SINAMICS S120 Safety Integrated Extended Functions Fail-Safe Drives Controlling the CU320 from a TM54F and F-CPU

Transcription

1 Functional Example MC-FE-I-005-V11-EN SINAMICS S120 Safety Integrated Extended Functions Fail-Safe Drives Controlling the CU320 from a TM54F and F-CPU

2 Preliminary remark The Functional Examples dealing with Safety Integrated are fully functional and tested automation configurations based on I IA&DT standard products for simple, fast and inexpensive implementation of automation tasks in safety engineering. Each of these Functional Examples covers a frequently occurring subtask of a typical customer problem in safety engineering. Aside from a list of all required software and hardware components and a description of the way they are connected to each other, the Functional Examples include the tested and commented code. This ensures that the functionalities described here can be reset in a short period of time and thus also be used as a basis for individual expansions. Important note The Safety Functional Examples are not binding and do not claim to be complete regarding the circuits shown, equipping and any eventuality. The Safety Functional Examples do not represent customerspecific solutions. They are only intended to provide support for typical applications. You are responsible for ensuring that the described products are used correctly. These Safety Functional Examples do not relieve you of the responsibility of safely and professionally using, installing, operating and servicing equipment. When using these Safety Functional Examples, you recognize that Siemens cannot be made liable for any damage/claims beyond the liability clause described. We reserve the right to make changes to these Safety Functional Examples at any time without prior notice. If there are any deviations between the recommendations provided in these Safety Function Examples and other Siemens publications e.g. Catalogs the contents of the other documents have priority. I DT Safety Integrated Page 2/43 MC-FE-I-005-V11-EN

3 Table of Contents 1 Warranty, Liability and Support Automation function of the function example Advantages / customer benefits Components that are required Hardware Components Software components Engineering software Firmware Configuration and wiring Overview of the hardware configuration Connecting-up the hardware components Connecting-up the control voltage Principle connection between the F-CPU and TM54F DRIVE-CLiQ interconnection Important settings at the hardware components Overview and operator control of the operator control Summary of the input signals Project example Passwords Hardware configuration of the fail-safe control Programming the fail-safe control SINAMICS parameterization of the motion functions Parameterizing the control of the safety functions (TM54F) Parameterizing the safety functions integrated in the drive Acceptance test History I DT Safety Integrated Page 3/43 MC-FE-I-005-V11-EN

4 1 Warranty, Liability and Support We accept no liability for information contained in this document. Any claims against us based on whatever legal reason resulting from the use of the examples, information, programs, engineering and performance data etc., described in this Safety Functional Example shall be excluded. Such an exclusion shall not apply in the case of mandatory liability, e.g. under the German Product Liability Act ( Produkthaftungsgesetz ), in case of intent, gross negligence, or injury of life, body or health, guarantee for the quality of a product, fraudulent concealment of a deficiency or breach of a condition which goes to the root of the contract ( wesentliche Vertragspflichten ). However, claims arising from a breach of a condition which goes to the root of the contract shall be limited to the foreseeable damage which is intrinsic to the contract, unless caused by intent or gross negligence or based on mandatory liability for injury of life, body or health. The above provisions do not imply a change in the burden of proof to your detriment. Copyright 2009 Siemens I DT. It is not permissible to transfer or copy these Application Examples or excerpts of them without first having prior authorization from Siemens I DT in writing. For questions about this document please use the following -address: Online-support.automation@siemens.com I DT Safety Integrated Page 4/43 MC-FE-I-005-V11-EN

5 2 Automation function 2.1 of the function example The following safety functions according to IEC have been integrated into SINAMICS S120 drives: Name Function STO Safe Torque Off The torque-generating power feed to the motor is disconnected in a safety-relevant fashion Restart is interlocked using a restart/power-on inhibit. (Category 0 stop function acc. to EN ) SBC Safe Brake Control SBC is only used when there is a motor brake; the motor brake is connected to the power connector via the outputs. SBC always responds in conjunction with STO or when internal safety monitoring functions respond with safety-relevant pulse cancellation. SS1 Safe Stop 1 The drive is quickly stopped along the OFF3 ramp and is monitored in a safety-relevant fashion at the same time After a delay time has expired or the shutdown speed is reached, a transition is made to STO (Category 1 stop function acc., to EN ) SS2 Safe Stop 2 The drive is quickly stopped along the OFF3 ramp and is monitored in a safety-relevant fashion at the same time After a delay time has expired or the shutdown speed is reached, a transition is made to SOS; the drive remains in closed-loop control (Category 2 stop function acc., to EN ) SOS Safe Operating Stop This function is used to safely monitor the standstill position of a drive. The drive remains in closed-loop control. SLS Safely-Limited Speed The drive speed is safely monitored Parameterizable shutdown response when the limit value is violated SSM Safe Speed Monitor Safety-relevant display when a speed limit is fallen below (n < nx) The control of these extended safety functions can be realized using PROFIsafe with PROFIBUS and also using a TM54F terminal expansion module. I DT Safety Integrated Page 5/43 MC-FE-I-005-V11-EN

6 Task description The extended safety functions integrated in the SINAMICS S120 drives are to be controlled from a TM54F via hardware signals. The drives belong to different drive groups. The safety-relevant logical pre-processing of the input signals is handled in an F-CPU. This application should comply with SIL 2 acc. to EN 62061:2005, ISO :2006 PL d or EN 954-1:1996 Category 3. Solution Hardware overview The control of the safety functions SS1 and SLS via the TM54F terminal expansion module connected to a SINAMICS S120 drive group is shown in this function example. The SLS initiates a Stop C (SS2 SOS) as response to the fault at the particular drive. The drive group in the booksize format comprises an infeed and a Double Motor Module. The motor is controlled using a CU320 Control Unit. The expanded setpoint channel is used to enter the speed setpoint. The two servomotors that are independent of one another are controlled by the Double Motor Module. A Smart Line Module is used as infeed. The safety-relevant signals are detected using the fail-safe inputs of an F- CPU and are then evaluated in the F-CPU. The pre-processed signals are transferred to the TM54F terminal expansion module via the fail-safe outputs of the F-CPU. This means that the safety functions integrated in the drive are controlled in the SINAMICS S120. I DT Safety Integrated Page 6/43 MC-FE-I-005-V11-EN

7 When an Emergency Stop is requested, both of the drives are stopped by the SS1 safety function integrated in the drive. The torque-generating power feed to the motor is interrupted in a safety-relevant fashion using safe pulse cancellation. The restart inhibit is activated. Each drive is assigned a safety door. If this safety door is opened, then the associated motor is operated at a lower speed and the set speed limit value is safely monitored using the SLS function. The other drive is not influenced. Other ways of using the TM54F terminal expansion module and controlling the safety functions via PROFIsafe are described in additional function examples. 2.2 Advantages / customer benefits The safety functions integrated in the drive are controlled in a simple fashion Simple design/configuring using standardized technology The existing system can be simply and quickly expanded. Space-saving configuration using integrated safety functions additional hardware is not required Complex safety concepts can be implemented using this as basis. I DT Safety Integrated Page 7/43 MC-FE-I-005-V11-EN

8 3 Components that are required The hardware components and software versions that are required to implement this function example are listed in this chapter. 3.1 Hardware Components Table 3-1 Components Type Order No./Ordering data Qty. Manufact. Power supply PS307 5A 6ES7 3071EA00-0AA0 1 Siemens IM151-7 F-CPU 6ES FA01-0AB0 1 Siemens SIMATIC ET200S CPU SIMATIC Micro Memory Card, 6ES LJ11-0AA0 Siemens 1 512KB SIMATIC ET200S Power Module SIMATIC ET200S fail-safe input module SIMATIC ET200S fail-safe output module F-CPU operator components PM-E 6ES CB10-0AB0 1 Siemens SIMATIC DP, Terminal Module TM-P15C23-A0 6ES CD30-0AA0 1 Siemens F-DI 4/8 6ES FA02-0AB0 1 Siemens SIMATIC DP, Terminal Module TM-E30C ES CG30-0AA0 1 Siemens F-DO 4 6ES FB01-0AB0 1 Siemens SIMATIC DP, Terminal Module TM 6ES CG30-0AA0 1 Siemens Components Type Order No./Ordering data Qty. Manufact. Empty pushbutton housing Emergency Stop command device -S3 Reset button -S4 Safety door/gate simulation switch -S1 Safety door/gate simulation switch -S2 Empty housing for 4 command positions, pushbutton in the enclosure, for metric gland, gray cover 3SB3 mushroom pushbutton (Ø 32 mm), plastic, round with holder Base element, 1OE, screw connection 3SB3 illuminated pushbutton with flat actuator knob, green, with holder 3SB AA3 1 Siemens 3SB FA20 1 Siemens 3SB C 2 Siemens 3SB AA41 1 Siemens Base element 1S, screw connection 3BS B 1 Siemens Lamp socket with integrated LED for base mounting, green, 24V DC 3SB PC 1 Siemens 3SB3 knob-operated switch, I-0-II, latching, 2x50 switching angle, black, not illuminated, with holder 3SB DA11 1 Siemens Base element 1S, screw connection 3BS B 2 Siemens 3SB3 knob-operated switch, I-0-II, 3SB DA11 1 Siemens latching, 2x50 switching angle, black, not illuminated, with holder Base element 1S, screw connection 3BS B 2 Siemens I DT Safety Integrated Page 8/43 MC-FE-I-005-V11-EN

9 SINAMICS operator components Components Type Order No./Ordering data Qty. Manufact. Empty pushbutton housing Drives, ON/OFF1 switch -S6 Reset button -S7 Max. speed button -S8 Empty housing for 4 command positions, pushbutton in the enclosure, for metric gland, gray cover 3SB AA3 1 Siemens Round actuator knob, O-I, latching, 50 switching angle, black with holder, not illuminated 3SB3000-2KA11 1 Siemens Base element 1S, screw connection 3BS B 1 Siemens Actuator, round pushbuttoon with 3SB3000-0AA11 1 Siemens flat actuator, black with holder, not illuminated Base element 1S, screw connection 3BS B 1 Siemens Actuator, round pushbuttoon with 3SB3000-0AA11 1 Siemens flat actuator, black with holder, not illuminated Base element 1S, screw connection 3BS B 1 Siemens Drive Components Type Order No./Ordering data Qty. Manufact. SINAMICS CU320 CU320 6SL MA00-0AA1 1 Siemens Compact Flash card for SINAMICS CU320 6SL3054-0CE01-1AA0 1 Siemens SINAMICS safety license SINAMICS license, Safety Integrated extended functions for CompactFlash card 6SL3074-0AA10-0AA0 2 Siemens SINAMICS Smart Line Module SLM 5 kw / 230 V 6SL3130-6AE15-0AA0- Z=220V 1 Siemens SINAMICS Terminal Module TM54F 6SL AA00-3BA0 1 Siemens Load resistors R1.. R8 Load resistor terminals (R1..R8) SINAMICS Double Motor Module Motors DRIVE-CLiQ cable TM54F to CU320: DRIVE-CLiQ cable SLM zu CU320: DRIVE-CLiQ cable DMM to CU320: Signal cable DMM to Motor1: 1kOhm 1W Type PO595-0 Style 0207 Power Metaloxide film resistors 8 Yageo Europe ST 2,5-QUATTRO-TG Phoenix Contact Component plug P-CO Phoenix Contact DMM 6SL TE21-0AA3 1 Siemens Synchronous servomotor 1FK7 COMPACT, 3000 rpm, 0.82 kw Synchronous servomotor 1FK7 COMPACT, 3000 rpm, 0.82 kw SINAMICS DRIVE-CLiQ cable IP20/IP20 length: 0.41 m SINAMICS DRIVE-CLiQ cable IP20/IP20 length: 0.41 m SINAMICS DRIVE-CLiQ cable IP20/IP20 length: 0.41 m Pre-fabricated signal cable (SINAMICS DRIVE-CLiQ) connector IP20/IP67, with 24 V MOTION- CONNECT 500 length (M) = 2 1FK AF71-1FG0 1 Siemens 1FK AF71-1DG0 1 Siemens 6SL3060-4AP00-0AA0 1 Siemens 6SL3060-4AP00-0AA0 1 Siemens 6SL3060-4AP00-0AA0 1 Siemens 6FX5002-2DC10-2AA0 1 Siemens I DT Safety Integrated Page 9/43 MC-FE-I-005-V11-EN

10 Components Type Order No./Ordering data Qty. Manufact. Signal cable DMM to Motor2: Power cable DMM to motor1: Power cable DMM to motor2: Pre-fabricated signal cable (SINAMICS DRIVE-CLiQ) connector IP20/IP67, with 24 V MOTION- CONNECT 500 length (M) = 2 Pre-fabricated power cable (1FT/1FK/1PH to SINAMICS) 4x1.5 C, connector size 1/1.5 mm 2 UL/CSA DESINA, MOTION- CONNECT 500 Dmax=11.5 mm, length (m) = 2 Pre-fabricated power cable (1FT/1FK/1PH to SINAMICS) 4x1.5 C, connector size1/1.5 mm 2 UL/CSA DESINA, MOTION-CONNECT 500 Dmax=11.5 mm, length (m) = 2 6FX5002-2DC10-2AA0 1 Siemens 6FX5002-5CS01-1AC0 1 Siemens 6FX5002-5CS01-1AC0 1 Siemens Note The function example was tested with the hardware components listed here. Other components that have the same function can be alternatively used. If other components are used it may be necessary to use a different parameterization and also change the component wiring. 3.2 Software components Engineering software Table 3-2 Components Type Order No./Ordering data Qty. Manufact. STEP 7 V5.4 SP2 6ES7810-4CC08-0YA5 1 Siemens S7 Distributed Safety Programming V5.4 SP3 6ES7833-1FC02-0YA5 1 Siemens STARTER V4.1 SP1 6SL3072-0AA00-0AG0 1 Siemens or, as an alternative to the STARTER software: SIMOTION SCOUT V4.1 SP1 6AU1810-1BA41-1XA0 1 Siemens Firmware All of the SINAMICS components must have firmware release V2.5 SP1 or higher. I DT Safety Integrated Page 10/43 MC-FE-I-005-V11-EN

11 4 Configuration and wiring 4.1 Overview of the hardware configuration Basic configuration I DT Safety Integrated Page 11/43 MC-FE-I-005-V11-EN

12 4.2 Connecting-up the hardware components Connecting-up the control voltage 24V DC wiring I DT Safety Integrated Page 12/43 MC-FE-I-005-V11-EN

13 4.2.2 Principle connection between the F-CPU and TM54F Connecting F-DO P/M switching (F-CPU) F-DI (TM54F) Load resistor dimensioning If the manufacturer documentation contains specific conditions for the digital output, for example, a minimum load resp. a maximum load resistor, these must be considered accordingly. For example, a maximum load of 1kΩ is specified for SIMATIC ET200S I/O module 4 F-D. As a result, two additional 1 kω load resistors with a permanent load capacity of at least P = U²/R = (28.8V)²/1 kω = 830 mw are required for connecting such an F-DO to a TM54F F-DI. Note: When using closed-loop controlled SITOP power supply units, the voltage tolerance on the 24V side is significantly lower than the maximum admissible tolerance of +20% for the supply voltage at the ET200S modules. In this case, the power transformed at the resistor is lower than the maximum power calculated above. I DT Safety Integrated Page 13/43 MC-FE-I-005-V11-EN

14 4.2.3 DRIVE-CLiQ interconnection DRIVE-CLiQ interconnection I DT Safety Integrated Page 14/43 MC-FE-I-005-V11-EN

15 4.3 Important settings at the hardware components In this function example, the PROFIBUS interfaces of the F-CPU and the CU320 are only used for programming. The safety-relevant signal exchange between the F-CPU and TM54F is only realized through the hardwired 24V signals. SINAMICS Control Unit CU320 PROFIBUS address = 3 The PROFIBUS address is set at the DIL switch below the blind cover of the Control Unit. SIMATIC IM151-7 F-CPU PROFIBUS address = 4 When commissioning the system, the programming device must be configured as the only master connected to the bus. I DT Safety Integrated Page 15/43 MC-FE-I-005-V11-EN

16 Prerequisites for operation The SIMATIC ET200S components must be mounted and connected with one another, latched on the mounting rail. The PROFIsafe addresses of the fail-safe input and output modules must be set using the DIL switch; also refer to Chapter 6.2 Hardware configuration of the fail-safe control. All of the components are connected-up as explained in Chapter 4.2 Connecting-up the hardware components. The DRIVE-CLiQ topology of the SINAMICS components is carefully observed. The motors are connected to the Motor Module using the power and encoder cables. The Motor Module is correctly connected to the infeed (DC link and 24 V DC control voltage). The infeed is connected to the line supply. The components are supplied with 24 V DC. I DT Safety Integrated Page 16/43 MC-FE-I-005-V11-EN

17 5 Overview and operator control 5.1 of the operator control Hardware overview The Emergency Stop pushbutton S3 is released to power-up the system. The safety function SS1 is de-selected at both drives using reset button S4 via output F-DO 0 of the F-CPU; pulse cancellation at the drives is withdrawn. The drives can then be moved (operated) using the knob-operated switch S6. When safety door 1 is closed (knob-operated switch -S1, ON switch position), drive 1 rotates with n=800 rpm. If safety door 1 (switch S1) is opened, the data set is changed-over in drive 1 and for drive 1 the setpoint speed is n=20 rpm. When switch -S1 is opened, the SLS safety function in drive 1 is activated. By closing safety door 1, a speed of n=800 rpm is again entered (speed setpoint). Drive 2 is not influenced. If safety door 2 is closed (knob-operated switch S2, switch position ON) then a setpoint speed of n=333 rpm is entered for drive 2. If safety door 2 (switch S2) is opened, then drive 2 has a speed setpoint of n=33 rpm as the data set is changed-over. When switch S2 is open, the SLS safety function in drive 2 is activated. By closing safety door 2, a speed setpoint of n=333 rpm is again entered. Also in this case, drive 1 is not influenced. If safety door 1 (knob-operated switch S1, center position) is opened, then the SLS function is activated for drive 1. Drive 2 is not influenced. When opening safety door 2 (knob-operated switch -S2, center position) the SLS function for drive 2 is activated. I DT Safety Integrated Page 17/43 MC-FE-I-005-V11-EN

18 The motors rotate in opposite directions. When button S8 is pressed, the drives receive a higher setpoint - independent of the position of the safety door. For drive 1, n=1000 rpm and for drive 2, n=666 rpm. When the safety door is open, then an SLS limited value is violated and the drive involved is stopped using an internal SS2 (Stop C), and for n=0 rpm is brought into SOS. In order to continue to operate the drive, the alarm, initiated by the internal SS2 (Stop C) as well as the "Internal Event" message signal in the TM54F must be acknowledged using the S4 reset button. 5.2 Summary of the input signals Digital inputs of the CU320 DI0 Digital input CU320 DI1 DI2 DI3 ON/OFF1 (1 signal, positive signal edge) and stopping (0 signal) (switch S6) Acknowledgement of the SINAMICS fault messages (1 signal, pushbutton S7) A higher setpoint speed is entered (1 signal, pushbutton S8) Both drives are started The SINAMICS fault messages are acknowledged at all of the drive objects A high setpoint speed is entered; this is used to violate the SLS limit as simulation (1 signal) I DT Safety Integrated Page 18/43 MC-FE-I-005-V11-EN

19 F-DIs of the F-CPU F-DI0/F-DI4 Emergency Stop pushbutton SS1 in both drives F-DI1 Reset button Acknowledges the Emergency Stop function Acknowledges an Internal Event in TM54F F-DI2/F-DI6 Protective door_1 open SLS_door_1 0 signal; drive_1 operates at a low speed. SLS in drive 1 activated F-DI3/F-DI7 Note Protective door_1 closed Protective door_2 open Protective door_2 closed SLS_door_1 1 signal; drive_1 operates at the normal speed. SLS in drive 1 not activated. SLS_door_2; drive_2 operates at a low speed. SLS in drive_2 activated SLS_door_2 1 signal; drive_2 operates at the normal speed. SLS in drive_2 not activated. The drives can only be operated when the infeed is powered-up and the DC link is charged. I DT Safety Integrated Page 19/43 MC-FE-I-005-V11-EN

20 6 Project example In this chapter, you will learn how the individual components must be parameterized. Both STARTER as well as also SIMOTION SCOUT can be used as engineering software for SINAMICS S120. Distributed Safety is required to program the F-CPU. A description is subsequently given as to how the software project associated with this function example was set-up. 6.1 Passwords For reasons of simplicity, in the project, one common safety password is used for the SIMATIC components for both the program and hardware. One password is also used for the safety configuring of the SINAMICS components for the drives and for the TM54F terminal expansion module. Safety password on the F-CPU: "0" Safety password on SINAMICS: "1" These passwords should be changed for real applications! I DT Safety Integrated Page 20/43 MC-FE-I-005-V11-EN

21 6.2 Hardware configuration of the fail-safe control In the SIMATIC Manager, insert a SIMATIC 300 station into the project. In the HW Config, completely set-up and parameterize the station. To do this, drag the modules contained in the parts list from the catalog window and drop them into the configuration window. I DT Safety Integrated Page 21/43 MC-FE-I-005-V11-EN

22 In the properties window of the F- CPU, under the "Protection" tab, activate the access protection for the F-CPU and protect using a password. Activate the safety program ("CPU contains safety program.") Set (binary) the PROFIsafe address (F_dest_address) at the particular module at the DIL-switch. For the fail-safe digital inputs, activate the channels used and for each channel, set the appropriate evaluation of the encoder. I DT Safety Integrated Page 22/43 MC-FE-I-005-V11-EN

23 For the fail-safe digital outputs, activate the channels that are being used and deselect the wire breakage diagnostics (the input current for the F-DIs of the TM54F is too less). Then compile and save the HW config. After that download this to the F-PLC Programming the fail-safe control In this example, the safety program in the F-CPU is executed in the failsafe FB1 function block. In order to clearly show the functions, a simple program sequence was selected. Please refer to the appropriate function examples and the manuals for Distributed Safety when complex safety logic functions are involved as well as a list of the limitations/constraints when writing the safety program. Make the following settings in the menu bar under Options/ Edit_Safety program/ F_Run-time groups: F_CALL: FC1 F_PROGRAM: FB1 IDB_F_PROGRAM: DB1 CALL in: OB35 Max. cycle time: 200 ms Call time: 100 ms Then generate the safety program and download to the module. I DT Safety Integrated Page 23/43 MC-FE-I-005-V11-EN

24 Enter the input and output variables in the symbol table. The safety program is executed in FB1. Re-integrate the F-modules I DT Safety Integrated Page 24/43 MC-FE-I-005-V11-EN

25 Emergency Stop analysis and output SLS_door1 signal at TM54F SLS_door2 signal at TM54F I DT Safety Integrated Page 25/43 MC-FE-I-005-V11-EN

26 Connect the Internal Event Acknowledge signal in the TM54F. Save FB1. In the SIMATIC Manager regenerate the modified safety program under "Options" > "Edit safety program" and then download to the target system (e.g. PLC). 6.4 SINAMICS parameterization of the motion functions The hardware in the drive system must first be commissioned and the required motion function set-up. Commissioning the hardware Open the STARTER program. Go online. I DT Safety Integrated Page 26/43 MC-FE-I-005-V11-EN

27 Perform the automatic first commissioning for the drive group. Select "Servo" as the drive object type. Complete the automatic configuration. Save the project. Test both of the drives. To do this, start both of the drives from the control panel. Start the drives from the control panel; if required, the automatic net (useful) data identification is performed at the start. I DT Safety Integrated Page 27/43 MC-FE-I-005-V11-EN

28 Operate drive_1 from the operator panel. Operate drive_2 from the operator panel. Execute "Download to PG".to save the current project version in the PG Then save the project. I DT Safety Integrated Page 28/43 MC-FE-I-005-V11-EN

29 Commissioning the motion functions (without safety) First - manually perform the post configuration. For the drives, under Control structure, activate the "Extended setpoint channel". As the 5 kw SLM has no DRIVE- CLiQ interfaces, parameterization is not required. I DT Safety Integrated Page 29/43 MC-FE-I-005-V11-EN

30 To power-up and power-down the drive, under Drive / Control logic / Control word_ execution control, interconnect parameter p840[0].0 with "CU, r722.1". DI1 is simultaneously interlocked with ON/OFF1 for drive 1 and drive 2. In order to be able to acknowledge possible fault messages/signals, under CU320 / Inputs/outputs, interconnect input DI2 with the following parameters: CU, p2103 SERVO_01, p2103[0] SERVO_02, p2103[0] TM54F_MA_05, p2103 TM54F_SL_06, p2103 Interconnect input DI3 with the fixed speed setpoint bit3 for both drives. SERVO_01, p1023[0] SERVO_02, p1023[0] Enter the speeds of the drives for normal operation and for the SLS safety function. To do this, open the appropriate setting window under Drives / Setpoint Channel / Fixed setpoints. I DT Safety Integrated Page 30/43 MC-FE-I-005-V11-EN

31 For drive_1 set the following: Bit0: Control Unit DI1 Bit1: TM54F F-DI1 Bit2: 0 Bit3: Control Unit DI3 Fixed value 1 : 20 rpm Fixed value 3 : 800 rpm Fixed value 9 : 1000 rpm Fixed value 11 : 1000 rpm Explanation: If the "SLS_door1" signal is active (in the diagram: "High"), the safety door is closed and the high speed setpoint is entered. For a low signal, a changeover is made from a high speed (setpoint) to a low speed (setpoint). By pressing S8, when the drive is operational, independent of the state of the safety door, a fixed speed of n=1000 rpm is entered (speed setpoint). The drive can only operate for a 1 signal at bit 0. The reason for this is that DI1 of the Control Unit is also interconnected with ON/OFF1. Set the OFF3 ramp-down time and the standard ramp-down time under the point Setpoint Channel / Ramp-function generator. I DT Safety Integrated Page 31/43 MC-FE-I-005-V11-EN

32 Press the button. Set the ramp-down time (p1121) so that when SLS is selected, the drive is below the SLS limit value within p9551. The OFF3 ramp-down time (p1135) is used to brake for SS1. I DT Safety Integrated Page 32/43 MC-FE-I-005-V11-EN

33 For drive_2 set the following: Bit0: Control Unit DI1 Bit1: TM54F F-DI2 Bit2: 0 Bit3: Control Unit DI3 Fixed value 1 : 33 rpm Fixed value 3 : 333 rpm Fixed value 9 : 666 rpm Fixed value 11 : 666 rpm Explanation: If the "SLS_door2" signal is active (in the diagram: "High"), then a changeover is made from a high speed (setpoint) to a low speed (setpoint). By pressing S8, independent of the state of the safety door, a fixed speed of n=666 rpm is entered. Save the project and compile. Go online. Download the project into the target device (e.g. PLC) and copy RAM to ROM. You can now operate the drives (without safety functions). This is realized with a positive signal edge at DI1. I DT Safety Integrated Page 33/43 MC-FE-I-005-V11-EN

34 6.5 Parameterizing the control of the safety functions (TM54F) Open the safety configuration window in STARTER under Input/output component / TM54F / Safety Integrated. Go online. Click on "Change settings" (this is only possible in the online mode!). Enter a security password (When commissioning the system for the first time: "0"). Click on "Configuration". I DT Safety Integrated Page 34/43 MC-FE-I-005-V11-EN

35 Enter Drive_1 under Drive group_1 and Drive_2 under Drive group_2. Interconnect input F-DI3 to "Acknowledge internal event". The falling edge at this input resets the "Internal event" status in the drives. Then, re-close the configuration window. Under "Inputs" you will obtain an overview of the states of the F-DIs connected to the TM54F. For this particular function example, all of the fail-safe inputs used should be parameterized as NC/NC contact. I DT Safety Integrated Page 35/43 MC-FE-I-005-V11-EN

36 If required, define the interconnections for the safety functions in the Drive group windows. All of the functions are "statically active (0)" in the default state. In this example the SS1 function is interconnected with F-DI0 and SLS with F-DI1 in Drive group_1 (this involves Drive_1). Set safety functions STO, SS2 and SOS to the state "Statically inactive (255)". In this example, the SS1 function is interconnected with F-DI0 and SLS with F-DI2 in Drive group_2 (this involves Drive_2). Set safety functions STO, SS2 and SOS to the state "Statically inactive (255)". I DT Safety Integrated Page 36/43 MC-FE-I-005-V11-EN

37 To accept the settings that have been made, click on "Copy parameters". Click on "Activate settings". When commissioning the project for the first time, you will be prompted to change the safety password. The default password when commissioning the project for the first time is "0" The password can be up to 8 characters long and is saved in the hexadecimal format. Acknowledge the message opposite with "Yes". Data is copied from RAM to ROM. To save the current project status in the PG, execute "Download to PG" and then save the project. Then, carry-out a power-on reset of the Control Unit. POWER ON 6.6 Parameterizing the safety functions integrated in the drive Before you start the actual parameterization process: Restart the system (new start). POWER ON I DT Safety Integrated Page 37/43 MC-FE-I-005-V11-EN

38 Open the corresponding configuration window in STARTER under Drives / Drive_xy / Functions / Safety_Integrated. Go online. In order to activate the safety functions set in the TM54F, proceed as follows: Click on the "Change settings" button. Change over the control selection to "Motion Monitoring via TM54F". Acknowledge the message with "OK". I DT Safety Integrated Page 38/43 MC-FE-I-005-V11-EN

39 The safety configuration window for the drive opens. The particular configuration window can be opened in which you can make the appropriate parameter settings using the various buttons. In the "Configuration" window, ensure that the correct drive type has been entered. The encoder data of the drive are entered in the "Encoder parameterization" window. Note: If, in the application, only the motor encoder is used, then for "2nd encoder" the same settings are entered as for "1st encoder". I DT Safety Integrated Page 39/43 MC-FE-I-005-V11-EN

40 Enter the adjacent values in the "Safe stops" screen form. The delay time SS1 -> pulse cancellation (p9556) must be selected so that when the drive decelerates from the maximum speed of the application down to standstill (zero speed), this time is not exceeded. The value of this parameter is, among other things, dependent on the load moment of inertia. The shutdown speed SS1 (p9560) is set to n = 0/min. In the screen form "Safely limited speed (SLS)" - enter the maximum limit speed (limit speed: when the safety door is opened, the speed that is still permissible) Only stage 1 is used for the speed monitoring function. Further, the stop response that is initiated when the limit value is exceeded should be selected. The drive speed must be below the limit value n_max. within the delay time "Select SLS -> SLS active" (p9551), Enable/activate the safety functions. I DT Safety Integrated Page 40/43 MC-FE-I-005-V11-EN

41 In order to accept the settings that have been made, click on Copy parameters. After the parameters have been correctly accepted: Click on the "Activate settings" button. (also in this case, change the password when commissioning the project for the first time) Click on "Axis parameters" to save the changes in the drive. Acknowledge the following message with "Yes". The data is copied from the RAM to ROM. To save the actual project status in the PG, carry-out "Download to PG" and then save the project. Acknowledge any messages regarding the acceptance test; also refer to Chapter 6.7 Acceptance test Then carry-out a power-on reset of the Control Unit. Repeat this procedure for the second drive! POWER ON Refer to Chapter 6.6 Parameterizing the safety functions integrated in the drive I DT Safety Integrated Page 41/43 MC-FE-I-005-V11-EN

42 Especially note the following settings for Drive 2: Enter the adjacent values in the "Safe stops" screen form. Select the delay time SS1 Pulse cancellation (p9556) so that when the drive decelerates from the maximum speed of the application down to standstill (zero speed) this time is not exceeded. The value of this parameter depends among other things on the load moment of inertia. Set the shutdown speed SS1 (p9560) to n = 0/min. In the screen form "Safely limited speed - enter the maximum limit speed, which is permissible when the safety door is open. Only use stage 1 for the speed monitoring function. Further, the stop response that is initiated when the limit value is exceeded should be selected. The drive speed must be below the limit value n_max. within the delay time "Select SLS -> SLS active" (p9551). To save all of the changes, click on "Entire project". You can operate the drives when the Emergency Stop has been deselected if you have performed the safety commissioning for all drives, then. I DT Safety Integrated Page 42/43 MC-FE-I-005-V11-EN

43 The use of the safety functions integrated in the drive has been selected and these can now be activated or deactivated using the operator elements at the F-CPU. Only the following messages should be visible These messages doe not influence the functionality described above. 6.7 Acceptance test To verify the safety-related parameters, when commissioning the machine for the first time and also when making changes to the safety-relevant parameters, an acceptance test must be carried-out. It is imperative that the acceptance test must be correspondingly logged and documented. The acceptance reports should be appropriately stored and archived. The acceptance test must be performed after parameterization has been completed and power-on reset. Information about the acceptance test, the acceptance report and an example of corresponding acceptance report are provided in the "Function Manual SINAMICS S120 Safety Integrated" (FHS) in the chapter, Acceptance test and acceptance report. 7 History Table 7-1 History Version Date Revision V First edition V Second edition I DT Safety Integrated Page 43/43 MC-FE-I-005-V11-EN