the following in this screen form: 1 Enable the function with hysteresis 2 Filter time Smoothes the signal for monitoring. Set the filter if you wish to monitor speeds that lie just below the velocity limit. 3 Hysteresis 4 Speed limit Set the speed to be monitored 5 Behavior when the motor is switched off See section: Switching off the motor when SSM is active (Page 51) Note Switching on the motor after commissioning SSM The SSM function is active immediately after commissioning has been completed. To switch on the motor after the commissioning of SSM has been completed, observe the procedure in section Switching the motor off and on again when SSM is active (Page 53). 156 Function Manual, 01/2011, FW 4.4, A5E B AB

159 Commissioning 4.6 Extended Safety Setting SDI The principle of operation of SDI is provided in section Safe Direction (SDI) (Page 42). Set the following in this screen form: 1 Enable the function 2 Delay time between selecting SDI and the active SDI: The delay time must be greater than the time that the motor requires, when SDI is selected, for braking with the maximum load from the maximum speed down to standstill. 3 Tolerance for the permissible motion in the monitored direction (Unit: degree) 4 Reaction when the monitoring responds See also section: STOP reactions (Page 192) 5 Behavior when the motor is switched off Also see section: Switching off the motor when SDI is active (Page 44) 6 7 If you interconnect the monitoring with speed limits p1051 and p1052, the inverter limits the speed when SDI is active Defining the F-DI status If you do not want to transfer the status of the fail-safe inputs via PROFIsafe, go straight to the section Activate settings (Page 158). If you want to transfer the status of the fail-safe digital inputs via PROFIsafe, you first have to configure the relevant PROFIsafe telegram; see the section Configuring communication in STEP 7 (telegram 900) (Page 102). In STARTER, you then have to specify which F-DI- Status you want to transfer via PROFIsafe. Function Manual, 01/2011, FW 4.4, A5E B AB 157

160 Commissioning 4.6 Extended Safety Click the "Safety Inputs" button. Specify which F-DI-Status you want to transfer via PROFIsafe: Note The F-DI status is transferred irrespective of whether you use the F-DI to activate a failsafe function Activate settings Click "Copy parameters" and then click "Activate settings": You are prompted to allocate a password if the password = 0 (factory setting). If you try to set a password that is not permissible, the old password will not be changed. Further information can be found in the section Password (Page 71). Confirm the prompt for saving your settings (copy RAM to ROM). Switch off the inverter supply voltage. Wait until all LEDs on the inverter go dark. Now switch on the inverter supply voltage again. Your settings only become effective after this power-on reset. 158 Function Manual, 01/2011, FW 4.4, A5E B AB

161 Commissioning 4.6 Extended Safety Starting communication via PROFIsafe When you connect the inverter to the central controller via the fieldbus for the first time, the central controller sends the PROFIsafe configuration to the inverter. Once the configuration data has been received, the inverter interconnects its internal signals with the PROFIsafe telegram. Note Monitoring PROFIsafe communication The inverter monitors communication with the central controller. The inverter does not start monitoring communication until the configuration data has been received from the central controller Multiple assignment of the DI Check whether the digital inputs used as fail-safe input are also assigned a further function. NOTICE Both, the assignment of digital inputs with the selection of a safety function or with a "standard" function can lead to an unexpected behavior of the motor. Remove multiple assignments of the digital inputs: Figure 4-7 Example: automatic assignment of digital inputs DI 4 and DI 5 with STO Function Manual, 01/2011, FW 4.4, A5E B AB 159

162 Commissioning 4.6 Extended Safety Figure 4-8 Remove pre-assignment of digital inputs DI 4 and DI 5 When you use the data set changeover CDS, you must delete the multiple assignment of the digital inputs for all CDS Further steps Commission the standard inverter functions by following the operating instructions. The link to the operating instructions can be found in the section Manuals for your inverter (Page 229). Perform an acceptance test for the safety functions: Document your settings in an acceptance report. Check whether the safety functions are functioning correctly in your application. The instructions for the acceptance test can be found in the section Acceptance test - Completion of commissioning (Page 164). 160 Function Manual, 01/2011, FW 4.4, A5E B AB

163 Commissioning 4.7 Offline commissioning 4.7 Offline commissioning When you set the safety function parameters offline, you have to download them to the inverter. Once you have downloaded them, you have to finish commissioning the safety functions online. The screens for the safety functions differ from each other slightly depending on whether you work with STARTER online or offline. Follow the descriptions in this manual in order to set all of the necessary parameters in line with the requirements of your application (this also applies when setting the parameters offline) Offline parameterization Call up the safety functions in STARTER. Select the checkbox at the bottom of the dialog to copy the parameters: Set the safety function parameters offline. Follow the descriptions in this manual starting with the section Selecting the commissioning method (Page 108). Once you have finished setting the parameters, save your project by clicking the button Downloading parameters Go online with STARTER and start downloading the parameters to the inverter. To do so, click the button. Call the safety functions screen form Click on the "Change settings" button Click on the "Activate settings" button Save your settings (copy RAM to ROM). Switch off the inverter supply voltage. Wait until all LEDs on the inverter go dark. Now switch on the inverter supply voltage again. Your settings only become effective after this power-on reset. Function Manual, 01/2011, FW 4.4, A5E B AB 161

164 Commissioning 4.7 Offline commissioning Further steps Commission the standard inverter functions by following the operating instructions. The link to the operating instructions can be found in the section Manuals for your inverter (Page 229). Perform an acceptance test for the safety functions: Document your settings in an acceptance report. Check whether the safety functions are functioning correctly in your application. The instructions for the acceptance test can be found in the section Acceptance test - Completion of commissioning (Page 164). 162 Function Manual, 01/2011, FW 4.4, A5E B AB

165 Commissioning 4.8 Series commissioning 4.8 Series commissioning In order to perform standard commissioning, you must have saved a project in STARTER. To copy all the parameters of one inverter to a second inverter, follow the instructions in the section Downloading parameters (Page 161). Steps to be carried out after downloading the parameters: If you activate your inverter via PROFIsafe, you have to modify the PROFIsafe address. Setting the PROFIsafe address for Basic Safety (Setting STO (Page 115)): Setting the PROFIsafe address for Extended Safety (Setting forced dormant error detection and the PROFIsafe address (Page 135)): Perform a reduced acceptance test for the safety functions. The necessary steps are described in the section Reduced acceptance test (Page 166). Function Manual, 01/2011, FW 4.4, A5E B AB 163

166 Commissioning 4.9 Acceptance test - Completion of commissioning 4.9 Acceptance test - Completion of commissioning Prerequisites and authorized persons Requirements for acceptance tests are derived from the EC Machinery Directive and ISO Check the safety-related functions and machine parts following commissioning. Issue an "Acceptance certificate" which describes the test results. Prerequisites for the acceptance test The machine is properly wired. All safety equipment such as protective door monitoring devices, light barriers or emergency-off switches are connected and ready for operation. Commissioning of the open-loop and closed-loop control must be complete. These include, for example: Configuration of the setpoint channel. Position control in the higher-level controller. Drive control. Authorized persons Authorization within the scope of the acceptance test is a person authorized by the machine manufacturer who, on account of his or her technical qualifications and knowledge of the safety functions, is in a position to perform the acceptance test in the correct manner. 164 Function Manual, 01/2011, FW 4.4, A5E B AB

167 Commissioning 4.9 Acceptance test - Completion of commissioning Complete acceptance test A complete acceptance test includes the following: 1. Documentation Description of the machines and overview/block diagram Safety functions of the drive Description of safety equipment 2. Function test Test of the shutdown paths Test of safety functions used 3. Conclusion of the report Inspection of safety function parameters Recording of the checksums Verify the data backup Countersignatures Function Manual, 01/2011, FW 4.4, A5E B AB 165

168 Commissioning 4.9 Acceptance test - Completion of commissioning Reduced acceptance test A complete acceptance test is only necessary following first commissioning. An acceptance test with a reduced scope is sufficient for expansions of safety functions. The reduced acceptance tests must be carried out separately for each individual drive, as far as the machine allows. Table 4-5 Reduced acceptance test for function extensions Measure Acceptance test Documentation Function test Conclusion of the report Replacing the Control Unit (SINAMICS G120) or the inverter. Supplement: Inverter data Yes Supplement: New checksums and countersignature Replacing the Power Module. Supplement: Yes No Hardware version in the inverter data Replacing the motor No Yes No Restriction to safety function SDI. Replacing the gear unit No Yes No Replacing the safety-related No Yes No peripherals (e.g. Emergency Stop Limitation to replaced switch). components. Inverter firmware update. Supplement: Yes Supplement: Firmware version in the inverter data New checksums and countersignature. Changing a single limit (e.g. SLS level). Supplement: Function table Limit values Yes Restriction to changed limit value. Supplement: New checksums and countersignature. Functional expansion of the machine (additional drive). Supplement: Machine overview Inverter data Yes Restriction to additional functions. Supplement: New checksums and countersignature. Function table Limit values Functional expansion of a drive (e.g. additional SLS level). Supplement: Function table Limit values Yes Restriction to additional functions. Supplement. New checksums and countersignature. Transfer of inverter parameters to other identical machines by means of standard commissioning. Supplement to the machine description (checking of the firmware versions). Yes No, if data are identical (checking of checksums). 166 Function Manual, 01/2011, FW 4.4, A5E B AB

169 Commissioning 4.9 Acceptance test - Completion of commissioning Documentation If you want to use the acceptance report as a template and edit it for your machine, configure a download of this manual using the "My Documentation Manager" service on the Internet. Open the "My Documentation Manager" via "Display and configure"under the link to this manual (Download manuals ( Once you have registered, you can load the individual chapters of this manual in the rtf format. Machine overview Enter your machine's data into the following table. Designation Type Serial number Manufacturer End customer Overview image of the machine: Converter data Document the hardware and firmware versions for each safety-related converter of your machine. MLFB and hardware version of the converter Converter firmware version Version of the safety functions Designation of the 1st drive r0018 = r9770[0] r9770[1] r9770[2] r9770[3] r9590[0] r9590[1] r9590[2] r9590[3] Designation of the 2nd drive Function Manual, 01/2011, FW 4.4, A5E B AB 167

170 Commissioning 4.9 Acceptance test - Completion of commissioning Function table Fill in the following table for your machine. Mode of operation Safety device Drive Activating the safety function Status of the safety function Table 4-6 Example: Mode of operation Safety device Drive Activating the safety function Production Setup Protective door closed and locked 1 2 Protective door unlocked 1 2 Protective door closed and locked 1 2 Protective door unlocked PROFIsafe F-DI 0 PROFIsafe - PROFIsafe F-DI 1 PROFIsafe Status of the safety function not active SLS level 2 active STO SS1 not active SLS level 2 active SS1 SLS level 0 active Limit values Enter the limit values for the safety functions in the following table. Drive Safety function Limit Table 4-7 Example: Drive Safety function Limit 1 2 STO - SS1 Reference speed = 1500 rpm Delay time = 250 ms Monitoring time = 5 s SS1 Reference speed = 1500 rpm Delay time = 250 ms Monitoring time = 8 s SLS rpm SLS rpm 168 Function Manual, 01/2011, FW 4.4, A5E B AB

171 Commissioning 4.9 Acceptance test - Completion of commissioning Function test The following is checked during the function test: The hardware is functioning properly. The digital inputs of the inverter are assigned correctly to the safety function. The PROFIsafe address of the inverter has been set correctly. The safety function has been parameterized correctly. Routine for the dormant error detection of the switch-off signal paths of the inverter. Note Perform the acceptance test with the maximum possible velocity and acceleration. Function Manual, 01/2011, FW 4.4, A5E B AB 169

172 Commissioning 4.9 Acceptance test - Completion of commissioning Safe Torque Off, STO (Basic Safety) Table 4-8 "Safe Torque Off" (STO) function No. Description Status 1. Initial state: The inverter is in "Ready" state (p0010 = 0). The inverter indicates neither faults nor alarms for safety functions (r0945, r2122, r2132). STO is not active. 2. Switch on the motor (ON command). 3. Ensure that the correct motor is running. 4. Select STO while the motor is running 5. Note: Test each configured activation, e.g. via digital inputs and PROFIsafe. Check the following: If a mechanical brake is not available, the motor coasts down. A mechanical brake brakes the motor and holds it to ensure that it remains at a standstill. The inverter indicates neither faults nor alarms for safety functions. The inverter indicates: "STO is selected" (r = 1). "STO is active" (r = 1). 6. Deselect STO. 7. Check the following: The inverter indicates neither faults nor alarms for safety functions. The inverter indicates: "STO is not selected" (r = 0). "STO is not active" (r = 0). The inverter is in "Closing lockout" state (p = 1). 8. Switch the motor off (OFF1 command) and then on again (ON command). 9. Ensure that the correct motor is running. 170 Function Manual, 01/2011, FW 4.4, A5E B AB

173 Commissioning 4.9 Acceptance test - Completion of commissioning Safe Torque Off, STO (Extended Safety) Table 4-9 "Safe Torque Off" (STO) function No. Description Status 1. Initial state The inverter is in the "Ready" state (p0010 = 0). The inverter signals neither faults nor alarms of the safety functions (r0945, r2122, r2132). STO is not active. 2. Switch on the motor (ON command). 3. Ensure that the correct motor is running. 4. Select STO while the motor is running. Note: Test each configured activation, e.g. via digital inputs and PROFIsafe. 5. Check the following: If a mechanical brake is not available, the motor coasts down. A mechanical brake brakes the motor and holds it to ensure that it remains at a standstill. The inverter signals neither faults nor alarms of the safety functions. The inverter signals: "STO is selected" (r = 0) "STO is active" (r = 1) 6. Deselect STO. 7. Check the following: The inverter signals neither faults nor alarms of the safety functions. The inverter signals: "STO is not selected" (r = 1) "STO is not active" (r = 0) The inverter is in "Closing lockout" state (p = 1). 8. Switch the motor off (OFF1 command) and then on again (ON command). 9. Ensure that the correct motor is running. Function Manual, 01/2011, FW 4.4, A5E B AB 171

174 Commissioning 4.9 Acceptance test - Completion of commissioning Safe Stop 1, SS1 Table 4-10 "Safe Stop 1" function (SS1) No. Description Status 1. Initial state: The inverter is in the "Ready" state (p0010 = 0). The inverter signals neither faults nor alarms of the safety functions (r0945, r2122, r2132). SS1 is not active. 2. Switch on the motor (ON command). 3. Ensure that the correct motor is running. 4. Select SS1 while the motor is running. 5. Note: Test each configured activation, e.g. via digital inputs and PROFIsafe. Check the following: The motor speed decreases in line with the selected ramp time (if necessary, use a stopwatch). The inverter signals: "SS1 is selected" (r = 0). "SS1 is active" (r = 1). The motor coasts to a standstill after the standstill detection threshold has been reached. The inverter signals: "STO is active" (r = 1). A mechanical brake brakes the motor and holds it to ensure that it remains at a standstill. The inverter signals neither faults nor alarms of the safety functions. 6. Deselect SS1. 7. Check the following: The inverter signals neither faults nor alarms of the safety functions. The inverter signals: "STO is not active" (r = 0). "SS1 is deselected" (r = 1). 8. Switch the motor off (OFF1 command) and then on again (ON command). 9. Ensure that the correct motor is running. 172 Function Manual, 01/2011, FW 4.4, A5E B AB

175 Commissioning 4.9 Acceptance test - Completion of commissioning Safely Limited Speed, SLS Table 4-11 "Safely Limited Speed" (SLS) function No. Description Status 1. Initial state The inverter is in the "Ready" state (p0010 = 0). The inverter signals neither faults nor alarms of the safety functions (r0945, r2122, r2132). SLS is not active. 2. Switch on the motor (ON command). Note: Select a higher motor speed than the SLS limit currently set (providing the machine allows this). 3. Ensure that the correct motor is running. 4. Select the SLS monitoring speed to be checked. Notes: If you are using several SLS monitoring speeds, repeat the test for each of the monitoring speeds. Test each configured activation, e.g. via digital inputs and PROFIsafe. 5. Select SLS while the motor is running. 6. Check the following: The motor speed decreases according to the selected ramp time. The motor then rotates below the parameterized safely limited speed. The inverter signals: "SLS is selected" (r = 0). "SLS is active" (r = 1). 7. Deselect SLS. 8. Check the following: The motor speed increases until the setpoint is reached. The inverter signals neither faults nor alarms of the safety functions. The inverter signals: "SLS is deselected" (r = 1). "SLS is not active" (r = 0). Function Manual, 01/2011, FW 4.4, A5E B AB 173

176 Commissioning 4.9 Acceptance test - Completion of commissioning Safe Direction (SDI) Table 4-12 "Safe Direction" (SDI) function No. Description Status 1. Initial state The inverter is in the "Ready" state (p0010 = 0). The inverter signals neither faults nor alarms of the safety functions (r0945, r2122, r2132). SDI is not active. 2. Switch on the motor (ON command). Note: Select a direction of rotation of the motor, which should be prevented by the SDI function. 3. Check that the correct motor rotates in the expected direction. 4. Select the SDI direction to be checked while the motor is running. Note: If you use SDI in both directions of rotation, perform this function test for both directions. 5. Check the following: The motor brakes corresponding to the selected ramp time down to standstill. The inverter does NOT switch off the motor, i.e. the motor is NOT torque-free. The inverter signals: "SDI is selected" (r = 0 or r = 0). "SDI is active" (r = 1 or r = 1). 7. Deselect SDI. 8. Check the following: The motor speed increases until the setpoint is reached. The inverter signals neither faults nor alarms of the safety functions. The inverter signals: "SDI is deselected" (r = 1 or r = 1). "SDI is not active" (r = 0 or r = 0). 174 Function Manual, 01/2011, FW 4.4, A5E B AB

177 Commissioning 4.9 Acceptance test - Completion of commissioning Safe Speed Monitor (SSM) Table 4-13 "Safe Speed Monitor" (SSM) function No. Description Status 1. Initial state The inverter is in the "Ready" state (p0010 = 0). The inverter signals neither faults nor alarms of the safety functions (r0945, r2122, r2132). 2. Switch on the motor (ON command). 3. Select a lower motor speed than the SSM speed limit. 4. Ensure that the correct motor is running. 5. Check the following: The inverter signals: "Speed below the limit value" (r = 1). The higher-level controller receives the message "speed below the limit value" (status word 0, bit 15 = 1) 6. Select a higher motor speed than the SSM speed limit. 7. Check the following: The inverter signals: "Speed above the limit value" (r = 0). The higher-level controller receives the message "speed above the limit value" (status word 1, bit 15 = 0) Function Manual, 01/2011, FW 4.4, A5E B AB 175

178 Commissioning 4.9 Acceptance test - Completion of commissioning Completion of certificate Document your machine's data for each drive based on the following specifications. Parameters of the safety functions The function test does not detect all faults in the parameter assignment of safety functions, e.g. forced dormant error detection time or filtering time of fail-safe inputs. Therefore, check all parameters once more. All parameter values checked Designation of the 1st drive Designation of the 2nd drive Checksums of the safety functions The inverter calculates checksums across all parameters and safety functions. The parameters of Basic Safety and Extended Safety have their own checksums. When you change the safety function settings, the inverter calculates new checksums. This means that subsequent changes in your machine can be tracked. In addition to the individual checksums of the parameters, the inverter calculates and saves the following values: 1. The "total" checksum across all checksums. 2. Time of the last parameter changed. Checksums Designation of the 1st drive Basic Safety Extended Safety Total Time stamp Processor 1 Processor 2 Processor 1 Processor 2 [0] = Parameter [1] = Actual values p9798 p9898 p9398[0] p9728[0] r9781[0] r9782[0] p9799 p9899 p9399[0] p9728[1] p9729[0] p9729[1] 176 Function Manual, 01/2011, FW 4.4, A5E B AB

179 Commissioning 4.9 Acceptance test - Completion of commissioning Data backup Storage medium Holding area Type Designation Date Parameter PLC program Circuit diagrams Countersignatures Confirmation that the tests and checks have been carried out properly. Table 4-14 Commissioning engineer Date Name Company/dept. Signature Confirmation that the parameters documented above are correct. Table 4-15 Machine manufacturer Date Name Company/dept. Signature Function Manual, 01/2011, FW 4.4, A5E B AB 177

180 Commissioning 4.9 Acceptance test - Completion of commissioning 178 Function Manual, 01/2011, FW 4.4, A5E B AB

181 Servicing and maintenance Replacing components of the modular SINAMICS G120 inverter Overview of replacing converter components In the event of a permanent function fault, you can replace the converter's Power Module or Control Unit independently of one another. In the following cases, you may immediately switch on the motor again after the replacement. Replacing the Power Module Replacement: Replacement: Replacing the Control Unit with external backup of the settings, e.g. on a memory card Replacement: Replacement: Same type Same type Same type Same type Same power rating Higher power rating Same firmware version higherfirmware version (e.g. replace FW V4.2 by FW V4.3) Power Module and motor must be adapted to one another (ratio of motor and Power Module rated power > 1/8) The converter automatically loads the settings on the memory card into the new CU. If you have saved the settings of your converter on another medium, e.g. on an operator panel or on a PC, then after the replacement, the settings must be loaded into the converter. WARNING In all other cases, you must recommission the drive. Function Manual, 01/2011, FW 4.4, A5E B AB 179

182 Servicing and maintenance 5.1 Replacing components of the modular SINAMICS G120 inverter Replacing the Control Unit After commissioning has been completed, we recommend that you back up your settings on an external storage medium, e.g.: on a memory card or the operator panel. If you do not back up your data, you have to recommission the drive when you replace the Control Unit. Procedure for replacing a Control Unit with a memory card Disconnect the line voltage of the Power Module and (if installed) the external 24 V supply or the voltage for the relay outputs DO 0 and DO 2 of the Control Unit. Remove the signal cables of the Control Unit. Remove the defective CU from the Power Module. Plug the new CU on to the Power Module. The new CU must have the same order number and the same or a higher firmware version as the CU that was replaced. Remove the memory card from the old Control Unit and insert it in the new Control Unit. Reconnect the signal cables of the Control Unit. Connect up the line voltage again. The converter adopts the settings from the memory card, saves them (protected against power failure) in its internal parameter memory, and switches to "ready to start" state. Switch on the motor and check the function of the drive. 180 Function Manual, 01/2011, FW 4.4, A5E B AB

183 Servicing and maintenance 5.1 Replacing components of the modular SINAMICS G120 inverter Procedure for replacing a Control Unit without a memory card Disconnect the line voltage of the Power Module and (if installed) the external 24 V supply or the voltage for the relay outputs DO 0 and DO 2 of the Control Unit. Remove the signal cables of the Control Unit. Remove the defective CU from the Power Module. Plug the new CU on to the Power Module. Reconnect the signal cables of the Control Unit. Connect up the line voltage again. The converter goes into the "ready-to-switch-on" state. If you have backed up your settings: Load the settings from the operator panel or via STARTER into the converter. For converters of the same type and the same firmware version, you can now switchon the motor. Check the function of the drive For different converter types, then the converter outputs alarm A This alarm indicates that the settings that have been loaded are not compatible with the converter. In this case, clear the alarm with p0971 = 1 and recommission the drive. If you have not backed up your settings, then you must recommission the drive. Inverter with enabled safety functions If you replace an inverter with enabled safety functions, then you also need to confirm the safety function settings on the new inverter. You will find the procedure in Section: Downloading parameters (Page 161). Acceptance test If you activated the safety functions in the inverter, after replacing the inverter you must perform an acceptance test for the safety functions. Switch off the inverter supply voltage. Wait until all LEDs on the inverter go dark. Now switch on the inverter power supply again (power on reset). If you commissioned the inverter for the first time, carry out a complete acceptance test, see Complete acceptance test (Page 165). In all other cases, after downloading the parameters into the inverter, carry-out a reduced acceptance test. The reduced acceptance test is described in Section Reduced acceptance test (Page 166). Function Manual, 01/2011, FW 4.4, A5E B AB 181

184 Servicing and maintenance 5.1 Replacing components of the modular SINAMICS G120 inverter Replacing the Power Module Procedure for replacing a Power Module Disconnect the Power Module from the line supply. If being used, switch off the 24 V supply of the Control Unit. DANGER Risk of electrical shock! Hazardous voltage is still present for up to 5 minutes after the power supply has been switched off. It is not permissible to carry out any installation work before this time has expired! Remove the connecting cables of the Power Module. Remove the Control Unit from the Power Module. Replace the old Power Module with the new Power Module. Snap the Control Unit onto the new Power Module. Connect up the new Power Module using the connecting cables. Switch on the line supply and, if being used, the 24 V supply for the Control Unit. If necessary, recommission the drive (also see Overview of replacing converter components (Page 179)). Acceptance test Acknowledge the fault code issued by the inverter. Perform a reduced acceptance test. The necessary measures are described in Chapter Reduced acceptance test (Page 166). 182 Function Manual, 01/2011, FW 4.4, A5E B AB

185 Servicing and maintenance 5.2 Replacing the SINAMICS G120C inverter 5.2 Replacing the SINAMICS G120C inverter Overview of how to replace an inverter You must replace the inverter if it continually malfunctions. In the following cases, you may immediately switch on the motor again after the replacement. Replacing the inverter with external backup of the settings, e.g. on a memory card. The inverter automatically loads the settings on the memory card. If you have saved the settings of your inverter on another medium, e.g. on an operator panel or on a PC, then after the replacement, the settings must be loaded into the inverter. Replacement: Replacement: Replacement: Replacement: Same type Same type Same type Same type Same power rating Same power rating Higher power rating Higher power rating Same firmware version higher firmware version (e.g. replace FW V4.2 by FW V4.3) Same firmware version higher firmware version (e.g. replace FW V4.2 by FW V4.3) Inverter and motor must be adapted to one another (ratio of the motor and inverter rated power > 1/8) WARNING In all other cases, you must recommission the drive. Function Manual, 01/2011, FW 4.4, A5E B AB 183

186 Servicing and maintenance 5.2 Replacing the SINAMICS G120C inverter Replacing the inverter After commissioning has been completed, we recommend that you back up your settings on an external storage medium, e.g.: on a memory card or the operator panel. Without a data backup, you must recommission the drive after replacing the inverter. Procedure to replace an inverter with memory card Disconnect the line voltage to the inverter. DANGER Risk of electrical shock! Hazardous voltage is still present for up to 5 minutes after the power supply has been switched off. It is not permissible to carry out any installation work before this time has expired! Remove the connectors for line, motor and braking resistor of the inverter. Remove the signal cables of the inverter. Remove the defective inverter. Mount the new inverter. Remove the memory card from the old inverter and insert it in the new inverter. Reconnect the signal cables of the Control Unit. Reconnect the connectors for line, motor and braking resistor of the inverter. Connect up the line voltage again. The inverter adopts the settings from the memory card, saves them (protected against power failure) in its internal parameter memory, and switches to "ready to start" state. For inverters of the same type and an equal or higher firmware version, you can switch on the inverter without any additional commissioning. Alarm A01028 will be output for inverters of different types. This alarm indicates that the parameter settings are not compatible with the inverter. In this case, delete the message using p0971 = 1 and recommission the drive. 184 Function Manual, 01/2011, FW 4.4, A5E B AB

187 Servicing and maintenance 5.2 Replacing the SINAMICS G120C inverter Procedure for replacing the inverter without a memory card Disconnect the line voltage of the inverter. DANGER Risk of electrical shock! Hazardous voltage is still present for up to 5 minutes after the power supply has been switched off. It is not permissible to carry out any installation work before this time has expired! Remove the connectors for line, motor and braking resistor of the inverter. Remove the signal cables of the inverter. Remove the defective inverter. Mount the new inverter. Reconnect the signal cables of the inverter. Reconnect the connectors for line, motor and braking resistor of the inverter. Connect up the line voltage again. The inverter goes into the "ready-to-switch-on" state. If you have saved your settings: Load the settings from the Operator Panel or via the STARTER in your inverter. For inverters of the same type and an equal or higher firmware version, you can now switch on the motor. Check the function of the motor. Alarm A01028 will be output for inverters of different types. This alarm indicates that the parameter settings are not compatible with the inverter. In this case, delete the message using p0971 = 1 and recommission the drive. If you did not save the parameter setting, you have to recommission the drive. Inverter with enabled safety functions If you replace an inverter with enabled safety functions, then you also need to confirm the safety function settings on the new inverter. You will find the procedure in Section: Downloading parameters (Page 161). Function Manual, 01/2011, FW 4.4, A5E B AB 185

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