Siemens SINUMERIK 840D Description Of Functions Download Page 41

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11.03

2 General Information about Integrated Safety Systems

2.9 System prerequisites

© Siemens AG 2003 All Rights Reserved
SINUMERIK 840D/SIMODRIVE 611 digital SINUMERIK Safety Integrated (FBSI) - Edition 11.03

2-41

2.9.1 Order

numbers

Table 2-6

SINUMERIK 840D

NCU modules

Order No.:

NCU 561.4

6FC5356-0BB12-0AE0

NCU 571.4

6FC5357-0BB12-0AE0

NCU 572.4

6FC5357-0BB23-0AE0

NCU 573.4

6FC5357-0BB34-0AE0

NCU 573.5

6FC5357-0BB35-0AE0

Software option SINUMERIK Safety
Integrated

Basic function up to 4 axes/spindles

6FC5250-0AC10-0AA0

Additional function from the 5th axis/spindle
onwards

6FC5250-0AC11-0AA0

Axis/spindle pack for additional 13 axes/
spindles

6FC5250-0AC12-0AA0

NCK I/Os

NCU terminal block

6FC5211-0AA00-0AA0

DMP Compact 16A, 24V, DC

6FC5111-0CA01-0AA0

DMP Compact 16A, 24V, DC, 0.5A

6FC5111-0CA02-0AA2

DMP Compact 8A, 24V, DC, 2A

6FC5111-0CA03-0AA2

Accessories

Cable distributor

6FX2006-1BA02

Software option
for I/O interface via PROFIBUS DP

6FC5252-0AD00-0AA0

Simple I/O module

6FC5411-0AA00-0AA0

Table 2-7

SIMODRIVE 611 digital

Designation Order

No.:

High-standard – 2 axis

6SN1118-0DM33-0AA0

High-performance – 1 axis

6SN1118-0DJ23-0AA0

High-performance – 2 axis

6SN1118-0DK23-0AA0

SINUMERIK 840D

SIMODRIVE 611 digital

Summary of Contents for SINUMERIK 840D

Page 1: ...Description of Functions 11 03 Edition sinumerik simodrive SINUMERIK Safety Integrated SINUMERIK 840D SIMODRIVE 611 digital ...

Page 2: ......

Page 3: ...ions 3 Data Description 4 Commissioning 5 Alarms 6 Engineering Examples 7 Application Examples 8 Appendix A Index I SINUMERIK 840D SIMODRIVE 611 digital SINUMERIK Safety Integrated Description of Functions Valid for Control Software version SINUMERIK 840D SIMODRIVE 611 digital 6 4 Edition 11 03 ...

Page 4: ...More information is available on the Internet at http www ad siemens com sinumerik This publication was produced with WinWord V8 0 and Designer V7 0 and the documentation tool AutWinDoc The reproduction transmission or use of this document or its contents is not permitted without express written authority Offenders will be liable for damages All rights including rights created by patent grant or r...

Page 5: ... siemens com Please send any queries about the documentation suggestions or corrections to the following fax number or email address Fax 49 0 9131 98 2176 E mail motioncontrol docu erlf siemens de Fax form Refer to the reply form at the end of the document http www ad siemens com sinumerik From 09 2001 SINUMERIK 840D powerline and SINUMERIK 840DE powerline will be available with improved performan...

Page 6: ...e number where you will find the information you need are listed in this chapter Note Documentation with Edition date 08 97 describes the scope of functions of the following products and SW versions SINUMERIK 840D 611 digital with software version 4 2 SINUMERIK 840C 611 digital with software version 6 1 The following functions added since 04 96 Edition are described in 08 97 Edition for SINUMERIK ...

Page 7: ...in 05 00 Edition for SINUMERIK 840D 611 digital Table 0 3 New functions described in 05 00 Edition Serial No New functions in SINUMERIK 840D 611 digital 1 SPL expansions Chapter 3 2 Drive systems with slip Chapter 3 3 Setpoint velocity limiting Chapter 3 4 Engineering examples Chapter 7 extended 5 Application examples Chapter 8 extended Note The documentation with Edition date 03 01 describes the ...

Page 8: ...e 11 03 describes the scope of functions of the following products and software version SINUMERIK 840D with software version 6 4 The following functions added since the 07 02 Edition are described in the 11 03 Edition for SINUMERIK 840D 611 digital Table 0 6 New functions described in 11 03 Edition Serial No New functions in SINUMERIK 840D 611 digital 1 ProgEvent Chapter 3 10 10 2 STOP E Chapter 3...

Page 9: ...esult if proper precautions are not taken Notice This symbol indicates that an undesirable result or state may result if proper precautions are not taken Important This notice indicates important facts that must be taken into consideration Note Always appears in this document where further explanatory information is provided IBM is a registered trademark of the International Business Corporation M...

Page 10: ...ord 11 03 Siemens AG 2003 All Rights Reserved x SINUMERIK 840D SIMODRIVE 611 digital SINUMERIK Safety Integrated FBSI Edition 11 03 Fig 0 1 Type examination certificate symbol for SINUMERIK 840D 611 digital ...

Page 11: ...ertificate for SINUMERIK 840D and 840DE with SIMODRIVE 611 digital SINUMERIK Safety Integrated The appendices to the type examination certificate are not included in this document If you require any data from this Appendix please contact the department named on the Corrections Suggestions sheet last page Type examination certificate for SINUMERIK 840D 611 digital ...

Page 13: ...ition paper of the working group WG 226 03 in the German Electrotechnical Commission DKE 2 31 2 5 Technical Bulletin about vertical axes from the German Trade Association 2 31 2 6 Basics of SINUMERIK Safety Integrated 2 32 2 6 1 Control category 3 2 32 2 6 2 Basic features of SINUMERIK Safety Integrated 2 33 2 6 3 Forced checking procedure 2 33 2 6 4 Monitoring clock cycle and crosswise data compa...

Page 14: ...speed 3 96 3 5 3 Safely reduced speed when using selector gearboxes 3 97 3 5 4 Effects when the limit value is exceeded for SG 3 98 3 5 5 SG specific stop responses 3 99 3 5 6 Override for safely reduced speed 3 100 3 5 7 Example Override for safely reduced speed 3 102 3 5 8 Application examples for SG 3 103 3 5 9 Examples for safe input of ratios 3 103 3 5 10 Overview of the machine data for the ...

Page 15: ... 5 2 and lower 3 176 3 12 SI I Os using fail safe modules connected to PROFIBUS DP 840D from SW 6 3 30 3 179 3 12 1 Description of functions 3 179 3 12 2 Available fail safe modules 3 180 3 12 3 System prerequisites 3 181 3 12 4 System structure 3 182 3 12 5 Configuring and parameterizing the ET 200S F I O 3 183 3 12 6 Parameterizing SINUMERIK 840D NCK 3 188 3 12 7 Parameterizing the SINUMERIK 840...

Page 16: ...ting information and instructions 5 293 5 5 Diagnostics 5 294 5 5 1 Troubleshooting procedure 5 294 5 5 2 Diagnostics support by configuring your own extended alarm text 5 298 5 5 3 Servo trace bit graphics for Safety Integrated 5 301 5 5 4 Bit graphics for SI signals in the servo trace 5 304 6 Alarms 6 309 6 1 Alarms for SINUMERIK 840digital 6 310 6 2 Alarms from SIMODRIVE 611 digital 6 343 6 3 A...

Page 17: ...he sensors and actuators 7 424 7 6 3 Individual application functions 7 428 7 6 4 Configuring and connecting up the ET200S I O 7 429 7 6 5 Parameterizing the Sinumerik 840D NCK 7 434 7 6 6 Programming the NCK SPL 7 435 7 6 7 Programming the PLC SPL 7 438 7 6 8 Modified limitations with PROFIsafe 7 441 8 Application examples 8 443 8 1 Conventional brake control single channel from the PLC 8 444 8 2...

Page 18: ...UMERIK Safety Integrated FBSI 11 03 Edition A Appendix A 477 A 1 Index of abbreviations A 477 A 2 List of References A 483 A 2 1 List of references general A 483 A 2 2 List of references for SINUMERIK 840D A 484 A 2 3 List of References for SIMODRIVE 611 A 485 I Index I 487 I 1 Keyword index I 487 ...

Page 19: ... related technology Fully digital systems now make it possible to implement safety relayed technology in which electronics and software play the major role Full integration into the control and drive technology means that the safety functions are now an inseparable part of the basic system They provide a previously unknown intelligent and direct link right through the system to the electric drives...

Page 20: ...ught to a standstill separately in the setting up mode when the protective door is open This means a high degree of protection for the personnel during set up and additional protection of the machine tool and workpiece in the automatic mode Activation of external braking mechanisms supplements the integrated functions and results in the shortest possible braking distance with safe standstill Exter...

Page 21: ...function safe software cams SN is also called safe cams SINUMERIK Safety Integrated has already been implemented successfully in many thousands of machines of many different types also outside Europe National product liability laws and standardized concepts of companies operating worldwide mean that the requirements of the EC Machinery Directive can also be fulfilled for the world market It has be...

Page 23: ... 292 1 2 30 2 4 Position paper of the working group WG 226 03 in the German Electrotechnical Commission DKE 2 31 2 5 Technical Bulletin about vertical axes from the German Trade Association 2 31 2 6 Basics of SINUMERIK Safety Integrated 2 32 2 6 1 Control category 3 2 32 2 6 2 Basic features of SINUMERIK Safety Integrated 2 33 2 6 3 Forced checking procedure 2 33 2 6 4 Monitoring clock cycle and c...

Page 24: ...egrated Safety Systems 11 03 2 1 Drives and CNC controls with integrated safety Siemens AG 2003 All Rights Reserved 2 24 SINUMERIK 840D SIMODRIVE 611 digital SINUMERIK Safety Integrated FBSI Edition 11 03 2 13 3 Overtemperature 2 53 ...

Page 25: ...operation in the power circuit thus causing the motion to stop Fig 2 1 With the integration of safety functions drive systems and CNC controls perform safety functions in addition to their functional tasks Very short response times can be achieved because of the short data paths from acquisition of the safety relevant information e g speed or position to evaluation The systems with integrated safe...

Page 26: ...n any special requirements A working group of the German Electrotechnical Commission has therefore drawn up a position document that describes the most important safety functions of electric drive systems in machines and defined the requirements to implement the various Categories according to EN 954 1 2 This position document is to be transformed into a draft Standard The description of the most ...

Page 27: ...gree of flexibility for innovative safety concepts Standards generally reflect state of the art technology However on the other hand innovative technical concepts reflect the state of science and state of the art technology The state of the art and technology is then included in updated standards When implementing EC Directives it is possible to deviate from the standards if the same degree of saf...

Page 28: ... far as the EMC and Low Voltage Directives there is a list of the relevant standards in the Declarations of Conformance 2 1 4 Hazard analysis and risk assessment According to the Machinery Directive 98 37 EC the manufacturer of a machine or a safety component or the person or persons responsible for placing such equipment on the market is legally obliged to carry out a risk analysis in order to de...

Page 29: ...whether harmonized Standards exist or not A machine must however pass an acceptance test successfully refer to Chapter 5 Acceptance test and Acceptance report Verification is greatly simplified even for machines that are covered by Appendix IV of the EC Machinery Directive for which no harmonized standards yet exist The machine manufacturer should indicate that his machine has a type examination c...

Page 30: ...he Machinery Directive and the Standards Testing such complex systems must always be conducted in parallel with development i e already starting in the conceptual phase In that way it is possible to avoid mistakes in the development phase and reduce the test effort The certificates that are acceptable for tests by the test and certification system of the German professional association are EC type...

Page 31: ...mited absolute position SE 3 6 Sichere Software Nocken Safe Cam SN 3 7 Sichere Ein Ausgangssignale Safe input output signals SGEs SGAs 3 9 2 5 Technical Bulletin about vertical axes from the German Trade Association This Technical Bulletin aims to summarize the knowledge and experience available with regard to improved safety at work for activities at or close to vertical axes This is realized by ...

Page 32: ...e The suitability of the measure depends on the application and type of the machine The occurrence of a fault error can lead to a loss in safety functions in between tests The loss of safety function s is detected in the course of testing Structure based 3 The requirements of B must be fulfilled Use of principles that have proven to be effective in terms of safety The controls must be designed suc...

Page 33: ... of the CPUs can be carried out on the shutdown paths forced checking procedure When monitoring functions respond the NCK and or the drive can send control commands to the power section via shutdown paths thus safely shutting down the axis or spindle 2 6 3 Forced checking procedure The forced checking procedure must be performed for all static signals and data The logic state must change from 1 to...

Page 34: ...relevant sensors and actuators In this case the entire circuit including the safe programmable logic SPL is tested for correct functioning Note A defined 8 hour cycle is not mandatory in the automatic mode when the protective door is closed A forced checking procedure after an 8 hour period has elapsed can be combined with the next opening of the protective door Any errors in the monitoring channe...

Page 35: ...e event of an error and the more the drives overshoot MD 10092 MN_INFO_CROSSCHECK_CYCLE_TIME specifies the maximum crosswise comparison clock cycle in seconds If the monitoring clock cycle is modified then the crosswise comparison clock cycle is also changed To be able to support the various functional configurations of the individual controls the crosswise data comparison between the NCK and 611 ...

Page 36: ...about the user agreement function please refer to Chapter 2 Adjustment measurement axis states and previous history Applicable to 840D with SW 3 6 and higher In the case of axes and spindles that do not have configured safety functions SE and SN the saved zero speed position is not evaluated if a user agreement has not been given Warning If the drive is not reliably referenced and a user agreement...

Page 37: ...ettings the following functions can be individually enabled SBH SG SE SN1 SN1 SN2 SN2 SN3 SN3 SN4 SN4 SG override Slip External stop signals Cam synchronization EMERGENCY STOP SW 6 4 15 and higher Note To ensure that SBH can always be selected in the event of an error the function SBH SG must be activated and correctly parameterized when the function SE and or SN is enabled The axis specific enabl...

Page 38: ...advantages of these new possibilities Integrated safety technology now takes the emphasis away from purely hardware and electro mechanical based solutions to those based on software and electronics thus gradually replacing technology that is subject to wear Integrated safety technology by its very concept provides intelligent system control right down to the sensors and actuators This results in a...

Page 39: ...he drive pulses are cancelled The energy feed is safely and electronically disconnected Safely reduced speed SG Configured speed limits are monitored e g when setting up without using an agreement button Safe software limit switches SE Variable traversing range limits Safe software cam SN Range detection Safe input output signals SGE SGA Interface to the process Safe programmable logic SPL All of ...

Page 40: ...system NCU terminal block with DMP modules for the NCK I Os SIMODRIVE 611digital High Standard or High Performance with an additional input for a direct measuring system SINUMERIK software release at least 6 3 30 NCU terminal block with DMP modules for the NCK I Os Simple I O module instead of SIMATIC I Os SIMATIC S7 I O modules for the PLC SINUMERIK 840 D with NCU 561 4 571 4 5 72 4 573 4 NCU 573...

Page 41: ...FC5250 0AC10 0AA0 Additional function from the 5th axis spindle onwards 6FC5250 0AC11 0AA0 Axis spindle pack for additional 13 axes spindles 6FC5250 0AC12 0AA0 NCK I Os NCU terminal block 6FC5211 0AA00 0AA0 DMP Compact 16A 24V DC 6FC5111 0CA01 0AA0 DMP Compact 16A 24V DC 0 5A 6FC5111 0CA02 0AA2 DMP Compact 8A 24V DC 2A 6FC5111 0CA03 0AA2 Accessories Cable distributor 6FX2006 1BA02 Software option ...

Page 42: ... inputs 120 V AC 6ES7321 1EH01 0AA0 32 inputs 120 V AC 6ES7321 1EL00 0AA0 8 inputs 120 230 V AC 6ES7321 1FF01 0AA0 Digital output modules SM322 16 outputs 24 V DC 0 5 A 6ES7322 1BH01 0AA0 16 outputs 24 V DC 0 5 A extended temperature range 6ES7322 1BH81 0AA0 32 outputs 24 V DC 0 5 A 6ES7322 1BL00 0AA0 8 outputs 24 V DC 0 5 A diagnostics capable 6ES7322 8BF00 0AA0 16 outputs 120 V AC 0 5 A 6ES7322 ...

Page 43: ...terminal 6ES7193 4CD20 0AA0 With spring loaded terminal 6ES7193 4CD30 0AA0 With screw terminal 6ES7193 4CK20 0AA0 With spring loaded terminal 6ES7193 4CK30 0AA0 S7 F configuration pack Distributed Safety 6ES7833 1FC00 0YX0 Please refer to Catalog ST 70 for further ET 200 S components 2 10 Customer Support The Centre of Competence Service CoCS Sinumerik Safety Integrated provides a range of service...

Page 44: ...entation and commissioning an acceptance report for the safety functions is drawn up These include Description of the machine name type Description of the safety and operating concepts Description of the axis specific safety functions Testing of all safety functions including the SPL logic Records of the test results The customer will receive the acceptance report as hardcopy and on an electronic ...

Page 45: ... the shutdown paths The position at which axes with safety functions reach a standstill is saved in a non volatile memory when safe operating stop SBH is selected For axes configured with SE and SN the position data is used for an internal position check when the system is powered up again The following applies when SE SN is active The standstill position is also saved cyclically For this reason t...

Page 46: ...op Axis speed too high According to currently applicable standards TC143 the SG function is depending on the technology only permissible in combination with jog mode start button and Emergency Stop Axis or spindle has inadmissibly moved away from standstill position Defect in the drive or control system operator error etc Safe standstill monitoring for position control with SBH configurable stop f...

Page 47: ...Chapter 1 4 3 No wear safe disconnection of energy feed to drive to allow manual intervention in danger zone function does not replace machine main switch Safe standstill with SH Stop function Cat 0 with respect to electrical isolation Axes have inadmissibly exited operating range Defect in the drive or control system operator error etc part program error or similar Safe software limit switches SE...

Page 48: ...nery protection can also be used to restrict working zones in conjunction with personnel protection Response of the machine control to incorrect position signal Defect in the control operator error part program error or similar Safe software cams SN safe signal and position data output Chapter 1 2 4 Chapter 1 2 7 Chapter 1 3 8 Chapter 1 4 2 Chapter 1 4 3 Wear free safe software cams for reliable d...

Page 49: ...V W and a reversal in the control direction can cause an increase in the spindle speed or axis motion Category 1 and 2 Stop functions according to EN 60204 1 defined as Stops B to E in Safety Integrated that are provided are not effective due to the fault Category 0 stop function according to EN 60204 1 defined as Stop A in Safety Integrated is not activated until the transition or delay time set ...

Page 50: ...ety Integrated means that the spindles axes are not braked to zero speed but coast to a stop this may take a very long time depen ding on the level of kinetic energy involved This must be included in the protective door locking mechanism logic e g with the logic operation n nx When a limit value is violated the speed may exceed the set value briefly or the axis spindle may overshoot the setpoint p...

Page 51: ...ed Axis no longer safely referenced SGA Axis safely referenced cancelled on NCK and drive side The user can align the actual value acquisition of the safety monitoring channels by referencing synchronizing to the machine position These alarms are only displayed for axes for which safety monitoring functions with absolute reference are activated i e for SE and SN They are not displayed for axes wit...

Page 52: ... with safety relevant drive inputs and outputs must not be written using the variable service of the NCDDE server 2 Writing machine data using the variable service An acceptance test must be performed if SI machine data has been changed using the variable service of the NCDDE server 3 Changing alarm priorities The alarm priorities selected for SI must be retained 4 Changing alarm texts The alarm t...

Page 53: ...ogic Safety related response required All safety related outputs SGAs should be brought into the safe state logical 0 The drives should be brought to a standstill and the pulses then cancelled It may make sense to derive an Emergency Stop request from the interface signal When the associated temperature monitoring responds this is indicated using the axial interface signal DB axis DBX94 0 Motor te...

Page 54: ...2 General Information about Integrated Safety Systems 11 03 2 13 Others Siemens AG 2003 All Rights Reserved 2 54 SINUMERIK 840D SIMODRIVE 611 digital SINUMERIK Safety Integrated FBSI Edition 11 03 Notes ...

Page 55: ...ced speed SG 3 92 3 5 1 Selecting de selecting the safely reduced speed 3 94 3 5 2 Limiting the setpoint speed 3 96 3 5 3 Safely reduced speed when using selector gearboxes 3 97 3 5 4 Effects when the limit value is exceeded for SG 3 98 3 5 5 SG specific stop responses 3 99 3 5 6 Override for safely reduced speed 3 100 3 5 7 Example Override for safely reduced speed 3 102 3 5 8 Application example...

Page 56: ...1 1 Encoder types 3 168 3 11 2 Adjustment calibration axis states and historical data 3 170 3 11 3 Overview of the data for mounting encoders 3 174 3 11 4 Actual value synchronization slip for 2 encoder systems with SW 5 2 and higher 3 175 3 11 5 Application Spindle with two encoders and drive with slip SW 5 2 and lower 3 176 3 12 SI I Os using fail safe modules connected to PROFIBUS DP 840D from ...

Page 57: ...reaker This measure provides protection against electric shock when working with live components When powered down the breaker must be locked out to prevent accidental re closure Integrated line contactor Effect central The entire converter can be electrically isolated using the line contactor As far as the converter is concerned this measure also corresponds to a STOP A In the past for an EMERGEN...

Page 58: ...els The machine manufacturer needs to configure a shutdown path in the NCK monitoring channel and another in the drive monitoring channel refer to Fig 3 2 Shutdown path of the drive CPU and Fig 3 3 Shutdown path of the NCK CPU via Terminal 663 For SI the shutdown paths are utilized by stop functions with the highest priority STOP A and STOP B These stop functions can be initiated through any monit...

Page 59: ...status Fig 3 2 Shutdown path of the drive CPU Two options are available from SW 6 3 30 onwards 1 Via Terminal 663 2 Via internal pulse cancellation Pulse cancellation is initiated via the NCK SGE test stop selection can also be initiated internally in the case of an error The comparator uses the SGA enable pulses to cancel the enabling command at module specific terminal 663 on the 611 digital dri...

Page 60: ...r with the 611 digital modules High Performance and High Standard Terminal 663 must then be wired to the SGA externally enable pulses Whether or not the pulses were successfully cancelled can be returned internally This considerably reduces the number of NCK I Os required Fig 3 4 shows the sequence when canceling pulses Internal pulse canceling is initiated via the NCK SGE test stop selection can ...

Page 61: ...so be configured so that the NCK has a further option for canceling pulses However this path is only used if the internal pulse cancellation fails MA_SAFE_PULSE_ENABLE_OUTPUT can still be configured on a hardware output or in the SPL refer to Chapter 3 10 This can be used for example in order to initiate responses in the SPL while canceling the pulses and not having to wait until the state pulses ...

Page 62: ... status NCK SGA pulses enabled For a test stop in the drive monitoring channel PLC SGE test stop selection PLC SGA pulses cancelled status For a test stop in the NCK monitoring channel for internal pulse disabling NCK SGE test external pulse cancellation NCK SGE externally enable pulses The message test stop in progress is displayed on the screen while a test stop is being executed Note To ensure ...

Page 63: ...the screen The checkback signal is returned via the NCK SGE pulses cancelled status received via terminal AS1 AS2 This checkback signal must have been made before the timer started at the beginning has expired If this is not the case then STOP A is initiated The internal pulse cancellation is also requested via the NCK SGE test stop selection for the NCK monitoring channel the NCK SGA enable pulse...

Page 64: ... at this output MA_SAFE_EXT_PULSE_ENAB_OUTPUT in Fig 3 4 this therefore means for all 6 axes X Y Z A B C Alarm 27006 Axis 1 Test ext pulse cancellation running is displayed for all of these axes during the external pulse cancellation test Note During test stop external shutdown no external stop may be present at the drive If an external stop is present and the test stop is present for longer than ...

Page 65: ...d from the SI interface of the 611 digital The test stop is executed internally in the drive monitoring channel via the NC PLC interface To implement the test stop for the NCK monitoring channel the SGEs SGAs must be appropriately connected up for each axis A large number of inputs and outputs are required in the NCK when there are several axes It is possible to group or distribute signals using i...

Page 66: ...Pulses disabled status Axis 1 Pulses disabled status Axis 2 Pulses disabled status Axis 3 Pulses disabled status Axis 4 24 V AS1 AS1 AS1 AS2 AS2 AS2 External circuitry External circuitry External circuitry Terminals of SIMODRIVE 611 drive modules ZWDYN_05 DSF Test stop selection Pulse disabling via terminal 663 Checkback signals AND linking via MDs SGE assignment without SPL logic DPR variable SGE...

Page 67: ...ote Data is described in Chapter 4 Machine data for SIMODRIVE 611digital Note The inputs and outputs of the SGEs SGAs are assigned to the drive channel using data blocks in the PLC user program refer to Chapter 4 Interface signals 3 1 5 Stop responses A high degree of protection against faults errors is afforded by the two channel monitoring structure with its continuous crosswise data comparison ...

Page 68: ...ses stop and retract start timer tD tD 0 Activation of SBH Drive is decelerated via the programmed retraction and stop motion ESR SBH active SG SE SBH RESET F Depending on situation a Safety function inactive Saved message to operator a NC start and traversing interlock a RESET b Safety function active Initiation of STOP B A configurable b Transition to STOP B A Crosswise data comparison SH b POWE...

Page 69: ... STOP F triggers STOP B if at least one safety relevant function is active Table 3 6 Stop response priorities Priority level Stop response Highest priority STOP A STOP B SGE test stop selection STOP C STOP D STOP E Lowest priority STOP F Note A stop response listed in Table 3 6 Stop response priorities can only be initiated if at least one safety relevant function is active except for STOP F Once ...

Page 70: ... B is active 0 signal STOP A B is not active 1 signal STOP A B is active Action in the drive and NCK monitoring channels The drive is braked along the current limit as the result of a 0 speed setpoint that is input instantaneously either directly or from the NCK via the drive bus Action in the drive monitoring channel If the speed actual value drops below the value set in MD_SAFE_STANDSTILL_VELO_T...

Page 71: ...int while the timer set in MD_SAFE_STOP_SWITCH_TIME_C is started in parallel The SBH function is automatically activated after the timer expires Action in the drive monitoring channel Essentially the same as in the drive channel the control specifies a zero speed setpoint and interface signal position controller active DB 0 DBX 61 5 of the drive involved is set to zero At the same time the timer s...

Page 72: ...unintentional restart is prevented for STOP D The error can be acknowledged using the NC RESET key SGA STOP D is active This signal indicates that STOP D is active 0 signal STOP D is not active 1 signal STOP D is active Action in the drive monitoring channel The drive monitoring channel requests an extended stop and retract ESR At the same time the timer set in MD_SAFE_STOP_SWITCH_TIME_E is starte...

Page 73: ...hed within the specified time The STOP F response is permanently assigned to the crosswise data comparison function Dormant errors in the drive and control systems are detected Effect When a discrepancy is detected between the drive and NCK monitoring channels the responses are as follows Dormant errors are detected even if there is no safety function active The saved message defect in a monitorin...

Page 74: ... be reset with the NC RESET key An unintentional restart is prevented for STOP B A The fault can only be acknowledged with a power on for the drive and control Example 1 delaying the transition from STOP F to STOP B The speed characteristic of an axis for parameterized stopping is shown in the following diagram In this case the axis should continue 500 ms and then brake along the parameterized ram...

Page 75: ... if there is a STOP F with active monitoring function Weiterfahren ESR Bremsen an Rampe Stillsetzen ESR t1 t2 t3 v t4 Fig 3 10 Speed characteristic of an SI axis when stopping with STOP F The following actions take place at the individual instants in time t1 STOP F occurs no response t2 Any time after t1 a monitoring function is activated At this instant in time the transition time to a STOP B is ...

Page 76: ...AFE_STANDSTILL_VELO_TOL 36961 MA_SAFE_VELO_STOP_MODE 36962 MA_SAFE_POS_STOP_MODE 36963 MA_SAFE_VELO_STOP_REACTION Note Data is described in Chapter 4 Machine data for SINUMERIK 840D Table 3 9 Overview of machine data for 611 digital Number Name 1352 MD_SAFE_STOP_SWITCH_TIME_C 1353 MD_SAFE_STOP_SWITCH_TIME_D 1354 MD_SAFE_STOP_SWITCH_TIME_E 1355 MD_SAFE_STOP_SWITCH_TIME_F 1356 MD_SAFE_PULSE_DISABLE_...

Page 77: ... selected for safety reasons until SPL crosswise data comparison of the PLC and NCK is started The function external STOPs is enabled and activated via the following machine data Enabling the function MD 36901 1301 MA_ MD_SAFE_FUNCTION_ENABLE enables safety relevant functions Bit 0 Enable SBH SG see note Bit 6 Enable external STOPs Bit 4 Enable external STOP E Note In addition to enabling of the f...

Page 78: ...parameterized in MD10097 without enabling the external Stop E in all axes with SI function enable Alarm 27033 is output for all of these axes The following SGEs are available to stop the drive Table 3 10 SGEs to stop the drive SGE Stop type Priority De selection ext STOP A SH de selection Pulse cancellation High De selection ext STOP C Braking with nset 0 De selection ext STOP D Braking along the ...

Page 79: ...igher priority stop request STOP A B C or D from the internal monitoring When a stop response is triggered it has the following effect on all of the other axes in the same channel STOP E extended stop and retraction is initiated STOP D braking along a path STOP C IPO rapid stop braking at the current limit STOP A IPO rapid stop braking at the current limit The effect on other axes in the channel c...

Page 80: ...Chapter 3 1 3 Testing shutdown paths Correct functioning of safe pulse cancellation is tested Successful completion of this phase is signaled as follows For the NCK monitoring channel A positive checkback signal is returned in the form of a 0 1 edge from SGE status pulses cancelled For the drive monitoring channel Positive checkback is indicated by the SGA status pulses cancelled Phase 2 Once the ...

Page 81: ... SGA STOP C is active NCK SGE de select ext STOP D NCK SGA STOP D is active NCK SGE de select ext STOP E NCK SGA STOP E is active Drive monitoring channel PLC SGE test stop selection PLC SGA status pulses cancelled PLC SGE de select ext STOP A PLC SGA STOP A B is active PLC SGE de select ext STOP C PLC SGA STOP C is active PLC SGE de select ext STOP D PLC SGA STOP D is active PLC SGE de select ext...

Page 82: ...raking at the current limit Braking along a path can be requested via this SGE When ext STOP D is triggered the time set via MD 36953 1353 MA_ MD_SAFE_STOP_SWITCH_TIME_D transition time STOP D to safe operating stop is started When this time has elapsed the system automatically switches over to SBH If a stop request is active SGA STOP D is active is set in the same way as it would be for an intern...

Page 83: ...s 0 signal STOP C is not active 1 signal STOP C is active This signal indicates that STOP D is active The signal must be used for the forced checking procedure for external STOPs 0 signal STOP D is not active 1 signal STOP D is active This signal indicates that STOP E is active The signal must be used for the forced checking procedure for external STOPs 0 signal STOP E is not active otherwise STOP...

Page 84: ...nable safety relevant functions Bit 0 Enable SBH SG Bit 3 Enable actual value synchronization Bit 4 Enable external ESR activation Bit 6 Enable external STOPs 36990 MA_SAFE_ACT_STOP_OUTPUT n n 0 3 n Associated status on level 1 0 STOP A B is active 1 STOP C is active 2 STOP D is active 3 STOP E is active Note Data is described in Chapter 4 Machine data for SINUMERIK 840D Table 3 14 Overview of mac...

Page 85: ... 30 the pulse enable can also be read back internally for all control modules This means that it is not necessary to read back signals from terminal AS1 AS2 Caution The machine manufacturer must take all of the appropriate measures to prevent any motion after the energy feed to the motor has been disconnected e g to prevent suspended vertical axes from dropping The main features of the safe stands...

Page 86: ...Note Data is described in Chapter 4 Machine data for SIMODRIVE 611digital 3 4 Safe operating stop SBH The purpose of the SBH function is to safely monitor the standstill position of an axis spindle operating in the closed loop position or speed controlled mode When SBH is active SGA SBH active 1 operating personnel can for example enter protected machine areas in the set up mode without first havi...

Page 87: ... enable in the axis specific machine data must be present The SGEs SBH SG de selection and SBH de selection must be supplied in the NCK and drive monitoring channels 3 4 1 Selecting de selecting safe operating stop The safe operating stop function is selected via the following SGEs Table 3 17 Selecting de selecting SBH SGE SGA SBH SG de selection SBH de selection SBH active 1 Meaning 1 x 0 SBH and...

Page 88: ... to 0 The changeover from safely reduced speed to the safe operating stop is initiated via the SGE SBH de selection A delay time that is parameterized in the following machine data is simultaneously started with the changeover to SBH signal SBH de selection 0 For 840D MD 36951 MA_SAFE_VELO_SWITCH_DELAY For 611 digital MD 1351 MD_ SAFE_VELO_SWITCH_DELAY SBH is activated as soon as the delay time ex...

Page 89: ...lting in general de activation of SBH and SG The SBH function is also de selected when the SG function is selected via the SGE SBH de selection Note The delay time must be selected as a function of the distance to the hazardous location The speeds to be taken into account in this respect are stipulated in Standard DIN EN999 If this SGA is set then safe operating stop SBH is active i e the axis is ...

Page 90: ...or 840D 36956 MA_SAFE_PULSE_DISABLE_DELAY for 611 digital 1356 MD_SAFE_PULSE_DISABLE_DELAY and for 840D 36960 MA_SAFE_STANDSTILL_VELO_TOL for 611 digital 1360 MD_SAFE_STANDSTILL_VELO_TOL An alarm is generated for 840D 27010 for 611 digital 300907 The time response of the system is as follows if the limit value is violated when the safe operating stop function is active n c t1 t2 STILL_02 DS4 t t6 ...

Page 91: ... required to reach the shutdown speed with STOP B t8 Time required to stop the axis with STOP B t9 Time required to stop the axis with STOP A Note Each axis must be measured during start up to determine the distance it travels between violation of the limit value and coming to a standstill 3 4 3 Overview of the machine data for the SBH function Table 3 19 Overview of machine data for 840D Number N...

Page 92: ...c modes Configurable stop response after the SG responds The following prerequisites must be fulfilled refer to Chapter 2 8 System requirements Option and functions must be enabled in the axis specific machine data The SGEs SBH SG de selection and SBH de selection must be configured The requirements regarding speeds and velocities that are stipulated for individual processes e g milling turning gr...

Page 93: ...p for each monitoring channel MD 1326 is effective in the drive MD_SAFE_ENC_FREQ_LIMIT The values in this MD are incorporated in the crosswise data comparison of the monitoring channels Note Changes to this MD may only be made carefully taking into account the prevailing conditions This functionality is only supported by 611digital Performance 2 control modules High Standard and High Performance C...

Page 94: ... individual machine types in the C Standards product standards The machine manufacturer is responsible for ensuring that the correct speed limit value is selected as a function of operating mode and application The required speed limit value is selected as follows by combining the following SGEs Table 3 23 Selecting speed limit values for the SGs SGE SG selection Bit 1 SG selection Bit 0 Meaning 0...

Page 95: ...w limit value when the time has expired an appropriate alarm is output with the configurable stop response SG1 V1 SG2 V2 SGEs for SG1 SGEs for SG2 SG1 is active SG2 is active Braking time Timer running SGH_SGN DS4 v t Delay time speed switchover a Initiation of braking Fig 3 15 Timing when changing over from a higher to a lower speed limit value The SG function can be de selected at any speed by a...

Page 96: ... value 0 corresponds to setpoint limiting active The setpoint limit is changed over when the SGEs are changed over SGE SBH SG de selection SGE SBH de selection SGEs Active SG stage bit 0 1 SGEs SG override bit 0 1 2 3 Beyond that internal changeover operations in SBH take effect as the result of a stop response stop D C E When a changeover is made via SGEs the states of both monitoring channels ar...

Page 97: ...gearboxes When a 1 encoder system is used gear ratios gear stage selection must be selected via two channels refer to Chapter 3 Example of application for safe sensing of gear ratios The user agreement if set is canceled during a gear change and the SGA axis safely referenced set to 0 When the gearbox stage is selected via PLC and or by selecting a new ratio a gear shift is detected using SGEs The...

Page 98: ... 1361 MD_SAFE_VELO_STOP_MODE MD 1363 MD_SAFE_VELO_STOP_REACTION n Note An alarm is displayed for 840D 27011 for 611 digital 300914 After the cause of the error has been eliminated the alarm can be acknowledged with RESET The monitoring function is then active again Depending on the selected monitoring clock cycle the dynamic drives may cause a brief increase in speed on the monitored axis spindle ...

Page 99: ...figured stop response maximum 2 5 monitoring clock cycles t6 Time until the stop response sequence starts time 0 depends on configured stop response refer to Chapter 2 Stop responses t7 Time required to bring the axis to standstill This time period and thus the residual distance traveled by the axis is determined by the axis design motor mass friction and the configured stop response STOP C is fas...

Page 100: ...sted to the variations in the grinding wheel peripheral speed by means of the SG override The following prerequisites must be fulfilled before the function can be used Function is enabled via MD 36901 MD 1301 MA MD _SAFE_FUNCTION_ENABLE bit 5 The SBH SG monitoring function is enabled The required SGEs SG override selection bits 3 2 1 0 are fully or partially configured SG override factors have bee...

Page 101: ...de 2 0 0 1 1 with override 3 0 1 0 0 with override 4 0 1 0 1 with override 5 0 1 1 0 with override 6 0 1 1 1 with override 7 1 0 0 0 with override 8 1 0 0 1 with override 9 1 0 1 0 with override 10 1 0 1 1 with override 11 1 1 0 0 with override 12 1 1 0 1 with override 13 1 1 1 0 with override 14 1 1 1 1 with override 15 1 0 x x x x Speed limit value for SG3 active 1 1 0 0 0 0 Speed limit value fo...

Page 102: ...2000 mm min 0 0 0 1 Limit value 2 with override 1 80 1600 mm min 0 0 1 0 Limit value 2 with override 2 50 1000 mm min 0 0 1 1 Limit value 2 with override 3 30 600 mm min 1 0 x x x x Limit value 3 4000 mm min 1 1 0 0 0 0 Limit value 4 with override 0 100 5000 mm min 0 0 0 1 Limit value 4 with override 1 80 4000 mm min 0 0 1 0 Limit value 4 with override 2 50 2500 mm min 0 0 1 1 Limit value 4 with o...

Page 103: ... For 840D For 611 digital MD number Value MD number Value 0 36932 0 100 1332 0 100 1 36932 1 80 1332 1 80 2 36932 2 50 1332 2 50 3 36932 3 30 1332 3 30 3 5 8 Application examples for SG Please refer to Chapter 7 Configuring example for an example of safely reduced speed 3 5 9 Examples for safe input of ratios The gear ratio encoder load must be safely sensed on a spindle with a four stage gearbox ...

Page 104: ...r the 1st drive The motor encoder system is parameterized in the drive machine data The second encoder system is parameterized in the NCK machine data of the control system Table 3 31 Overview of encoder data for 840D Number Name 36910 MA_SAFE_ENC_SEGMENT_NR 36911 MA_SAFE_ENC_MODULE_NR 36912 MA_SAFE_ENC_INPUT_NR 36915 MA_SAFE_ENC_TYPE 36916 MA_SAFE_ENC_IS_LINEAR 36917 MA_SAFE_ENC_GRID_POINT_DIST 3...

Page 105: ...arison between the two channels NCK HW I O NCK monitoring channel SBH SG SE SN per axis spindle SBH SG SE SN per axis spindle PLC HW I O Drive monitoring channel Monitoring comparators Monitoring comparators O I I O I O images I O images SG_02 DSF Pro cessing SGE SGA Bit 0 Bit 1 Bit 2 Bit 0 Bit 1 Bit 2 PLC user program Result and data cross check 1PH6 motor Encoder 1 Gearbox I1 I2 O1 O2 Spindle IM...

Page 106: ...is may result in an offset of the SI actual values As this cannot be avoided gear stage changeover without errors is only possible under the following conditions 1 The gear stage is selected at zero speed the time delay does not cause an offset of the two SI values The gear stage is selected when the motor is moving e g oscillating i e the motor is moving although this cannot be detected at the di...

Page 107: ... 36921 MA_SAFE_ENC_GEAR_DENOM n 36922 MA_SAFE_ENC_GEAR_NUMERA n 36925 MA_SAFE_ENC_POLARITY Note Data is described in Chapter 4 Machine data for SINUMERIK 840D Table3 36 Encoder data overview for 611 digital Number Name 1316 MD_SAFE_ENC_CONFIG 1317 MI_SAFE_ENC_GRID_POINT_DIST 1318 MI_SAFE_ENC_RESOL 1320 MI_SAFE_ENC_GEAR_PITCH 1321 MI_SAFE_ENC_GEAR_DENOM n 1322 MI_SAFE_ENC_GEAR_NUMERA n Note Data is...

Page 108: ...or the NCK PLC and drive simultaneously There is usually a delay in the internal gear stage selection because of the different processing speeds of the two channels due to the PLC cycle time the NCK usually detects the signal change earlier than the PLC As this cannot be avoided gear stage changeover without errors is only possible under the following conditions 1 The gear stage is selected at zer...

Page 109: ... 2 0 1 0 1 0 0 1 2 5 1 3 1 0 1 0 0 1 0 1 6 1 4 1 1 1 1 0 1 1 1 1 Input assignment of gear ratio selection Table 3 38 Supplying the machine data for the SGEs for 840D Signal Assignment SGE SGA Name MD No Value SGE Gear ratio selection bit 0 36974 0 01 05 03 01 SGE Gear ratio selection bit 1 36974 1 01 05 03 02 Table 3 39 Entering gear ratios into machine data Setting 840D 611 digital MD No Value MD...

Page 110: ...SAFE_VELO_OVR_FACTOR n 36933 MA_SAFE_DES_VELO_LIMIT 36951 MA_SAFE_VELO_SWITCH_DELAY 36961 MA_SAFE_VELO_STOP_MODE 36963 MA_SAFE_VELO_STOP_REACTION n SW4 2 and higher 36970 MA_SAFE_SVSS_DISABLE_INPUT 36972 MA_SAFE VELO_SELECT_INPUT n 36974 MA_SAFE_GEAR_SELECT_INPUT n 36980 MA_SAFE_SVSS_STATUS_OUTPUT 36982 MA_SAFE_VELO_STATUS_OUTPUT n SW 4 2 and higher Table 3 41 Overview of machine data for 611 digi...

Page 111: ...IT_PLU n MD 1335 MD_SAFE_POS_LIMIT_MINUS n Note The upper and lower position limit values must be selected so that when the axis is traversing in this direction the software limit switches that are used as standard are first reached The most important features include Safe definition and evaluation of software limit switches as a software function Configurable stop response when software limit swi...

Page 112: ...ted For 840D MD 36962 MA_SAFE_POS_STOP_MODE For 611 digital MD 1362 MD_SAFE_POS_STOP_MODE The user can select either STOP C D or STOP E The configured stop response is initiated The relevant alarm is displayed Traverse the axis to a position in which the monitoring does not respond refer to Description of Alarm safe software limit switch passed in Chapter 6 Alarms The user agreement must be cancel...

Page 113: ...r 840D MD 10090 MN_SAFETY_SYSCLOCK_TIME_RATIO For 611 digital MD1300 MD_SAFETY_CYCLE_TIME t3 Time until passing limit position is detected maximum 1 monitoring clock cycle t4 Delay until the configured stop response is output maximum 2 monitoring clock cycles t5 Delay until the configured stop response takes effect time 0 depends on the configured stop response refer to Chapter 2 Stop responses t6...

Page 114: ...AFE_FUNCTION_ENABLE 36934 MA_SAFE_POS_LIMIT_PLUS n 36935 MA_SAFE_POS_LIMIT_MINUS n 36962 MA_SAFE_POS_STOP_MODE 36973 MA_SAFE_POS_SELECT_INPUT Note Data is described in Chapter 4 Machine data for SINUMERIK 840D Table 3 44 Overview of machine data for 611 digital Number Name 1301 MD_SAFE_FUNCTION_ENABLE 1334 MD_SAFE_POS_LIMIT_PLUS n 1335 MD_SAFE_POS_LIMIT_MINUS n 1362 MD_SAFE_POS_STOP_MODE Note Data...

Page 115: ... Important The enabled cam signals are immediately output when the control system is pwered up but are only safe after safe referencing signaled via the SGA axis safely referenced For safe evaluation of the cam signals the SGA axis safely referenced must be taken into account The most important features include Safe definition and evaluation of cam positions as a software function Definition of wo...

Page 116: ...values between the two monitoring channels This must be taken into account in the further processing of the cam signals e g by filtering the different signal states by means of a logic circuit refer to synchronization of cam signals When cam signal synchronization is activated the cam results calculated by one monitoring channel are ANDed with the cam results of the other monitoring channel before...

Page 117: ... 840D MD 36988 MA_SAFE_CAM_PLUS_OUTPUT n MD 36989 MA_SAFE_CAM_MINUS_OUTPUT n In the drive monitoring channel the PLC SGAs are mapped in the NC PLC interface refer to Chapter 4 Interface signals and output via the PLC I O by the PLC user program The modulo display of the safe actual value is selected and parameterized for rotary axes using the following machine data MD 30300 MA_IS_ROT_AX MD 30320 M...

Page 118: ...on is active lower modulo value POS_TOL cam position upper modulo value POS_TOL CAM_TOL cam position Meanings POS_TOL Actual value tolerance for 840D MD 36942 MA_ MD_SAFE_POS_TOL for 611digital MD 1342 MA_ MD_SAFE_POS_TOL CAM_TOL Cam tolerance for 840D MD 36940 MA_ MD_SAFE_CAM_TOL for 611digital MD 1340 MA_ MD_SAFE_CAM_TOL Lower upper modulo value MD 36905 1305 MA_ MD_SAFE_MODULO_RANGE Cam positio...

Page 119: ...s when the cam position is passed n t2 SN_03 DSF t t3 t4 t5 NCK SGA I Os 611digital SGA axis interface a Axis crosses cam a t1 Fig 3 21 Timing when the cam position is passed Table 3 45 Explanation of the diagram Time Explanation t1 Position control clock cycle defined by the following MDs For 840D MD 10050 MN_SYSCLOCK_CYCLE_TIME MD 10060 MN_POSCTRL_SYSCLOCK_TIME_RATIO t2 Monitoring clock cycle de...

Page 120: ... then its speed must be monitored for violation of speed limit value 1 3 4 The position ranges are defined using cam signals SN1 and SN1 Machine zero 2nd axis 1st axis Position value of SN1 of SN1 SN_01 DSF 1 0 1 0 Signal chart of SN1 Signal chart of SN1 SN1 SN1 Area 0 0 1 SG1 1 0 2 SG3 1 1 3 SG4 Fig 3 22 Signal characteristics positioning and ranges Note In this example cam synchronization must b...

Page 121: ...e Axis safely referenced SBH deselection SBH SG SE SN SBH SG SE SN 1 2 I I PLC User program Monitoring comparators per axis spindle Fig 3 23 Interconnecting the required SGEs SGAs without SPL The example is applicable for the 1st axis Position values SN1 300 mm SN1 600 mm Speed limit values Area 1 1000 mm min Area 2 2000 mm min Area 3 4000 mm min Definition of SGEs SGAs in the NCK monitoring chann...

Page 122: ... are described in Chapter 4 Table 3 46 Supplying MD for cam positions For 840D For 611 digital MD No Value MD No Value SN1 36937 300 1337 0 300 000 SN1 36936 600 1336 0 600 000 Table 3 47 Supplying MD for speed limit values For 840D For 611 digital Limit value MD No Value MD No Value 1 36931 0 1000 1331 0 1000 2 36931 1 0 1331 1 0 3 36931 2 2000 1331 2 2000 4 36931 3 4000 1331 3 4000 Table 3 48 As...

Page 123: ...ic operation in the NCK monitoring channel can then be implemented by means of machine data refer to Chapter 4 Machine data for SINUMERIK 840D 3 7 3 Overview of machine data for the SN function Table 3 50 Overview of machine data for 840D Number Name 36901 MA_SAFE_FUNCTION_ENABLE 36905 MA_SAFE_MODULO_RANGE from SW4 2 36936 MA_SAFE_CAM_POS_PLUS n 36937 MA_SAFE_CAM_POS_MINUS n 36940 MA_SAFE_CAM_TOL ...

Page 124: ...hen a STOP B or C has been triggered STOP A is triggered when SBR responds When a stop request is triggered the actual speed plus the speed tolerance defined in the machine data is activated as the speed limit This limit is compared with the actual speed must decrease or remain the same and is cyclically corrected If the axis starts to re accelerate while braking this is detected as quickly as pos...

Page 125: ...BR tolerance Actual speed for SBR acceleration acceleration duration The following setting rules apply For a linear axis SBR tolerance mm min a m s2 ÜT s 1000 mm m 60 s min For a rotary axis spindle SBR tolerance rev min a rev s2 ÜT s 60 s min To determine the value the maximum value of the acceleration values should be taken account from the following list that is also effective for the particula...

Page 126: ... of machine data for 840D Number Name 36948 MA_SAFE_STOP_VELO_TOL 32300 MA_MA_AX_ACCEL 35200 MA_GEAR_STEP_SPEEDCTRL_ACCEL 35210 MA_STEP_POSCTRL_ACCEL 35410 MA_SPIND_OSCILL_ACCEL Note Data is described in Chapter 4 Machine data for SINUMERIK 840D Table 3 53 Overview of machine data for 611 digital Number Name 1348 MD_SAFE_STOP_ VELO_TOL Note Data is described in Chapter 4 Machine data for SIMODRIVE...

Page 127: ...ia separate PLC and NCK I Os or via PROFIBUS with PROFIsafe protocol and S7 fail safe modules Fig 3 26 SGE SGA via PROFIBUS with PROFIsafe protocol Using these signals the following can be requested or signaled in each monitoring channel and for each axis spindle with safety technology Safety functions can be selected and de selected Speed limit values can be selected and changed over Position lim...

Page 128: ...ered or retrieved through 2 channels via both monitoring channels Process Machine HW inputs out puts HW Inputs out puts NCK signal proces sing NCK SGE SGAs Comparator Data PLC signal proces sing NC PLC interface Axis spindle DB Comparator Data SGESGA03 DSF NCK monitoring channel Drive monitoring channel System Interface Interface NCK signal processing PLC signal processing NCK I O devices PLC I O ...

Page 129: ...nnel processing of I O signals The data and results in the two mutually independent monitoring channels are subject to a crosswise data comparison If any discrepancy is found STOP F is activated Note Owing to the two channel structure of Safety Integrated the machine manufacturer must supply the SGEs and SGAs in both the NCK monitoring channel and the drive monitoring channel The actual signal sta...

Page 130: ... SBH SG active Axis safely referenced SN1 SN2 SN3 SN4 SN1 SN3 SN2 SN4 n nx 1 SG active bit 1 1 SG active bit 0 1 SBH active 1 Enable pulses NCK or Pulses are disabled status drive 1 840D from SW4 2 2 840D from SW 4 4 18 Fig 3 29 SGEs and SGAs in each monitoring channel for each axis spindle Note The SGE SGA signals are described in Chapter 4 Description of Interface Signals Only a subset of the ma...

Page 131: ... required SN1 SN2 SN3 SN4 only if required Enable pulses NCK Pulses cancelled status drive The signal timing characteristics in the two monitoring channels varies the PLC cycle time takes up most of the available time in the drive monitoring channel To prevent the crosswise data comparison function from being activated immediately after a signal change a tolerance time is defined using the followi...

Page 132: ...gnal processing for the NCK monitoring channel Note The SGEs SGAs must be supplied by the machine manufacturer both in the NCK monitoring channel and in the drive monitoring channel The number of inputs and outputs that can be connected increases when the SI safety function is used up to 64 digital inputs and outputs for the function Safe programmable logic SPL by additional digital inputs and out...

Page 133: ...s 1 for axis 2 for axis 3 I1 I2 Ix In NCK HW SGE SGE SGE NCK SGE SGA interface Inversion yes no yes no yes no SGESGA05 DSF Fig 3 30 Multiple distribution of NCK inputs It must be possible to change over between the safe software limit switches 1 and 2 for axes 1 2 and 3 as a group via an NCK input x The machine data must be parameterized as follows Axis 1 MD 36973 MA_SAFE_POS_SELECT_INPUT input x ...

Page 134: ...TUS_OUTPUT output x Axis 2 MD 36987 MA_SAFE_REFP_STATUS_OUTPUT output x Axis 3 MD 36987 MA_SAFE_REFP_STATUS_OUTPUT output x output x ss mm xx nn refer to Chapter 4 Machine data for SINUMERIK 840D 3 9 2 Signal processing in the drive monitoring channel The safety relevant input and output signals SGEs and SGAs are signals that are sent to and received from the system via two channels Via the NCK mo...

Page 135: ...signals for SINUMERIK 840D 3 9 3 Overview of the machine data for SGE SGA Table 3 55 Overview of machine data for 840D Number Name 36950 MA_SAFE_MODE_SWITCH_TIME 36970 MA_SAFE_SVSS_DISABLE_INPUT 36971 MA_SAFE_SS_DISABLE_INPUT 36972 MA_SAFE_VELO_SELECT_INPUT n 36973 MA_SAFE_POS_SELECT_INPUT 36974 MA_SAFE_GEAR_SELECT_INPUT n 36975 MA_SAFE_STOP_REQUEST_INPUT 36976 MA_SAFE_PULSE_STATUS_INPUT 36977 MA_...

Page 136: ...n of the signals that are input into the SPL and the safety relevant signals generated by the SPL as well as internal states markers Direct connection of max 64 safety related sensors e g mode switch light barrier EMERGENCY OFF Connection of max 64 safety related actuators e g protective door locking motor brakes PLC combinational logic Event and data cross checking SGAs SGAs SGEs NCK combinationa...

Page 137: ...erfaces via its assignment MD or the external SPL interfaces A_OUTSE A_INSE have been parameterized via MD MN_SAFE_OUT_HW_ASSIGN MN_SAFE_IN_HW_ASSIGN When PROFIsafe I Os are used refer to Chapter 3 12 the MD MN_PROFISAFE_IN OUT_ADDRESS apply In this case the external STOP A must be parameterized at the SPL interface for all of the axes that use Safety Integrated In addition the following machine d...

Page 138: ...CK and the PLC A_INSE 1 64 A_OUTSE 1 64 A_INSI 1 64 A_OUTSI 1 64 A_MARKERSI 1 64 To ensure that this crosswise data comparison functions correctly the user must observe the following points Both channels NCK PLC must execute the same logic Cleared SPL SGAs are the safe state of SPL Do not implement any response sequences or sequence controllers that are controlled externally using short input puls...

Page 139: ... ouputs HW inputs out puts NCK signal pro cessing NCK SGE SGA signals Comparator Data PLC signal pro cessing NC PLC interface Axis spindle DB Comparator Data SPL033 DSF System Interface Interface NCK signal processing PLC signal processing NCK I Os PLC I Os Result and data cross check Result and data cross check Drive monitoring channel NCK monitoring channel Fig 3 33 Communications between the NC...

Page 140: ...from being influenced by the PLC or other programs using MD MN_PREVENT_SYNACT_LOCK It is then no longer possible to change these synchronous actions CANCEL LOCK have no effect once _N_SAFE_SPF has been started The system variables A_OUTSI A_OUTSID A_OUTSE A_OUTSED A_MARKERSI A_TIMERSI and A_CMDSI are protected from being written to by programs other than the _N_CST_DIR _N_SAFE_SPF If an error occu...

Page 141: ...e correct access level for writing reading deleting access operations manufacturer or service As long as the protective mechanisms for the NCK SPL have not been activated MN_PREVENT_SYNACT_LOCK 0 1 equal to 0 Alarm 27095 is displayed when crosswise data comparison between the NCK and the PLC starts This alarm can be acknowledged with NCK key so that the SPL can be commissioned 3 10 2 Starting the ...

Page 142: ...OG_EVENT SPF In conjunction with the call of SAFE SPF via PROG_EVENT SPF there are additional bits in the SPL status that can be used for synchroniziing the NCK SPL execution and the start of the PLC SPL DB18 DBX137 0 status bit 8 This bit is set if the NCK SPL was started using the PROG_EVENT mechanism Only the start is displayed and not that SAFE SPF was successfully executed DB18 DBX137 5 statu...

Page 143: ... N300 CALL _N_CST_DIR _N_SAFE_SPF N400 ENDIF N500 N600 N700 M17 end of cycle The part program SAFE SPF is called if the system variable check P_PROG_EVENT indicated that the part program PROG_EVENT SPF was called when the control system ran up A simple example for SAFE SPF will now be shown that is started via PROG_EVENT when the system runs up and includes status synchronous actions File SAFE SPF...

Page 144: ...ere is an additional bit in the SPL status that can be used to synchronize NCK SPL execution and the start of the PLC SPL DB18 DBX137 5 status bit 13 from SW 6 4 15 This bit is set if the end of the SAFE SPF program is identified In conjunction with this the end IDs M02 M17 or M30 are permissible for SAFE SPF as end of program If an error occurs while executing SAFE SPF and the end of the program ...

Page 145: ...D 10092 MN_SAFE_OUT_HW_ASSIGN n n 0 7 A_OUTSI 1 A_OUTSI 64 A_INSI 1 A_INSI 64 I1 I2 In O1 O2 On Fig 3 34 Input output variables for the NCK SPL The following system variables are available for binary and double word oriented access 32 bits to the NCK SPL interfaces Table 3 57 System variables for the NCK SPL System variables Description Binary Word oriented A_INSE 1 64 A_INSED 1 2 System variable ...

Page 146: ...40D The NCU local binary I O signals connected at the cable distributor of the NCU box X121 interface have only been available via the system variables A_OUT 1 4 and A_IN 1 4 Now both the SPL SGEs SGAs and the axial SGEs SGAs have been extended in the parameterization to allow local NCU connections to be used Parameterization of the connections is carried out via the MD MN_SAFE_IN OUT_HW_ASSIGN fo...

Page 147: ...PL to be commissioned without the crosswise data comparison constantly responding the following minimum NCK SPL can be installed in this phase Simulate external SPL interface IDS 03 DO A_OUTSED 1 A_OUTSEPD 1 IDS 04 DO A_OUTSED 2 A_OUTSEPD 2 Simulate internal SPL interface IDS 07 DO A_OUTSID 1 A_OUTSIPD 1 IDS 08 DO A_OUTSID 2 A_OUTSIPD 2 Emulate PLC markers for all markers used in the PLC IDS 09 DO...

Page 148: ... 30 The standard SPL module safe software relay is designed to meet the requirements of an emergency stop function with safe programmable logic However it can also be used to implement other similar safety functions e g control of a protective door Parameter FirstRun must be switched to the value TRUE via a retentive data memory bit bit in data block at the first run through after the control has ...

Page 149: ...ust have a steady state 0 signal level error detection using different states of the particular SPL marker for the PLC and NCK Three timer initialization values TI1 to TI3 The times after which outputs A1 to A3 are switched to 0 given a negative edge in output signal A0 are defined here One timer value TM1 This limit value is used to define the maximum time that the shutdown inputs E1 to E3 and th...

Page 150: ... timer limit TM1 and the timer initialization values TI1 TI2 and TI3 The return value contains the number of the first incorrect parameter the value 0 indicates that the parameter assignment is correct Syntax SIRELTIME x status TM1 TI1 TI2 TI3 The transfer parameters TM1 to TI3 are REAL numbers times in seconds TI1 to TI3 are optional If these parameters are not specified the corresponding outputs...

Page 151: ... correctly parameterized Remedy Call SIRELOUT and SIRELTIME with correct parameterization 7 The initialization of the safety relay was not carried out or not correctly carried out Remedy Call SIRELIN SIRELOUT and SIRELTIME with correct parameterization Notes on possible alarms 1 The SIRELAY call must be made in the NCK SPL program SAFE SPF since the allocation of the output variables corresponds t...

Page 152: ... Emergency Stop implemented using NCK SPL in SAFE SPF DEF INT RESULT_IN RESULT_OUT RESULT_TIME N10 DEFINE IE_NH_E AS A_INSE 1 N20 DEFINE IE_NH_Q AS A_INSE 2 N30 DEFINE MI_NH_Q AS A_MARKERSI 1 N40 DEFINE MI_C_ABW AS A_MARKERSI 2 N50 DEFINE MI_A_ABW_A AS A_MARKERSI 3 N60 DEFINE MI_A_ABW_S AS A_MARKERSI 4 N70 DEFINE M_STATUS_1 AS AC_MARKER 1 N200 SIRELIN 1 RESULT_IN IE_NH_Q MI_NH_Q IE_NH_E N210 SIREL...

Page 153: ...e capable 3 10 7 System variables for SINUMERIK 840D The following system variables can only be used in combination with SINUMERIK Safety Integrated They are used when programming the safe programmable logic SPL A detailed description of the system variables is provided in Chapter 4 4 2 Table 3 59 Overview of system variables System variables Meaning Value range Data type Possible access with Part...

Page 154: ... INT x x x x A_OUTSEP n Image of a PLC output n 1 2 64 stands for No of output BOOL x x A_OUTSEPD n Image of the PLC outputs n 1 2 INT x x SPL markers and timers A_MARKERSI n Markers n 1 2 64 stands for No of marker BOOL x x x x A_MARKERSID n Markers SW 4 4 18 and higher n 1 2 INT x x x x A_MARKERSIP n Image of the PLC markers n 1 2 64 BOOL x x A_MARKERSIPD n Image of PLC the markers SW 4 4 18 and...

Page 155: ...value 1 at run up up to SW 4 4 29 5 31 The double word values are A_INSI 1 32 uses A_INSID 1 pre assigned FFFF FFFF H A_INSI 33 64 uses A_INSID 2 pre assigned FFFF FFFF H This behavior must be emulated in the PLC SPL With SW 4 4 29 5 3 1 and higher the system behavior with respect to A_INSI is exactly the same as for other system variables 3 Pre assignments of other variables before cyclic process...

Page 156: ...byte In this case the supply of this data byte can be organized by the user program SPL_READY The SPL_READY TRUE signal indicates that the commissioning phase has been completed i e if a crosswise data comparison error has occurred the basic program sends a STOP D E to all the axes SPL_DATA The useful net data for the PLC SPL is contained in the SPL_DATA structure The useful data area is sub divid...

Page 157: ... the NCK side and the 1 level on the PLC side The PLC SPL program must invert the sensor signal so that the same level appears in DB18 as is active on the NCK side Otherwise the crosswise data comparison function would indicate an error Transfer into the DB18 must be performed by the user program for such signals because the basic program can only copy but it cannot invert The crosswise data compa...

Page 158: ...t until after power on 3 10 10 Direct communications between the NCK and PLC SPL from SW 6 3 30 In SPL applications a certain degree of single channel communications between the two SPLs NCK and PLC is always required in addition to the two channel connection of safety relevant switching elements The test stop and emergency stop acknowledgement are typical applications There are various ways to do...

Page 159: ...rface represents an extension of DB18 on the NCK side new system variables have been introduced for this interface and these are available to the user The meanings of the individual bits in this interface are defined by the user NCK PLC A_PLCSIOUT 1 32 DB18 DBD128 32 bits from NCK to PLC A_PLCSIIN 1 32 DB18 DBD132 32 bits from PLC to NCK For status queries on the PLC side DB18 is supplemented by t...

Page 160: ...ut 2nd output 1st output byte byte byte byte byte byte byte byte DBB 3 INSEP_ADDR Address 1st input byte DBW 4 INSEP_ADDR Address 2nd input byte DBW 6 INSEP_ADDR Address 3rd input byte DBW 8 INSEP_ADDR Address 4th input byte DBW 10 INSEP_ADDR Address 5th input byte DBW 12 INSEP_ADDR Address 6th input byte DBW 14 INSEP_ADDR Address 7th input byte DBW 16 INSEP_ADDR Address 8th input byte DBW 18 OUTS...

Page 161: ... SPL_DATA INSIP 33 64 DBD 58 SPL_DATA OUTSIP 1 32 DBD 62 SPL_DATA OUTSIP 33 64 DBD 66 SPL_DATA MARKERSIP 1 32 DBD 70 SPL_DATA MARKERSIP 33 64 DBD 74 Difference in level NCK PLC for diagnostics SPL_DELTA INSEP 1 32 DBD 78 SPL_DELTA INSEP 33 64 DBD 82 SPL_DELTA OUTSEP 1 32 DBD 86 SPL_DELTA OUTSEP 33 64 DBD 90 SPL_DELTA INSIP 1 32 DBD 94 SPL_DELTA INSIP 33 64 DBD 98 SPL_DELTA OUTSIP 1 32 DBD 102 SPL_...

Page 162: ...7 24 DBB 134 A_PLCSIIN 25 32 DBB 135 SPL status DBW 136 PROFIsafe module s for DBB 138 8th input 7th input 6th input 5th input 4th input 3rd input 2nd input 1st input byte byte byte byte byte byte byte byte DBB 139 PROFIsafe module s for DBB 140 8th output 7th output 6th output 5th output 4th output 3rd output 2nd output 1st output byte byte byte byte byte byte byte byte DBB 141 Test stop data bei...

Page 163: ...Parameterization part INSEP_VALID 1 8 r w Bool 0 INSEP 1 8 No automatic transfer can be supplied by the user program 1 Transfer of input byte defined in INSEP_ADDR 1 8 to INSEP 1 8 by basic program OUTSEP_VALID 1 8 r w Bool 0 OUTSEP 1 8 No automatic transfer can be retrieved by the user program 1 Transfer to output byte defined in OUTSEP 1 8 from OUTSET_ADDR 1 8 by the basic program INSEP_ADDR 1 8...

Page 164: ...or A_OUTSE must be subject to a forced checking procedure to ensure that faults e g wire breakage do not accumulate over a period of time so that both monitoring channels could fail Internal inputs outputs Internal inputs outputs A_INSI A_OUTSI markers A_MARKERSI etc A_TIMERSI do not have to be subject to a forced checking procedure It will always be possible to detect an error at these locations ...

Page 165: ...ere is a system fault and the test analysis test block must prevent the power supply being reconnected to the load The timer or event controlled triggering of the test stop is activated in one channel by the PLC The function itself is separately executed in both channels Triggering and checking test signals for SPL input output signals can also be completely executed in one channel in the PLC 1 Th...

Page 166: ...ernally In order to increase the probability that a requested external STOP takes effect the STOPs between the two channels are exchanged internally Failure of the stop control in one channel does not cause an error for these signals in contrast to the operating mode switchover signals e g SG SBH active in the crosswise data comparison Whereas other channels can be subjected to a forced checking p...

Page 167: ...l SINUMERIK Safety Integrated FBSI Edition 11 03 3 167 Note An application example for an integrated EMERGENCY STOP is given in Chapter 7 Configuring Example Note An application example for a door interlocking is given in Chapter 7 Configuring Example Note An application example for a test stop for SI Level 2 is given in Chapter 7 Configuring Example ...

Page 168: ...emental encoder Absolute encoder at the motor at the load at the motor at the load Comments x 1 encoder system x 1 encoder system x x 2 encoder system x x 2 encoder system x x 2 encoder system Note x Encoder connection For a 1 encoder system the incremental or absolute encoder at the motor is used for the actual values of the NC and drive The 611 digital control module supplies one actual value to...

Page 169: ...the motor encoder and the NC for example the measuring system connected to the 2nd actual value input The 611digital control module transfers the two actual values to the NCK and drive via two separate actual value channels Encoder Gearbox Back lash Linear scale GEBER_03 DSF Connection of direct position encoder DMS Connection of motor encoder IMS Motor FDD Machine table FDD Fig 3 40 2 encoder sys...

Page 170: ...he encoders in motor measuring systems in the conventional sense The machine zero and encoder zero are calibrated purely on the basis of the offset value the machine must be calibrated This process must be carried out for both incremental and absolute encoders Absoluter Geberistwert Verschiebe wert Lageistwert Geber nullpunkt Maschinen nullpunkt Einschaltposition Stillstandsposition ABSOL_01 DSF F...

Page 171: ...he axis referenced state is displayed using the axis specific interface signal referenced point reached as follows Interface signal Reference point reached 1 Axis state axis referenced Reference point reached 0 Axis state axis not referenced For 840D DB31 48 DBX60 4 DBX60 5 References IAD SINUMERIK 840D Installation Start Up Guide To reach the axis state axis safely referenced the axis state axis ...

Page 172: ...safely referenced is always reset refer to Fig 3 36 Axis states during referencing The status of the user agreement function is saved in non volatile memories This agreement data constitutes the previous history in combination with the standstill position data that is also saved in a non volatile fashion The saved standstill position data is combined with the permanently saved user agreement to fo...

Page 173: ...ion with absolute measuring systems or reference position with incremental measuring systems and the saved standstill position including traversing distance to reference point with ERN must be within a tolerance window specified via machine data Axis safely referenced EQN Read absolute value fromencoder ERN Approach reference point Axis status not OK Check Previous history no Check OK Axis referen...

Page 174: ...verview of the data for mounting encoders Table 3 65 Overview of machine data for 840D Number Name 36910 MA_SAFE_ENC_SEGMENT_NR 36911 MA_SAFE_ENC_MODULE_NR 36912 MA_SAFE_ENC_INPUT_NR 36915 MA_SAFE_ENC_TYPE 36916 MA_SAFE_ENC_IS_LINEAR 36917 MA_SAFE_ENC_GRID_POINT_DIST 36918 MA_SAFE_ENC_RESOL 36920 MA_SAFE_ENC_GEAR_PITCH 36921 MA_SAFE_ENC_GEAR_DENOM n 36922 MA_SAFE_ENC_GEAR_NUMERA n 36925 MA_SAFE_EN...

Page 175: ...med in two channels Machine data MA_ MD_SAFE_SLIP_VELO_TOL is introduced to both channels and the maximum offset between the NCK and drive actual value entered in it as a speed This machine data is converted to an internal format and is used as the actual value tolerance for the crosswise data comparison The tolerance value entered in MD 36949 MA_SAFE_SLIP_VELO_TOL is not relevant as only the new ...

Page 176: ...monitoring function with absolute reference is enabled at the same time If SE and or SN are also selected power ON Alarms 27033 and 301708 are also output during power up Actual value synchronization is therefore only permitted with SBH SG axes as in this case the absolute position is not necessarily needed Further actual value synchronization is only permitted for two encoder systems If this func...

Page 177: ...e are derived from one encoder the motor encoder As the actual value of the motor encoder is used for both monitoring channels the slip is ignored in this configuration the same behavior as for 1 encoder system If there is no free actual value input an additional module must be used An actual value input on another drive module must be used for spindle positioning This drive may not be an SI axis ...

Page 178: ...p between load and motor can exist V belt and is ignored Slip between load and motor may not exist toothed belt Table 3 67 Machine data for SINUMERIK 840D MD No MD name MD value for 1 for 2 30110 CTRLOUT_MODULE_NR 0 3 3 30200 NUM_ENCS 1 1 30220 ENC_MODULE_NR 0 4 3 30230 ENC_INPUT_NR 0 2 2 32110 ENC_FEEDBACK_POL 0 1 1 36912 SAFE_ENC_INPUT_NR 1 2 36925 SAFE_ENC_POLARITY 1 1 1316 SAFE_ENC_CONFIG 0 4 ...

Page 179: ...nected in the same way for the PLC and NCK SPL via the PROFIBUS DP HMI Embedded or HMI Advanced Distributed module block PROFIBUS DP MPI Bus DP Slave ET 200S DP Slave ET 200S BEI1_PS DSF SINUMERIK 840D Fig 3 46 SI I Os via F modules on PROFIBUS DP The benefits of this type of connection for safety relevant I O signals are Fewer cables are required as a result of the distributed structure Unified P...

Page 180: ...es and the actuators sensors field devices using the standard PROFIBUS functions The useful net data of the safety function plus the safety measures are sent This does not require any additional hardware components since the protocol chips driver repeater cable can still be used as they are Therefore both standard components and F components can be used on a PROFIBUS system 3 12 2 Available fail s...

Page 181: ...Order No 6ES7 151 1BA00 0AB0 Power module Power module PM E F DC24V PROFIsafe Order No 6ES7 138 4CF00 0AB0 Power module PM D PROFIsafe Order No 3RK1 903 3BA00 F electronic modules Digital electronics module 4 8 F DI DC24V PROFIsafe Order No 6ES7 138 4FA00 0AB0 Digital electronics module 4 F DO DC24V 2A PROFIsafe Order No 6ES7 138 4FB00 0AB0 Note 1 Standard power modules can used to shutdown fail s...

Page 182: ...and S7 F Configuration Pack V5 3 can be downloaded free of charge SINUMERIK Parameterizing NCK and PLC Software release from SW 6 3 30 Software option Distributed I Os via PROFIBUS DP Software option SINUMERIK Safety Integrated safety functions for personnel and machines 3 12 4 System structure PS_KOMSTRU1 DSF PROFIBUS DP DP Slave ET 200S PLC SPL PLC SINUMERIK 840D User level Operating system leve...

Page 183: ...guration and parameterization needed to connect the F modules to the external NCK PLC SPL interfaces entails the following steps 1 Create the configuration using SIMATIC STEP7 Refer to Chapter Configuring and parameterizing the ET 200S F I Os 2 Perform a standard SINUMERIK 840D commissioning minimum requirement 3 Load the configuration and the PLC basic and user program modules into the SINUMERIK ...

Page 184: ...ule Choose the appropriate DP slave IM 151 1 in the station window and then open the properties dialog box of the relevant F module in the detailed view The input output addresses that are assigned to an F module in the input output address area of the DP master are parameterized in the properties dialog box under Dialog box Properties of ET 200S standard module Tab Addresses Input Start Output St...

Page 185: ...lowing NCK machine data F DI module MD 10386 MN_PROFISAFE_IN_ADDRESS Index PROFIsafe address of an input module F DO PM E F PM D F module MD 10387 MN_PROFISAFE_OUT_ADDRESS Index PROFIsafe address of an output module Refer to Chapter Parameterizing the SINUMERIK 840D NCK The DIL switch setting shown corresponds to the PROFIsafe address to be set on the DIL switch of the F module The F monitoring ti...

Page 186: ...0D A_INSE INSEP n A_INSE INSEP n 1 A_INSE INSEP n 2 A_INSE INSEP n 3 ET 200S F DI module Channel 3 Channel 1 Channel 2 Channel 4 Channel 5 Channel 6 Channel 7 Channel 0 Configuration channel x y 2v2 AND AND AND AND Fig 3 48 2v2 mapping of the F DI channels to SPL input data 1v1 parameterization For 1v1 parameterization the process signals of both channels are transferred from the F DI module and c...

Page 187: ...put data to F DO channels When parameterizing the PROFIsafe clock cycle the DP cycle time determined by the HW Config must be observed to ensure correct PROFIsafe communications Also refer to the following Chapter Parameterizing the SINUMERIK 840D NCK After the station has been fully configured the DP cycle time can be determined by activating the isochronous bus cycle as follows In HW Config open...

Page 188: ... PROFIsafe communications In order to check the correct assignment of F module to F master the PROFIsafe address assigned by the HW Config for the F master must be entered in the following NCK machine data MD 10385 MN_PROFISAFE_MASTER_ADDRESS PROFIsafe address of F master Input format 0s 00 0a aa s Bus segment currently only 5 DP connection on the PLC side aaa hexadecimal PROFIsafe address of the ...

Page 189: ...ime the NCK is started Alarm 27200 PROFIsafe cycle time time ms is too long The PROFIsafe clock cycle should be parameterized longer than the DP clock cycle time displayed by the STEP7 HW Config refer to Chapter Configuring and parameterizing the ET 200S F I Os Otherwise the load on the PLC user program is increased as a result of unnecessary OB40 interrupts Note The PROFIsafe clock cycle should b...

Page 190: ...he PROFIsafe address of the F module is the value of the F parameter defined by HW Config F_Target_Address refer below Example of an assignment Note 1 The PROFIsafe address of an F module can be found under HW Config Properties dialog box of the F module F parameter F_Target_Address e g 1022D 3FEH Refer to Chapter Configuring and parameterizing the ET 200S F I Os 2 The PROFIsafe address of the F m...

Page 191: ...x assignment between ext SPL SST A_OUTSE OUTSEP and PROFIsafe output modules Index 0 15 Input format eee sss sss decimal SGE SGA start address 1 64 eee decimal SGE SGA end address 1 64 The SGE SGA start address always assigns bit 0 of the F useful data to the SPL SGE SGA sss The SGE SGA end address always assigns bit n of the F useful data to the SPL SGE SGA eee Bit number n is calculated as follo...

Page 192: ...ssigned more useful data bits of an F DI module of the SPL SGEs than are transferred to the relevant bits defined by the parameterization of the F DI module this cannot be detected by the NCK Example For 2v2 parameterization of all of the channels of the F module ET 200S F F DI module 4 8 F DI 24VDC the 8 transferred useful data bits contain only 4 actually relevant bits bit 0 to bit 3 In this cas...

Page 193: ...start address 005 SGE end address 008 03FEH 1022 No of bits SGE end address SGE start address 1 F DI block 1021 Transferred F useful data F DI block Module parameters Channel 1 5 activated Encoder evaluation Channel 2 6 activated Encoder evaluation Channel 3 7 activated Encoder evaluation Channel 4 8 activated Encoder evaluation Parameter F parameter F_target_address 2v2 2v2 2v2 2v2 1021 Used F us...

Page 194: ...241 PROFIsafe DP M version different NCK Version PLC Version 3 Alarm 27242 PROFIsafe F module F target address Parameter incorrect The following error states are detected during the NCK runtime and the appropriate alarms are displayed A new configuration was downloaded into the DP master during operation 1 Communications error between the F master and an F module 2 Communications error between the...

Page 195: ... is made available to the PLC from the NCK when the SINUMERIK 840D runs up This is in the form of an image of the relevant NCK machine data Data block DB18 has been extended to include two read only bit arrays INSEP_PROFISAFE OUTSEP_PROFISAFE The two bit fields are used to display which INSEP OUTSEP bytes are only assigned to F modules as a result of the parameterization in the NCK machine data MD...

Page 196: ...ote The PLC response time is decisive when activating 0 1 an output where TINPUT Processing transfer times for F DI module and DP slave TOUTPUT Processing transfer times for F DO module and DP slave TDPM Internal transfer cycle of DP master typically 2 ms TIPO Parameterized IPO cycle TPST Parameterized PROFIsafe cycle TOB1 OB1 processing time 3 12 9 Functional limitations I O modules available for...

Page 197: ...ition 11 03 3 197 Inputs outputs F useful data of an F module are automatically connected to the SPL interface in data block DB18 by the PLC basic program It is not possible to connect them in a PLC user program The I Os F useful data of an F module cannot be connected to axial 611D SGE SGAs They can only be connected in the context of the NCK SPL which must be installed for the purpose PLC SPL SG...

Page 198: ...changeover is selected this remains ineffective as the axial NCK monitoring functions are de activated However when an external STOP A is selected this results in the pulses being immediately cancelled via terminal 663 just the same as for an SBH selection An SG changeover can also result in immediate pulse cancellation If the NCK SGA enable pulses is not output via the local outputs on the NCU bu...

Page 199: ...puts on the NCU The DMP modules on the drive bus immediately set their outputs to 0 when the bus fails The axial SGE are still read in if they are not supplied from the DMP modules on the drive bus This means for example that an immediate pulse cancellation can be triggered e g by selecting SBH The images of the SGE from the DMP modules on the drive bus are left at their old values 3 13 3 Behavior...

Page 200: ...ion if the drive bus was to fail A_INSI is the input interface to the axial NCK monitoring functions This means that it includes the NCK SGA The NCK SGA are left in their old state so that when the drive bus fails no further action is require here A_OUTSI is the output interface to the axial NCK monitoring functions This means that it includes the NCK SGE In this interface only the SGE de selectio...

Page 201: ...AIL or the appropriate drive machine data 3 13 6 Limitations An ESR executed autonomously in the drive when the drive bus fails is only possible if the pulse enable is output at terminal 663 via the local outputs on the NCU The DMP modules themselves are connected to the same drive bus and when the drive bus fails they automatically clear their outputs When using the NCK SPL the input quantities o...

Page 202: ... MA_SAFE_VELO_STOP_REACTION 1 AX5 13 SG stage 2 MA_SAFE_VELO_STOP_REACTION 2 AX5 3 SG stage 3 MA_SAFE_VELO_STOP_REACTION 3 AX5 13 SG stage 4 Parameterization for the C axis AX6 pulses are only immediately cancelled in SG stages 1 and 3 STOP D is initiated when the SG is exceeded in SG stages 1 and 2 STOP C in SG stage 3 and STOP E in SG stage 4 MA_SAFE_VELO_STOP_MODE AX6 5 MA_SAFE_VELO_STOP_REACTI...

Page 203: ... for the Z axis AX3 STOP D is initiated when the SG is exceeded in SG stage 1 STOP E in SG stages 2 3 and 4 MA_SAFE_VELO_STOP_MODE AX3 5 MA_SAFE_VELO_STOP_REACTION becomes effective MA_SAFE_VELO_STOP_REACTION 0 AX3 3 SG stage 1 MA_SAFE_VELO_STOP_REACTION 1 AX3 14 SG stage 2 MA_SAFE_VELO_STOP_REACTION 2 AX3 14 SG stage 3 MA_SAFE_VELO_STOP_REACTION 3 AX3 14 SG stage 4 This results in the following b...

Page 204: ...nctions 11 03 3 13 Behavior of Safety Integrated when the drive bus fails from SW 6 4 15 Siemens AG 2003 All Rights Reserved 3 204 SINUMERIK 840D SIMODRIVE 611 digital SINUMERIK Safety Integrated FBSI Edition 11 03 Notes ...

Page 205: ...ne data 4 206 4 1 2 Description of the machine data 4 208 4 2 Machine data for SIMODRIVE 611 digital 4 240 4 2 1 Overview of the machine data 4 240 4 2 2 Description of the machine data 4 242 4 3 Interface signals 4 255 4 3 1 Interface signals for SINUMERIK 840D 4 255 4 3 2 Description of the interface signals 4 256 4 4 System variable 4 263 4 4 1 System variable for SINUMERIK 840D 4 263 4 4 2 Des...

Page 206: ...LE_TIME PROFIsafe communications clock cycle 10200 INT_INCR_PER_MM Calculation resolution for linear positions FBD G2 10210 INT_INCR_PER_DEG Calculation resolution for angular positions FBD G2 10366 HW_ASSIGN_DIG_FASTIN Hardware assignment of external digital NCK inputs FBD A4 10368 HW_ASSIGN_DIG_FASTOUT Hardware assignment of external digital NCK outputs FBD A4 10385 PROFISAFE_MASTER_ADRESS PROFI...

Page 207: ...Actual value comparison tolerance referencing 36946 SAFE_VELO_X Speed limit nx from SW4 2 36948 SAFE_STOP_VELO_TOL Tolerance actual speed for SBR from SW4 2 36949 SAFE_SLIP_VELO_TOL Speed tolerance slip 36950 SAFE_MODE_SWITCH_TIME Tolerance time for SGE changeover 36951 SAFE_VELO_SWITCH_DELAY Delay time speed changeover 36952 SAFE_STOP_SWITCH_TIME_C Transition time STOP C to safe standstill 36953 ...

Page 208: ...mode 37090 SAFE_BRAKETEST_TORQUE Brake test holding torque 37092 SAFE_BRAKETEST_POS_TOL Position tolerance for brake test 4 1 2 Description of the machine data General information about machine data and an explanation of their contents such as unit data type protection level effectiveness etc can be found in the following references References LIS Lists SINUMERIK 840D 10089 MD number MN_SAFE_PULSE...

Page 209: ...TIME Displays the monitoring cycle 840D Default Min input value Max input value Change becomes effective after POWER ON Protection level R W 7 Unit ms Data type DOUBLE Applies from SW 3 4 Meaning This data displays the monitoring clock cycle time that is actually effective For display purposes only cannot be written into Corresponds with MD 10090 MN_SAFETY_SYSCLOCK_TIME_RATIO References Refer to C...

Page 210: ...e of the specified Alarms 270xx or 300xxx is initiated The alarm of the monitoring channel that then subsequently initiates the alarm with the same significance is no longer displayed Furthermore Alarm 27001 with error code 0 is suppressed This alarm occurs as a result of drive Alarm 300911 In this particular case drive machine data 1391 1392 193 1394 provide information regarding the cause of the...

Page 211: ...ection DB3 x DBX22 0 Bit 1 SBH de selection DB3 x DBX22 1 Bit 3 SG selection bit 0 DB3 x DBX22 3 Bit 4 SG selection bit 1 DB3 x DBX22 4 from SW 6 Bit 12 SE selection DB3 x DBX23 4 Bit 28 SG correction bit 0 DB3 x DBX33 4 Bit 29 SG correction bit 1 DB3 x DBX33 5 Bit 30 SG correction bit 2 DB3 x DBX33 6 Bit 31 SG correction bit 3 DB3 x DBX33 7 x is the axis number The differences are indicated via A...

Page 212: ...nd MD MN_PROFISAFE_IPO_TIME_RATIO For display purposes only cannot be written into Special cases errors Corresponds with 10385 MD number MN_PROFISAFE_MASTER_ADDRESS PROFIsafe address of F master 840D Default 0 Min input value 0 Max input value 50FA7DH Change becomes effective after RESTART Protection level R W 7 2 Unit Data type DWORD Applies from SW 6 3 Meaning Defines the PROFIsafe address for t...

Page 213: ...d PROFIsafe output module 840D Default 0 Min input value 0 Max input value 64064 Change becomes effective after RESTART Protection level R W 7 2 Unit Data type DWORD Applies from SW 6 3 Meaning The three lower positions indicate the least significant A_OUTSE variables to be supplied The three upper positions indicate the most significant A_OUTSE variables to be supplied Example PROFISAFE_IN_ASSIGN...

Page 214: ...ic SPL 10392 MD number MN_SAFE_OUT_HW_ASSIGN n 0 7 Output assignment ext SPL interface 840D Default 0 Min input value 0 Max input value 01 1E 08 02 Change becomes effective after POWER ON Protection level R W 7 2 Unit Data type DWORD Applies from SW 4 4 18 Meaning One output byte of the NCK I Os can be assigned bytewise byte serial to the system variables A_OUTSE x using this machine data n System...

Page 215: ...rminal with each entry The structure is the same as MN_HW_ASSIGN_ANA_FASTOUT n 20108 MD number MC_PROG_EVENT_MASK Event controlled program call 840D Default 0x0 0x0 0x0 Min input value 0 Max input value 0xF Change becomes effective after POWER ON Protection level R W 7 2 Unit Data type DWORD Applies from SW 6 1 Meaning Parameterizes the event where the user program set with MN_PROG_EVENT_NAME defa...

Page 216: ...hecked if there is an error configuration Alarm 27033 is output The more partial functions that are set then the more computing time the safe functions require High byte Bit 15 Bit 14 Bit 13 Bit 12 Bit 11 Bit 19 Bit 9 Bit 8 Enable safe cams SN4 SN4 SN3 SN3 SN2 SN2 SN1 SN1 Low byte Bit7 Bit6 Bit5 Bit4 Bit 3 Bit 2 Bit 1 Bit 0 Enable from SW4 2 SW 6 3 From SW 5 2 Reserve d Enable Cam synchron ization...

Page 217: ...during run up The cam positions are also checked with respect to the parameterized actual value range during run up An appropriate alarm is output if parameterization errors are detected Actual value ranges set in MA_SAFE_MODULO_RANGE and MA_MODULO_RANGE must be a multiple integer Corresponds with MD 1305 MD_SAFE_MODULO_RANGE MD 30330 MA_MODULO_RANGE MD 36935 1336 MA_ MD_SAFE_CAM_POS_PLUS n MD 369...

Page 218: ...Absolute encoder with EnDat interface Special cases errors The value is coded in the same way as in data MA_ENC_TYPE Only the value 1 or 4 is permitted An incorrect configuration e g entry of values 0 2 3 or 5 is flagged with Alarm 27033 Corresponds with MD 30240 MA_ENC_TYPE 36916 MD number MA_SAFE_ENC_IS_LINEAR Linear scale 840D Default 0 Min input value 0 Max input value 1 Change becomes effecti...

Page 219: ...D Applies from SW 3 4 Meaning Denominator of the gearbox between encoder and load i e the denominator of the fraction No of encoder revolutions No of load revolutions n 0 1 7 stands for gear stage 1 2 8 The current value is selected via safety relevant input signals SGEs Corresponds with MD 36922 MA_SAFE_ENC_GEAR_NUMERA n MD irrelevant for a linear encoder 36922 MD number MA_SAFE_ENC_GEAR_NUMERA n...

Page 220: ...input value Change becomes effective after POWER ON Protection level R W 7 2 Unit mm min inch min rev min Data type DOUBLE Applies from SW 3 4 Meaning The limit values for safely reduced speeds 1 2 3 and 4 are set in this data When SG1 SG2 SG3 or SG4 is selected and the current speed exceeds the limit set here then the control system activates Alarm 27011 with the stop response configured in MA_SA...

Page 221: ...DOUBLE Applies from SW 3 4 Meaning The upper limit value for safe end positions 1 and 2 is specified here If SE1 or SE2 is selected and the actual position exceeds the limit set in this data the control system activates Alarm 27012 with the stop response configured in MA_SAFE_POS_STOP_MODE and changes over to the SBH mode A violation of the SBH tolerance window initiates stop response STOP B and A...

Page 222: ...inus cam position of SN1 SN2 SN3 SN4 Corresponds with MD 36989 MA_SAFE_CAM_MINUS_OUTPUT n MD 36901 MA_SAFE_FUNCTION_ENABLE 36940 MD number MA_SAFE_CAM_TOL Tolerance for safe cams 840D Default 0 1 mm Min input value 0 001 Max input value 10 mm Change becomes effective after POWER ON Protection level R W 7 2 Unit mm inches degrees Data type DOUBLE Applies from SW 3 4 Meaning Due to the different mou...

Page 223: ... and a new user agreement is required for referencing 36946 MD number MA_SAFE_VELO_X Speed limit nx 840D Default 20 0 Min input value 0 0 Max input value 1 000 0 Change becomes effective after POWER ON Protection level R W 7 2 Unit mm min inch min rev min Data type DOUBLE Applies from SW 4 2 Meaning This data defines limit speed nx for SGA n nx Corresponds with MD 1346 MD_SAFE_VELO_X References Re...

Page 224: ...n this data is started when changing from a high to a lower safely reduced speed or when a safe operating stop is selected when the safely reduced speed function is active While the timer is running the speed continues to be monitored for the last selected speed limit value During this period the axis spindle can be braked for example via the PLC user program without the monitoring function signal...

Page 225: ...ection level R W 7 2 Unit s Data type DOUBLE Applies from SW 3 4 Meaning For a STOP B the axis is braked along the current limit with speed setpoint 0 After the delay time defined in this data the braking mode changes to STOP A for pulse cancellation Special cases errors The pulses are cancelled earlier than defined in this data if the condition for the pulse cancellation is present as specified i...

Page 226: ...n level R W 7 2 Unit mm min inch min rpm Data type DOUBLE Applies from SW 3 4 Meaning When the axis spindle speed drops below this limit it is considered to be at a standstill In STOP B mode the pulses are then cancelled through transition to STOP A Corresponds with MD 36956 MA_SAFE_PULSE_DISABLE_DELAY 36961 MD number MA_SAFE_VELO_STOP_MODE Stop response safely reduced speed 840D Default 5 Min inp...

Page 227: ...peed is exceeded The tens position defines the behavior when the drive bus fails on an SG specific basis if a time greater than 0 was parameterized in MN_SAFE_PULSE_DIS_TIME_BUSFAIL 0 Stop A 1 Stop B 2 Stop C 3 Stop D 4 The tens position defines the behavior when the drive bus fails on an SG specific basis if a time greater than 0 was parameterized in MD MN_SAFE_PULSE_DIS_TIME_BUSFAIL 10 Stop A in...

Page 228: ...ax input value Change becomes effective after POWER ON Protection level R W 7 2 Unit Data type BOOLEAN Applies from SW 5 2 Meaning Enable the suppression of Alarms 27000 300950 Axis not safely referenced when the Parking function is selected Corresponds with 36966 MD number MA_SAFE_BRAKETEST_TORQUE Brake test holding torque 840D Default 5 Min input value 0 Max input value 800 Change becomes effect...

Page 229: ...essing s Segment No 1 4 1 I Os on 611 digital bus terminal 4 Internal map in system memory system variable Further parameterization if one terminal is assigned s 1 mm Module no 01 1F Number of the logical slot in which the terminal block with external I Os is inserted drive number xx Submodule No 01 08 Slot number of the sub module inside the I O module nn I O No 01 10 Bit number input output numb...

Page 230: ... and SBH cannot be de selected Input value 80 00 00 00 means There is no assignment the input remains at 1 If MD bit 31 is set then the signal is processed inverted ss 81 References FB A4 Digital and Analog NCK I Os Corresponds with MD 10366 MN_HW_ASSIGN_DIG_FASTIN MD 13010 MN_DRIVE_LOGIC_NR 36971 MD number MA_SAFE_SS_DISABLE_INPUT Input assignment SBH de selection 840D Default 0 Min input value 0...

Page 231: ... means 0 SE1 is active 1 SE2 is active Special cases errors If MD bit 31 is set then the signal is processed inverted ss 81 References MD 36970 MA_SAFE_SVSS_DISABLE_INPUT 36974 MD number MA_SAFE_GEAR_SELECT_INPUT n Input assignment gear ratio selection 840D Default 0 Min input value 0 Max input value Change becomes effective after POWER ON Protection level R W 7 2 Unit Data type DWORD Applies from...

Page 232: ...e current limit Index 2 Assignment for de selection ext STOP D braking along the path Index 3 Assignment for de selection ext STOP E ESR braking along the path For safety reasons inverted logic is used for these signals Corresponds with MD 36970 MA_SAFE_SVSS_DISABLE_INPUT References Refer to Chapter 3 External STOPs 36978 MD number MA_SAFE_OVR_INPUT n 0 3 Input assignment SG override selection 840...

Page 233: ...n of the SGA machine data MD 36980 to MD 36990 Structure of the output assignment SBH SG de selection is mm xx nn Perm values Explanation i Inversion 0 8 0 No inversion 8 Inversion before processing s Segment No 1 4 1 I Os on 611 digital bus terminal 4 Internal image in system memory system variable Further parameterization if one terminal is assigned s 1 mm Module No 01 1F Number of the logical s...

Page 234: ...ed to a terminal the following applies If MD bit 31 is set then the signal is processed inverted ss 81 If several output signals are connected to the same terminal the following applies If MD bit 31 is set ss 81 the relevant signal is initially inverted The in some cases inverted output signals are then ANDed and the result output at the terminal References FB A4 Digital and analog NCK I Os 36981 ...

Page 235: ...lse enable 840D Default 0 Min input value 0 Max input value 0x811E0810 Change becomes effective after RESTART Protection level R W 7 2 Unit Data type DWORD Applies from SW 6 3 Meaning This MD must be parameterized as soon as the internal pulse cancellation is used bit 30 in MA_SAFE_PULSE_ENABLE_OUTPUT 1 Structure Refer to coding of input assignment With each machine data of this kind a single I O ...

Page 236: ...BLE_OUTPUT and MA_SAFE_STOP_REQUEST_EXT_INPUT Possible values of i Value Meaning 0 The SGA enable pulses is output at the parameterized interface SPL or periphery 4 The pulses are internally cancelled via the drive bus The SGA enable pulses contains the same information and is output at the parameterized interface SPL or periphery This SGA is not transferred if mm xx and nn 0 8 The SGA enable puls...

Page 237: ... ss 81 If several output signals are connected to the same terminal the following applies If MD bit 31 is set ss 81 the relevant signal is initially inverted The in some cases inverted output signals are then ANDed and the result output at the terminal Further references MD 36980 MA_SAFE_SVSS_STATUS_OUTPUT 36989 MD number MA_SAFE_CAM_MINUS_OUTPUT n Output assignment SN1 to SN4 840D Default 0 Min i...

Page 238: ...E_CROSSCHECK_CYCLE Displays axial crosswise comparison clock cycle 840D Default 0 Min input value 0 Max input value Change becomes effective after POWER ON Protection level R W 7 2 Unit Data type DWORD Applies from SW 6 3 Meaning Indicates effective axial comparison clock cycle in seconds Obtained from INFO_SAFETY_CYCLE_TIME and the number of data to be compared crosswise The axial value displayed...

Page 239: ...eference to the machine has been lost then the user agreement is automatically cancelled e g during gear changes or if the plausibility comparison with the stored standstill position fails during referencing Special cases errors Any manual changes to the MD are detected the next time the control is powered up and the axis reference checked for plausibility User agreement is required again after re...

Page 240: ...ANDSTILL_TOL 36930 MA_SAFE_STANDSTILL_TOL Standstill tolerance SBH Standstill tolerance 1331 MD_SAFE_VELO_LIMIT n 36931 MA_SAFE_VELO_LIMIT n Limit values for safely reduced speed Limit value for safely reduced speed 1332 MD_SAFE_VELO_OVR_FACTOR n 36932 MA_SAFE_VELO_OVR_FACTOR n Correction factor for SG SG override values 1334 MD_SAFE_POS_LIMIT_PLUS n 36934 MA_SAFE_POS_LIMIT_PLUS n Upper limit valu...

Page 241: ...r NCK SI acceptance test mode 1371 MD_SAFE_TEST_STATE corresponds to BTSS variables for NCK SI acceptance test status 1380 MD_SAFE_PULSE_DIS_TIME_FAIL corresponds to BTSS variables for NCK Time until pulse cancellation 1390 MD_SAFE_FIRMWARE_VERSION not available for 840D Firmware release Safety Integrated 1391 MD_SAFE_DIAG_NC_RESULTLIST1 not available for 840D Diagnostics NC result list 1 1392 MD_...

Page 242: ...al functions for safe operation on an axis specific or spindle specific basis The bit assignment is as follows Bit 15 Bit 14 Bit 13 Bit 12 Bit 11 Bit 10 Bit 9 Bit 8 High byte Enable safe cams SN4 SN4 SN3 SN3 SN2 SN2 SN1 SN1 Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Low byte Enable 840D from SW4 2 Reserved these bits must be set to 0 Enable Cam synchron ization External STOPs Override safely ...

Page 243: ...hine data MD 36905 MA_SAFE_MODULO_RANGE MD 36936 1336 MA_ MD_SAFE_CAM_POS_PLUS n MD 36937 1337 MA_ MD_SAFE_CAM_POS_MINUS n 1316 MD_SAFE_ENC_CONFIG 611 digital Motor encoder configuration safety relevant functions Relevant for FD MSD Unit Default 0 Minimum value 0 Maximum value 00 07 Data type Binary Becomes effective POWER ON Axis and encoder bits related to safety functions Bit 15 Bit 14 Bit 13 B...

Page 244: ... a total of 8 values n 0 7 the current value is selected by means of SGEs 1322 MD_SAFE_ENC_GEAR_NUMERA n 611 digital Numerator of encoder load gear Relevant for FD MSD Unit Default 1 Minimum value 1 Maximum value 8 388 607 Data type long integer Becomes effective POWER ON Numerator of the gear between encoder and load i e the numerator of the fraction number of encoder revolutions number of load r...

Page 245: ...m SW version 4 2 Unit Default 100 Minimum value 1 Maximum value 100 Data type short integer Becomes effective POWER ON It is possible to select overrides via SGEs for safely reduced speeds 2 and 4 and to set the associated override value percentage in this machine data n 0 1 15 stand for overrides 0 1 15 The override for safely reduced speed function is enabled via MD 36901 MD 1301 MA MD _SAFE_FUN...

Page 246: ...N4 If the safe actual position exceeds the position set in the machine data then the SGA assigned to the relevant cam is set to 1 1340 MD_SAFE_CAM_TOL 611 digital Tolerance for safe cams Relevant for FD MSD Unit µm or 0 001 degrees Default 100 Minimum value 1 Maximum value 10 000 Data type long integer Becomes effective POWER ON Tolerance threshold for all safe cams As a result of the minimum meas...

Page 247: ...tor gearboxes lower resolution for 2 encoder systems oscillating travel for selector gearboxes 1346 MD_SAFE_VELO_X 611 digital Speed limit nx Relevant for FD MSD Valid from SW4 2 for 840D Unit mm min rpm Default 20 Minimum value 0 Maximum value 1 000 Data type float Becomes effective POWER ON This data defines the speed limit nx for SGA n nx Setting 0 means n nx is not active 1348 MD_SAFE_STOP_VEL...

Page 248: ...t 1351 MD_SAFE_VELO_SWITCH_DELAY 611 digital Delay time speed changeover Relevant for FD MSD Unit ms Default 100 Minimum value 0 Maximum value 10 000 Data type float Becomes effective POWER ON Timer for the SGE delay timer The timer is started at the transition from the safely reduced speed function to the safe operating stop mode or when the speed monitoring limit is reduced to a lower speed Duri...

Page 249: ...1 digital Transition time from STOP F to STOP B Relevant for FD MSD Unit ms Default 100 Minimum value 0 Maximum value 60 000 Data type float Becomes effective POWER ON When this time in this timer stage expires a transition is made from STOP F to STOP B 1356 MD_SAFE_PULSE_DISABLE_DELAY 611digital Delay time pulse cancellation Relevant for FD MSD Unit ms Default 100 Minimum value 0 Maximum value 10...

Page 250: ...ore the speed drops below the limit set in the above data then the drive pulses are prematurely cancelled 1361 MD_SAFE_VELO_STOP_MODE 611 digital Stop response for safely reduced speed Relevant for FD MSD Unit Default 5 Minimum value 0 Maximum value 15 Data type short integer Becomes effective POWER ON Selects the STOP response when the safely reduced speed monitoring responds 0 1 2 3 4 correspond...

Page 251: ...SS variables safeAcceptTestState for the NCK signals the state of the drive regarding the acceptance test mode 0 Acceptance test mode inactive 0xC At least 1 active SI POWER ON alarm present when the system goes into the acceptance test mode 0xD Incorrect ID received in MD 1370 0xF Acceptance timer has expired 0xAC Acceptance test mode is active 1380 MD_SAFE_PULSE_DIS_TIME_FAIL 611 digital Time up...

Page 252: ...rror in the result cross check of the safe operating stop SBH function Data that is relevant for the safe operating stop function must be checked in the NCK and drive channels 1393 1394 MD_SAFE_DIAG_NC_RESULTLIST2 MD_SAFE_DIAG_611digital_RESULTLIST2 611 digital Diagnostics NC result list 2 Diagnostics 611 digital result list 2 Relevant for FD MSD Unit Default 0 Minimum value 0 Maximum value FFFF F...

Page 253: ...type Binary Becomes effective Immediate The user must input his agreement acknowledgement manually to change over the axis from the axis referenced IS state to the axis safely referenced SGA state The user agreement does not have to be given when the axis is referenced again provided that the comparison of the standstill position and the reference position which is automatically made during power ...

Page 254: ...chine data for safety functions Relevant for FD MSD Unit Default 00 00 00 00 Minimum value 00 00 00 00 Maximum value FF FF FF FF Data type Long integer Becomes effective POWER ON This data contains the setpoint checksum of the actual values of the SI machine data that was saved during the last machine acceptance test After POWER ON the actual checksum is calculated entered into MD 1398 MD_SAFE_ACT...

Page 255: ...l structure of Safety Integrated the machine manufacturer must supply the SGEs and SGAs in both the NCK monitoring channel and the drive monitoring channel Unused SGEs must be set to a defined state 4 3 1 Interface signals for SINUMERIK 840D Table 4 3 Interface signals for 840D DB 31 Signals to from drive Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 22 Reserved Reserved Reserved SG selecti...

Page 256: ...ect the SBH and SG functions Table 4 4 Selection de selection of SBH and SG SGE SBH SG de selection SBH de selection Meaning 1 x SBH and SG are deselected 0 0 SBH is selected refer to Chapter 3 Safe operating stop SBH 0 1 SG is selected x Signal state optional This signal provides the NC monitoring channel with feedback as to whether the pulses were cancelled during the test stop By combining thes...

Page 257: ...can be more finely graduated An override factor of between 1 and 100 can be assigned to the selected override via the following machine data For 840D MD 36932 MA_SAFE_VELO_OVR_FACTOR n override factor safely reduced speed For 611 digital MD 1332 MD_SAFE_VELO_OVR_FACTOR n This signal is used to initiate the shutdown path test for the drive monitoring channel SGE Teststop Anwahl Vorgang Impulse lösc...

Page 258: ...STOP A C D and E from SW 6 4 15 onwards via SGEs The test stop of external STOPs is divided into the following 2 phases Phase 1 The shutdown path is tested as always refer to Chapter 3 1 3 Testing shutdown paths The safe pulse cancellation is tested to ensure that it is functioning correctly Successful completion of this phase is signaled as follows For the NCK monitoring channel A positive checkb...

Page 259: ...er to SBH If a stop request is active SGA STOP C is active is set in the same way as it would be for an internally triggered STOP C 0 signal Braking with nset 0 is requested 1 signal No request for braking with nset 0 Note Stopping with an external STOP A pulse cancellation has a higher priority and can interrupt an external STOP C braking at the current limit Braking along a path can be requested...

Page 260: ...re internally cancelled This SGA is used by the drive monitoring channel to signal the status of the SBH and SG functions in the following way 0 signal SBH SG is not active 1 signal SBH SG is active This SGA controls terminal 663 to enable signals for the drive After the shutdown path test has been initiated via the SGE test stop selection or if a limit value is violated with a resulting STOP A re...

Page 261: ... not active 1 signal STOP C is active This signal indicates that STOP D is active The signal must be used for the forced checking procedure for external STOPs 0 signal STOP D is not active 1 signal STOP D is active This signal indicates that STOP E is active The signal must be used for the forced checking procedure for external STOPs 0 signal STOP E is not active Otherwise STOP E is active This SG...

Page 262: ... the SGA The SGAs SG active bit 1 0 display which safely reduced speed and therefore which speed limit value is actively monitored The SGAs are only updated when the function SBH SG is enabled and SG is active SGE SBH SG de selection 0 and SBH de selection 1 Table 4 7 Display of the active safely reduced speed SGA SG active Bit 1 SG active Bit 0 SBH SG active SBH active Meaning 0 0 1 1 SBH is acti...

Page 263: ... x A_OUTSI n NCK output n 1 2 64 stands for No of output BOOL x x x x A_OUTSID n NCK outputs n 1 2 INT x x x x A_OUTSIP n Image of the PLC output n 1 2 64 BOOL x x A_OUTSIPD n Image of the PLC SPL outputs from the drive monitoring channel n 1 2 INT x x External inputs outputs A_INSE n NCK input n 1 2 64 stands for No of input BOOL x x A_INSED n NCK inputs n 1 2 INT x x A_INSEP n Image of a PLC SPL...

Page 264: ...tands for No of timer REAL x x x x A_STATSID Crosswise data comparison error initiated if the value is not equal to 0 n 0 Error not triggered n 1 Error triggered INT x x A_CMDSI 10 fold change timer timeout value for long forced checking procedure pulses and or single channel test stop logic Bit 0 0 10 fold time active BOOL x x x x A_LEVELSID Crosswise data comparison stack level display Number of...

Page 265: ...is between NCK and 611D an actual value error has been detected 1 In the crosswise data comparison between NCK and 611D of any axis an error was detected and the delay time until STOP B is initiated in this axis is running or has already expired 0 3 INT x x VA_STOPSI from SW 6 4 15 Actual Safety Integrated stop of relevant axis 1 No stop 0 Stop A 1 Stop B 2 Stop C 3 Stop D 4 Stop E 5 Stop F 10 Tes...

Page 266: ...ontrol References PGA Programming Guide Production Planning Reading actual value crosswise data comparison errors using system variables If a crosswise data comparison between NCK and 611 digital detects errors the response is determined by the current operating state SBH SG SE or SN active After a Stop F a crosswise data comparison error leads to a Stop B which initiates the fastest possible brak...

Page 267: ... Cam 1 can be evaluated in the SPL via system variable A_INSI 1 For a precise description of MD parameterization refer to Chapter 4 Machine data for SINUMERIK 840D Programming example Copying an SGA from the internal SPL interface into the external SPL interface NCK I O N1010 IDS 01 DO A_OUTSE 1 A_INSI 1 These system variables can only be read by the user program The status signals of the NCK moni...

Page 268: ...ASSIGN 7 A_INSE 57 64 For a precise description of MD parameterization refer to Chapter 4 Machine data for SINUMERIK 840D The user program can only read these system variables The external control signals can be evaluated double word serial in the NCK SPL via these system variables A_INSED 1 corresponds to A_INSE 1 32 A_INSED 2 corresponds to A_INSE 33 64 The user program can only read these syste...

Page 269: ...IMERSI 1 2 0 DO A_TIMERSI 1 0 0 A_TIMERSI 1 1 0 A_MARKERSI 2 1 This system variable can be used in the NCK SPL to evaluate whether in the crosswise data comparison between NCK and PLC an error was detected in the two channel control processing of the control and status signals This gives the user the opportunity to respond to this error with special synchronous actions Programming example For cros...

Page 270: ...Associated DB18 values DB18 DBD54 DBD58 Images of the PLC side internal SPL output signals control signals to the drive monitoring channel can be read via these system variables Associated DB18 values DB18 DBX62 0 DBX69 7 Images of the PLC side internal SPL output signals control signals to the drive monitoring channel can be read double word serial 32bit via these system variables Associated DB18...

Page 271: ...een NCK and PLC SPL Signals can be read by the PLC and written by the NCK The system variables are updated in the same clock cycle as the crosswise data comparison between the NCK and the PLC These system variables can only be accessed reading These system variables may only be used in the commissioning phase As soon as commissioning has been signaled as completed access to these system variables ...

Page 273: ...5 1 5 Changing data 5 280 5 2 Acceptance report 5 282 5 3 Conventional acceptance test 5 286 5 4 NCK acceptance test support 5 288 5 4 1 Scope of the test list 5 289 5 4 2 Internal mechanisms to support the test procedure 5 290 5 4 3 Trace techniques 5 292 5 4 4 Basic operating information and instructions 5 293 5 5 Diagnostics 5 294 5 5 1 Troubleshooting procedure 5 294 5 5 2 Diagnostics support ...

Page 274: ... have been enabled then they become operational after the control system has run up basic display on screen Cam and limit positions can be evaluated reliably for the SN and SE functions once the axes have been safely referenced Caution Protection of operating personnel must be the primary consideration when configuring machine data for SINUMERIK Safety Integrated This is this reason that the param...

Page 275: ...m Freigabe X 10 04 95 DIR GP Makros Diagnose DIR 10 04 95 X X X X X X X X X X X X X X X 10 04 95 10 04 95 10 04 95 10 04 95 10 04 95 10 04 95 10 04 95 10 04 95 10 04 95 10 04 95 10 04 95 10 04 95 10 04 95 10 04 95 DIR DIR DIR DIR DIR DIR DIR DIR DIR DIR MDN DIR DIR DIR Datenhaltung Dialog Programmierung DP Anwenderbilder DP Werkzeuge DP Hilfe DP Basisinfo HSA Daten MBDDE Alarmtexte Teileprogramme ...

Page 276: ...es are automatically saved after data has been copied After an NCK RESET and the current checksum is saved by selecting the softkey labeled CONFIRM SI DATA in the Drive configuration display and acknowledging the following dialog box with OK From now on the SI data will be monitored for changes The boot files are automatically saved after being acknowledged 5 1 2 First commissioning It is advisabl...

Page 277: ...oring function for all of the axes to be safely monitored Enter the following in the specified sequence in the axis specific machine data display Function enabling bits Axis characteristics rotary or linear axis Measuring circuit assignment i e which encoder will supply the safety actual value what type of encoder it is and how it is mechanically flanged For rotary axes an NCK RESET must be given ...

Page 278: ...els and monitored for changes from this point onwards Drive data is also automatically saved to a non volatile memory as with SAVE BOOTFILES A dialog box is now displayed on the screen requesting you to perform an acceptance test You must acknowledge the box The safety monitoring functions are now ready to be used and can be activated as described in Chapter 2 Monitoring clock cycle and crosswise ...

Page 279: ... password go to the screen Start up Machine configuration and select the vertical softkey labeled PASSWORD DELETE PASSWORD 5 1 3 Series commissioning The settings for the safety monitoring functions are automatically transferred with other data in the course of a normal series commissioning process The following steps need to be taken in addition to the normal commissioning procedure 1 Enter a use...

Page 280: ...unction s involved and then recorded and confirmed in the acceptance report Changes made to NCK machine data important for Safety Integrated are recorded in a display data These change times are displayed in axial MD 36996 MA_SAFE_CONFIG_CHANGE_DATE 0 4 This MD can neither be overwritten by manual entry nor by loading an MD archive It can only be deleted by running up the control from the general ...

Page 281: ...the function enable are automatically cancelled again for the excess number of axes when the control runs up Loading an MD archive that is different to the NCK MD set currently active Upgrade corresponds to downloading an MD archive Series commissioning corresponds to downloading an MD archive Changes to the MD configuration are only noted when the change becomes active i e after altering MD MA_SA...

Page 282: ...person who carried out the acceptance tests The acceptance test report must be kept in the logbook of the particular machine After the SPL has been commissioned the access rights for the NCK SPL SAFE SPF via the HMI interface must be reduced to the manufacturer or service level and documented in the acceptance report Authorization in the above sense is a person authorized by the machine manufactur...

Page 283: ...toring functions depending on the operating mode the protective doors and other sensors Ideally this table should be the object and result of the configuring work 5 SI functions per axis 6 Information about the safety equipment FUNCTION TEST PART 1 General function check incl checking the wiring programming 7 Test the shutdown paths path test the forced checking procedure of the shutdown paths 8 T...

Page 284: ...rade software NCU drive PLC Supplement version data Yes with note about when the new function is to be introduced Yes if system cycles or acceleration behavior e g also jerk have been changed and the new function tested Supplement possibly new checksums and counter signature Upgrade software MMC Possible supplement SW version No No No Replace NCU hardware e g upgrade of NCU 572 NCU 573 If the NCU ...

Page 285: ... supplement machine description check the SW version Yes with note No if data are identical No if data are identical check checksums Replace hardware of SI relevant peripherals e g I O modules No Yes with note about limitation to replaced components No No The acceptance report is included as a Word file in the toolbox supplied and is made up of the following parts System description Description of...

Page 286: ...he position closed loop control by reversing the polarity of the position actual value using the machine data Start the function generator with speed controller setpoint input References IAD SINUMERIK 840D Installation Start Up Guide The distance traveled by the axis until it is stopped by the configured stop response can be read from the actual value display The time required to stop the axis can...

Page 287: ... until the desired cam signal NCK SGA PLC SGA is output Test the limit positions enstops by passing them at various axis speeds Locate the limit position enstops at the center of the axis Pass the position at various axis speeds and in the rapid traverse mode Calculate the remaining distance traveled by the axis until it is stopped by the configured stop response Locate the safe limit in front of ...

Page 288: ...nces by changes made to the PLC program and to MD settings and the alarms that were issued were documented Further servo trace plots were evaluated using the associated measuring function and the results and graphics transferred into a document that the OEM had created The principle contents and structure of such a document is described in Chapter 5 2 Acceptance report Based on this method the exi...

Page 289: ...tdown paths for the NCK and drive External stops Test the forced checking procedure of the used external stop responses when using SPL SPL inputs outputs Test the forced checking procedure if required of the external SPL I O Qualitative function checks EMERGENCY STOP Test the internal EMERGENCY STOP functionality when executed via external stop responses and the response to the external SPL I O In...

Page 290: ...st mode acceptance test from group 1 e g SBH test SG test and in groups that do not require an acceptance test mode acceptance tests from group 2 e g acceptance test for SE For the test steps of group 1 these include testing the SBH response and SG response an additional state is active under defined secondary conditions This state has specific internal features that support the test procedure Thi...

Page 291: ...me to time as the described acceptance test mode has some associated internal and extensive consequences It is de selected using the following conditions As a result of an NCK Reset When an internal timer value expires that defines the maximum time that the state can be active This timer value is set in the following machine data MD 36958 MA_SAFE_ACCEPTANCE_TST_TIMEOUT NCK and MD 1358 MD_SAFE_ACC_...

Page 292: ...ive e g when changing over from SE1 to SE2 monitoring with the mode active With the mode active if the JOG NC mode is no longer active 5 4 3 Trace techniques A test is carried out prompted step by step using the SinuCom NC operator interface There are various trace techniques which can be used to confirm and log as to whether the test was positively carried out Text entry by the operator A table o...

Page 293: ...esources for the function The values to be set should be taken from the SINUMERIK SinuCom NC start up tool 5 4 4 Basic operating information and instructions The operator is prompted step by step when carrying out a test The following secondary conditions must be observed especially for those tests that use the internal trace function If a traversing direction has been selected then this must also...

Page 294: ...test that was carried out are incorporated in the document The report is structured the same as the document that was previously manually created Some sections such as for example the machine overview function table of the configured safety functions etc that are not standardized are still manually incorporated in the document at a later data 5 5 Diagnostics 5 5 1 Troubleshooting procedure The ala...

Page 295: ...p monitoring active Safely reduced speed monitoring active Active SG step Active SG correction factor Safely reduced actual speed limit Setpoint speed limit Actual speed difference Maximum speed difference Active safe software limit switch Active gear ratio step Active stop Currently requested external stop Stop F code value Alarm 300911 Pulses enabled Traversing inhibit due to a stop in other axi...

Page 296: ...NUMERIK Safety Integrated FBSI Edition 11 03 Fig 5 4 Status display of SGE SGA The available signals are shown in the figure above The vertical softkey Status SI accesses the SI status screen the SPL softkey accesses the screen for safe programmable logic Fig 5 5 shows the status display of the safe input output signals ...

Page 297: ...ed status Axis safety referenced SN1 SN1 SN2 SN2 SN3 SN3 SN4 SN4 SBH active n n x Bit 0 Bit 1 Bit 2 Bit 0 Bit 1 0 X 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1 0 1 0 0 1 0 0 0 1 1 1 1 1 0 1 1 Safe output signals drive 1 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 Safe output signals axis 2 Enable pulses SG active Bit 1 Bit 0 Axis NCK monitoring channel Drive Drive monitoring channel Stop A Sto...

Page 298: ...it areas are saved and are taken into account when subsequently selecting the screen Using the select key the following formats can be selected in the variable rows B Binary H Hexadecimal D Decimal The selected format applies for all of the variables displayed in the screens 5 5 2 Diagnostics support by configuring your own extended alarm text In order to upgrade the level of diagnostics informati...

Page 299: ...ntry The processing of an extended alarm text for the above specified alarms is prepared as part of this definition File excerpt aln_gr com 027090 0 0 Error for crosswise data comparison NCK PLC 1 2 NCK 3 4 ALSI 027254 0 0 PROFIsafe F module 1 error in channel 2 3 ALSI An extended alarm text can be defined for an alarm using the supplement 4 ALSI Alarm 27090 and 3 ALSI Alarm 27254 If required this...

Page 300: ...bles A_INSI P 01 64 only Alarm 27090 193 256 Error in system variables A_OUTSI P 01 64 only Alarm 27090 257 320 Error in system variables A_MARKERS P 01 64 only Alarm 27090 The file in which the extended texts are defined is also declared in the configuration file for the alarm server file MBDDE INI in the section IndexTextFiles File excerpt mbdde ini IndexTextfiles ALSI f dh mb dir alsi_ Example ...

Page 301: ...ace for drive signals and NCK signals measurements can be started by entering a measuring time and trigger conditions The results of the measurements are then graphically displayed Two curves can be displayed in 2 graphics The results of the measurements can be saved in files Further the graphics can be saved as bitmap file in the HMI_ADV data manager or directly printed out After MMCWIN has been ...

Page 302: ...gger time specific thresholds and various trigger signals can be set e g a trigger from the part program These settings are used to parameterize the PI services at segment values and offset values of NCK using the vertical start softkey A measure ment that has already been started can be interrupted using the vertical stop softkey In this case the NCK does not supply any measured values If the phy...

Page 303: ... be used to troubleshoot the problem When NCK ends the measurement the buffers that contain the factors that are used to convert from the formats on the NCK side to the physical units for display with HMI_ADV and the actual measured values are transferred to the HMI_ADV The number of buffers depends on the number of trace channels that are assigned trace 1 to trace 4 When the buffers are being tra...

Page 304: ...ameterization of the measurement can be seen from the basic screen of the servo trace this can be accessed using the horizontal measurement softkey Measurement settings and the measured values of the servo trace functions can be saved downloaded or deleted using the horizontal file functions softkey A detailed description will not be provided here More detailed information can be found in the foll...

Page 305: ...to an Ini file hmi_adv ibsvtsi ini If the user wishes to change the default assignment he can do this in the file hmi_adv ibsvtsi ini or using the appropriate forms in the operator interface These different bit coded SI signals are parameterized on the operator interface The settings do not modify the measurement but only how the results of the measurement are actually displayed in the graphic No ...

Page 306: ... 1 to trace 4 bit names of these SI signals to be assigned a possible 10 character channels tracks in the bit graphics for these signals A dedicated graphic is displayed for trace 1 trace 2 trace 3 and trace 4 If a bit coded SI signal is not selected in a trace channel then when the corresponding softkey is pressed it has no effect information is output in the dialog line to signal that it does no...

Page 307: ...ignated with free or reserved Using the scrollbar it is possible to scroll over the bit range from 0 to bit 31 Starting values for the track assignments have been entered into the file hmi_adv ibsvtsi ini If the user does not like these then he can make changes as he wishes These changes for the bit graphics become effective if the vertical Accept softkey and are also transferred into the file hmi...

Page 308: ...tics Siemens AG 2003 All Rights Reserved 5 308 SINUMERIK 840D SIMODRIVE 611 digital SINUMERIK Safety Integrated FBSI Edition 11 03 comparison purposes This means that especially inputs and outputs of various SI signals can be combined ...

Page 309: ... Siemens AG 2003 All Rights Reserved SINUMERIK 840D SIMODRIVE 611 digital SINUMERIK Safety Integrated FBSI Edition 11 03 6 309 6 Alarms 6 1 Alarms for SINUMERIK 840digital 6 310 6 2 Alarms from SIMODRIVE 611 digital 6 343 6 3 Alarm suppression 6 355 6 ...

Page 310: ...ake test Response Alarm display The function test of the brake mechanical system is aborted Remedy Check the parameterization for the brake test function The torque for the weight equalization in drive machine data 1192 should be nearly the same as the actual holding torque The specified torque for the brake test in MD MA_SAFE_BRAKETEST_TORQUE must be set higher than the actual holding torque Prog...

Page 311: ...e is carried out to verify the standstill position saved prior to powering down the control The alarm display can be set using MD MN_SAFE_ALARM_SUPPRESS_LEVEL MD 3 so that the group alarm 27100 is displayed for all SI axes Response Alarm display The SGA Axis safely referenced is not set SE is disabled if the safety actual position has not yet been acknowledged by user agreement If user agreement i...

Page 312: ...n enable signals MA_SAFE_FUNCTION_ENABLE 6 Speed limit MA_SAFE_VELO_LIMIT 0 7 Speed limit MA_SAFE_VELO_LIMIT 1 8 Speed limit MA_SAFE_VELO_LIMIT 2 9 Speed limit MA_SAFE_VELO_LIMIT 3 10 Tolerance for safe operating stop MA_SAFE_STANDSTILL_TOL 11 Limit position MA_SAFE_POS_LIMIT_PLUS 0 12 Limit position MA_SAFE_POS_LIMIT_MINUS 0 13 Limit position MA_SAFE_POS_LIMIT_PLUS 1 14 Limit position MA_SAFE_POS...

Page 313: ...MA_SAFE_VELO_X 57 Position actual value n_x tolerance MA_SAFE_VELO_X MA_SAFE_POS_TOL 58 Active external stop request 59 SG correction factor 1 MA_SAFE_VELO_OVR_FACTOR 0 60 SG correction factor 2 MA_SAFE_VELO_OVR_FACTOR 1 61 SG correction factor 3 MA_SAFE_VELO_OVR_FACTOR 2 62 SG correction factor 4 MA_SAFE_VELO_OVR_FACTOR 3 63 SG correction factor 5 MA_SAFE_VELO_OVR_FACTOR 4 64 SG correction factor...

Page 314: ...FE_PULSE_DIS_CHECK_TIME 1011 NCK drive acceptance test status differs 1020 Communications error between NCK and the drive monitoring channel Response NC start inhibit in this channel Alarm display If safe monitoring was active STOP B was also automatically triggered It is necessary to power down power up the control power on Remedy Find the difference between the monitoring channels The fault code...

Page 315: ...STOP C to SBH Enter equal MDs 38 Transition time STOP D to SBH Enter equal MDs 39 Transition time STOP E to SBH Enter equal MDs 40 Stop response after SG Enter equal MDs 41 Stop response after SE Enter equal MDs 42 Shutdown speed after pulse cancellation Enter equal MDs 43 Data save test stop response 44 Actual position value limit value SG1 45 Actual position value limit value SG1 46 Actual posit...

Page 316: ...r missing pulse enable fault in the wiring of the SGEs Pulses are cancelled 1006 Error for SGA forced checking procedure 1007 Communications failure between PLC and drive 1008 Data transfer error between PLC and drive 1009 Trigger a subsequent stop after test stop Check the wiring Check the configuring of the SGE via MD MA_SAFE_PULSE_STATUS_INPUT Check the timer stage for the test stop 1010 Pulses...

Page 317: ...nvolved 2 SS SV Difference in the SGE De selection safe operating stop safely reduced speed SS Difference in SGE De selection safe operating stop SV Difference in SGE Selection safely reduced speed SP Difference in SGE Selection safe limit position SVOVR Difference in SGEs Selection SG corrections Interface label NCK input 3 DMP drv mod bit value drv drive number of the terminal block 1 31 mod sub...

Page 318: ...User enable screen must be compared with the current machine position This is obligatory to ensure proper functioning of the safe limit positions SE and safe cams SN The user agreement can only be changed in key actuated switch setting 3 or after entering a password Program continuation Alarm display disappears with the alarm cause No further operator action necessary 27006 Axis 1 test ext pulse c...

Page 319: ... for alarm Channel not ready Stop the axis with speed setpoint 0 STOP B As soon as the speed actual value is less than that defined in the MD MA_SAFE_STANDSTILL_VELO_TOL at the latest however after the time in MD MA_SAFE_PULSE_DISABLE_DELAY expires the pulses are cancelled STOP A Remedy Check the tolerance for the standstill monitoring does the value match the precision and control dynamics of the...

Page 320: ...reement can be re issued and the program can be restarted 27013 Axis 1 safe braking ramp exceeded Parameter 1 axis number Explanation After the initiation of STOP B or C the speed exceeded the tolerance value entered in MD MA_SAFE_STOP_VELO_TOL Response Mode group not ready Channel not ready NC start inhibit in this channel Interface signals are set Alarm display NC stop for alarm Interlock the pu...

Page 321: ... configuration in MD MA_SAFE_VELO_STOP_MODE MA_SAFE_VELO_STOP_REACTION or MA_SAFE_POS_STOP_MODE Response NC start inhibit in this channel Interface signals are set Alarm display NC stop for alarm Braking along the current limit is initiated and the safe operating stop SBH is internally activated after the time set in MD MA_SAFE_STOP_SWITCH_TIME_C has expired Remedy Remove the causes for Safely red...

Page 322: ...611D module Parameter 1 axis number Explanation SINUMERIK Safety Integrated can only be used with the 611D Performance control modules with 2 measuring circuits per drive and shutdown relay An attempt has been made to activate a safety function although no such module is plugged in Response Mode group not ready Channel not ready NC start inhibit in this channel Interface signals are set Alarm disp...

Page 323: ...ety functions should be subject to a new acceptance test Program continuation Power down the control and power up again 27033 Axis 1 parameterization of the MD 2 3 not valid Parameter 1 axis number 2 machine data label 3 machine data index Explanation The parameterization of machine data 2 is incorrect An additional indication is the field index of the machine data If the machine data is a single ...

Page 324: ...r the n n_x monitoring function calculated from MD MA_SAFE_VELO_X and MD MA_SAFE_POS_TOL are the same magnitude 18 One of the activated cam positions is outside the actual value modulo range 19 The parameterized cam modulo range MD MA_SAFE_MODULO_RANGE is not an integral multiple of 360 degrees 20 The parameterized cam modular range MD MA_SAFE_MODULO_RANGE and the modulo range in MD MA_MODULO_RANG...

Page 325: ...Stop E in all axes with SI function enable signals MD MA_SAFE_FUNCTION_ENABLE not equal to 0 34 The test of the brake mechanical system was enabled in MD MA_FIXED_STOP_MODE bit 1 1 without safe operation having been enabled for this axis in MD MA_SAFE_FUNCTION_ENABLE The test of the brake mechanical system is only permissible in this axis with safety functions 35 The MD MA_SAFE_VELO_STOP_MODE or M...

Page 326: ...m line Example Error for crosswise data comparison NCK PLC DMP 04 03 bit 01 A_INSE 2 NCK 1 The information in the example 04 03 corresponds to the entries made in the machine data MN_SAFE_IN_HW_ASSIGN 0 7 about the system variables They specify DMP 04 xx The drive number of the terminal block involved value range 01 21 Module number of the input module value range 01 08 The specified numbers are i...

Page 327: ...The monitoring channel specified in 1 NCK or PLC has triggered a stop D or E depending on the parameterization in MD MN_SAFE_SPL_STOP_MODE Alarm 27090 provides additional information about the reason for the Stop D E Response Alarm display A STOP D E has been initiated this can be set using MD MN_SPL_STOP_MODE on all of the axes with safety functionality if the SPL commissioning phase MD MN_PREVEN...

Page 328: ...T_DIR _N_SAFE_SPF If this error occurs an instruction from another part program was detected Response Alarm display Remedy Check the part program used for write access to safety system variables Program continuation Clear the alarm with the RESET key Restart part program 27095 1 SPL protection not activated Parameter 1 name of the component for which the protection is not activated NCK or PLC Expl...

Page 329: ...can be set in MN_SAFE_ALARM_SUPPRESS_LEVEL MD 3 in such a way that incorrect referencing is displayed separately for each axis Response Alarm display The SGA Axis safely referenced is not set SE is disabled if the safe actual position has not yet been acknowledged by the user agreement If the user agreement is set SE remains active The safe cams are calculated and output but their significance is ...

Page 330: ...ctive in this monitoring channel OK monitoring active in this monitoring channel limit values not violated L monitoring active in this monitoring channel upper limit value violated L monitoring active in this monitoring channel lower limit value violated Response Alarm display If safe monitoring was active then STOP B was also automatically initiated It is necessary to power down the control and p...

Page 331: ...n During the crosswise comparison of result list 2 between the monitoring channels NCK and drive a difference was detected in the monitoring state of the safe cam plus monitoring safe cam 1 Bits 0 1 in result list 2 safe cam 2 Bits 4 5 in result list 2 safe cam 3 Bits 8 9 in result list 2 safe cam 4 Bits 12 13 in result list 2 Monitoring state 3 4 OFF monitoring inactive in this monitoring channel...

Page 332: ...iagnostics the drive machine data 1393 1394 and the servo trace signals Result list 2 NCK and Result list 2 drive can be used Program continuation Clear the alarm with the RESET key Restart part program 27106 Axis 1 difference in function safe velocity nx NCK 2 drive 3 Parameter 1 Axis number 2 Monitoring status safely reduced speed nx 3 Monitoring status safely reduced speed nx Explanation In the...

Page 333: ...in both monitoring channels match For further diagnostics the drive machine data 1393 1394 and the servo trace signals Result list 2 NCK and Result list 2 drive can be used Program continuation Clear the alarm with the RESET key Restart part program 27124 Stop A initiated for at least 1 axis Explanation This alarm only indicates that Stop A has been triggered in at least one axis and power on is r...

Page 334: ... Response Mode group not ready Channel not ready NC start inhibit in this channel Interface signals are set Alarm display NC stop for alarm Remedy Correct the MD Program continuation Power down the control and power up again 27203 PROFIsafe MD 1 2 Wrong SPL assignment Parameter 1 MD name 2 MD field index Explanation The parameterization in the specified MD for the connection between the SPL interf...

Page 335: ...D Program continuation Power down the control and power up again 27205 PROFIsafe Number of signals in MD 1 2 MD 3 4 Parameter 1 MD name 1 2 MD field index to the MD name 1 3 MD name 2 4 MD field index to the MD name 2 Explanation The parameterized number of signals used must be the same in both machine data Response Mode group not ready Channel not ready NC start inhibit in this channel Interface ...

Page 336: ...data MN_PROFISAFE_IN OUT_ADDRESS is greater than the number of PROFIBUS slaves configured in the S7 PROFIBUS less than the number of F modules in the configured S7 PROFIBUS greater than the number of F modules in the configured S7 PROFIBUS Response Mode group not ready Channel not ready NC start inhibit in this channel Interface signals are set Alarm display NC stop for alarm Remedy Check the F pa...

Page 337: ...on 3 INPUT NCK F parameterization expects an INPUT module 3 OUTPUT NCK F parameterization expects an OUTPUT module 3 IN OUT NCK F parameterization expects an INPUT or OUTPUT module Response Mode group not ready Channel not ready NC start inhibit in this channel Interface signals are set Alarm display NC stop for alarm Remedy Check the module in the S7 PROFIBUS configuration Program continuation Po...

Page 338: ...ady Channel not ready NC start inhibit in this channel Interface signals are set Alarm display NC stop for alarm Remedy increase MD MN_PLC_RUNNINGUP_TIMEOUT check the PLC operating state check the PLC operating system software release delete the F parameterization in the NCK MD Program continuation Power down the control and power up again 27241 PROFIsafe DP M version different NCK 1 PLC 2 Paramet...

Page 339: ... be guaranteed Response Mode group not ready Channel not ready NC start inhibit in this channel Interface signals are set Alarm display NC stop for alarm Communications with the F slaves is terminated A STOP D E is initiated this can be set using MD MN_SPL_STOP_MODE on all of the axes with safety functionality Remedy Restart the PLC NCK Program continuation Power down the control and power up agai...

Page 340: ...lty components NCK PLC 2 fault error detected Explanation The F master signals a communications error between the NCK and PLC The cause of the error is indicated by error code 1 1 NCK Link between PROFIsafe and SPL interface is interrupted 1 PLC The PLC no longer executes the OB40 request 1 PLC DPM DP master is no longer in the OPERATE state Parameter 2 provides additional information about the re...

Page 341: ... this error can only occur if there already is a channel error when cyclic communication starts between the F master and module Response Mode group not ready Channel not ready NC start inhibit in this channel Interface signals are set Alarm display NC stop for alarm Remedy Check the wiring A STOP D E is initiated this can be set using MD MN_SPL_STOP_MODE on all of the axes with safety functionalit...

Page 342: ...4 Parameter 1 error ID 1 2 error ID 2 3 error ID 3 4 error ID 4 Explanation Internal error in the NCK PROFIsafe implementation Response Alarm display Remedy Please contact the Siemens A D MC Hotline with the error text Tel 0180 5050 222 Germany Fax 0180 5050 223 Tel 49 180 5050 222 outside Germany Fax 49 180 5050 223 email techsupport ad siemens de Program continuation Power down the control and p...

Page 343: ...y Channel not ready NC stop for alarm NC start inhibit in this channel NC switches into the tracking mode Alarm display Interface signals are set Remedy Increase the relevant clock cycle or subordinate clock cycle e g current control speed control or position control clock cycle or deselect any functions that are not required Program continuation Power down the control and power up again 300743 Ax...

Page 344: ...ontinuation Power down the control and power up again 300745 Axis 1 drive 2 limit values for safe end positions exchanged Parameter 1 NC axis number 2 drive number Explanation The data for the upper limit for the SE monitoring function contains a lower value than the data for the lower limit Interrogation When the control runs up Response Mode group not ready Channel not ready NC start inhibit in ...

Page 345: ...cle in MD 1300 MD_SAFETY_CYCLE_TIME monitoring time for the two axes of a 2 axis module has not been set to the same value Interrogation When the control runs up Response Mode group not ready Channel not ready NC start inhibit in this channel NC stop for alarm Alarm display Interface signals are set Remedy Set MD 1300 MD_SAFETY_CYCLE_TIME monitoring cycle the same on all drives of the module Progr...

Page 346: ...owing safety relevant MDs depending on the motor encoder type and axis type and correct if necessary MD 1317 SAFE_ENC_GRID_POINT_DIST Grid division linear scale for linear encoder MD 1318 SAFE_ENC_RESOL Encoder pulses per revolution for rotary encoder MD 1318 SAFE_ENC_RESOL MD 1320 SAFE_ENC_GEAR_PITCH for rotary encoder and linear axis MD 1321 SAFE_ENC_GEAR_DENOM MD 1322 SAFE_ENC_GEAR_NUMERA when ...

Page 347: ...has responded 5 SG specific stop response is set to STOP A and has responded The alarm can be re configured in the MD ALARM_REACTION_CHAN_NOREADY channel not ready Response Mode group not ready Channel not ready NC start inhibit in this channel NC stop for alarm Alarm display Interface signals are set Remedy Please inform the authorized personnel service department The user must identify the cause...

Page 348: ...ter 1 NC axis number 2 drive number Explanation The drive is stopped using a STOP A or STOP B This inhibits the pulses using the relay Antrieb_IMP Drive_IMP Interrogation In the monitoring clock cycle The actual position has moved too far away from the setpoint standstill position outside the standstill window The standstill window is parameterized using MD 1330 MD_SAFE_STANDSTILL_TOL standstill t...

Page 349: ...se 840D from SW 4 2 2 The safe limit position monitoring has been triggered MD 1362 MD_SAFE_POS_STOP_MODE safe limit position stop response The alarm indicates the initiation of a braking along the path in the NC and the internal activation of safe operating stop in the NC and drive Response NC start inhibit in this channel NC stop for alarm Alarm display Interface signals are set Remedy Please in...

Page 350: ...me level re measure or check in SI service display If no error of this type is apparent an error may have occurred in the CPU e g a flipped memory cell This error can be temporary in this case it can be eliminated by a power on or permanent if it re occurs again after power on replace the hardware Program continuation Clear the alarm with the RESET key Restart part program 300914 Axis 1 drive 2 Sa...

Page 351: ...ve 2 Axis not safely referenced Parameter 1 NC axis number 2 drive number Explanation No stop response is initiated When the SN SE functions are enabled the message remains until the axis state Axis safely referenced has been reached Interrogation In the monitoring clock cycle 1 Axis is not safely referenced or 2 User agreement for this axis is missing or has been withdrawn This can occur for exam...

Page 352: ... cancellation is acknowledged within the configured time in the drive no stop response is triggered When selected via the SGE test stop selection the message remains until the selection has been withdrawn de selected Response Alarm display Remedy The message disappears automatically if the user terminates the test by withdrawing the SGE Test stop selection If a STOP A was initiated then the system...

Page 353: ...upper modulo value POS_TOL cam position for active cam synchronization MD 1301 bit 7 1 lower modulo value POS_TOL cam position upper modulo value POS_TOL CAM_TOL cam position Explanations POS_TOL Actual value tolerance MD 1342 MD_SAFE_POS_TOL tolerance crosswise actual value comparison CAM_TOL Cam tolerance MD 1340 MD_SAFE_CAM_TOL tolerance for safe cams lower upper modulo values is defined using ...

Page 354: ...8 Axis 1 drive 2 actual value synchronisation not allowed Parameter 1 NC axis number 2 drive number Explanation The actual value synchronization for drift slip in MD 1301 MD_SAFE_FUNCTION_ENABLE enable safety relevant functions is selected This is only permissible for SBH SG because the absolute actual position is of no significance for these monitoring types However safe limit position and or cam...

Page 355: ...is alarm suppression This functionality is implemented and ensured irrespective of how the type of alarm was initiated All NCK and 611 digital safety alarms are listed in the table below The alarms marked with No are not suppressed if triggered in two channels those marked with Yes are only displayed for one monitoring channel if actively suppressed Table 6 2 Comparison of NCK and 611 digital safe...

Page 356: ...K alarm is more extensive than that of the drive alarm and must continue to appear in the alarm log so that this information is accessible to service personnel 27002 300951 These alarms continue to be displayed separately because under normal conditions they are never triggered by both channels simultaneously and because simultaneous occurrence of these alarms causes problems in the test stop inte...

Page 357: ...0745 300746 300747 301706 301707 301708 These monitoring functions are displayed by the NCK using Alarm 27033 with reference to the associated MD The function is activated via MD 10094 MN_SAFE_ALARM_SUPPRESS_LEVEL The function is already active when standard data is loaded This means that the alarms are displayed with a reduced scope Alarms 27000 and 300950 can be replaced by Alarm 27100 using MD ...

Page 359: ...ted switch 7 398 7 3 9 SG changeover 7 400 7 3 10 NCK SPL 7 401 7 3 11 PLC blocks 7 403 7 3 12 Appendix 7 410 7 4 Safety Integrated without SPL 7 413 7 4 1 Connecting up the drives 7 413 7 4 2 EMERGENCY STOP and connecting up the I R module 7 414 7 4 3 Test stop 7 416 7 4 4 Protective door interlocking 7 417 7 4 5 De selecting SBH using the key operated switch SG changeover using the door safety c...

Page 360: ...ailable Safety Integrated without safe programmable logic Safety Integrated with safe programmable logic SPL without contactless EMERGENCY STOP Safety Integrated with safe programmable logic SPL and contactless EMERGENCY STOP The EMERGENCY STOP circuit and door monitoring for limitations refer to Chapter 7 4 4 Protective door locking must be implemented conventionally with safety switching devices...

Page 361: ...monitored by the SPL in this case the safety switching devices are also not required 7 2 Circuit examples A machine tool with two axes and one spindle was selected as an example MASCHINE DSF Fig 7 1 Schematic diagram of a machine The following must be taken into account before the machine is configured What is the magnitude of the hazard potential Which measures can be implemented to reduce the ri...

Page 362: ... axes according to the machine configuration SI functions are used to safely monitor the drives for standstill or a specific speed and to stop them safely in the event of an error 7 2 1 Control and drive components The configuration of the individual components is illustrated below The system requirements are described in the Description of Functions E R NCU MSD FDD FDD MMC MCP SINUMERIK 840D NCK ...

Page 363: ... is achieved in conjunction with the other protective equipment of the machine system e g protective doors EMERGENCY STOP buttons The aim of this configuration is to describe the machine specific combination of SINUMERIK Safety Integrated and other protective equipment When engineering the SI system the machine functions are sub divided into different operating modes these operating modes are init...

Page 364: ...door is closed Production with the protective door open The NC operating modes MDA and AUTO are disabled by the PLC program automatic mode is not permitted when the protective door is open The safety function safe operating stop SBH is activated with the key operated switch position Production when the protective door is open This means that the drive is monitored for zero speed The axes and the s...

Page 365: ...c Safe_SPF Logic FC XXX Logic Fig 7 3 Function chart a detailed view of this diagram is provided in the Appendix 7 3 12 Note Examples of the PLC blocks can be requested from the Centre of Competence Service CoCS Sinumerik Safety Integrated Also refer to Chapter 2 10 The PLC blocks listed in Chapter 7 are available as example in the toolbox for the basic PLC program Further an S7 library can be req...

Page 366: ...LOCK When the NCK SPL has been successfully started by the PLC FC95 processing of the PLC SPL FC96 is enabled in OB1 Two more predefined blocks are integrated in FC97 FC60 Example blocks can be requested from the hotline telephone No 0180 525 8000 and FC21 basic program block FB1 P3 Modifications must also be made to OB100 to ensure perfect operation of the safe programmable logic The markers outp...

Page 367: ...riables if SPL is used Any NC alarm can prevent ASUB SAFE SPF from starting up They must be cancelled when the system is running up For example in the program excerpt the EMERGENCY STOP alarm is cancelled during run up OB100 program excerpt Set ASUB_start_marker and forced checking procedure output Reset alarms e g EMERGENCY STOP SET S M 210 0 NCK ASUB Start S A 88 1 Supply EMERGENCY STOP R DB10 D...

Page 368: ...nd PLC SPL ABLAUF01 DSF Switch on Start up control OB100 M210 0 1 PLC waiting for checkback drive group is in cyclic operation Scan DB10 DBX108 5 Drive in cyclic operation Drive in cyclic operation ASUB not running OB1 Loop when M210 0 1 PLC starts NCK SPL via FB4 and FC9 PLC SPL is not activated until ASUB checkback successfully started ASUB started FC 95 M210 0 0 PLC SPL FC96 NCK SPL ASUB starte...

Page 369: ... started Before running the ASUB SAFE SPF it is not advisable to run any of the user program blocks Exception To check correct functioning of function block FC 19 it might be necessary to run it immediately In this case critical function keys such as RESET and single block must be de activated until the SPL has started Example U M 210 0 NCK SPL inactive R E3 7 Reset RESET key R E3 5 Reset single b...

Page 370: ...1 Priority 1 WVar3 W 16 0 LIFTFAST 0 WVar4 W 16 0 BLKSYNC Error DB120 DBX 68 0 Error occurred Done DB120 DBX 68 1 Task error free State DB120 DBW 70 Error code U DB120 DBX 68 1 Task successfully completed S M 210 4 Start ASUB R M 210 3 Reset PI service start ASUB CALL FC 9 Start M 210 4 Start ASUB ChanNo 1 Channel number 1 IntNo 1 Interrupt number 1 Active DB120 DBX 72 0 ASUB active Done DB120 DBX...

Page 371: ...and SGAs are transferred to DB 18 or supplied from DB18 The PLC SPL only has to be programmed with the variables of DB18 exception test stop and the forced checking procedure of the inputs and outputs To ensure clear configuration and programming it is necessary to list the variables used and to document their meaning A suggestion for how to do this is documented below To achieve clarity and unifo...

Page 372: ...E_OUTPUT 04010101 X Z A_INSI 2 IMP_FREI_C 36986 SAFE_PULSE_ENABLE_OUTPUT 04010102 C A_OUTSI 1 STOP_A_ABWS 36977 SAFE_EXT_STOP_INPUT 0 04010101 C A_OUTSI 2 STOP_A_ABWA 36977 SAFE_EXT_STOP_INPUT 0 04010102 X Z A_OUTSI 3 STOP_C_ABW 36977 SAFE_EXT_STOP_INPUT 1 04010103 X Z C A_OUTSI 4 STOP_D_ABW 36977 SAFE_EXT_STOP_INPUT 2 04010104 X Z C A_OUTSI 5 SBH_ABW 36971 SAFE_SS_DISABLE_INPUT 04010105 X Z C A_O...

Page 373: ...OUT_HW_ASSIGN 0 01 04 02 01 H LOW Byte MD 10392 SAFE_OUT_HW_ASSIGN 1 01 04 02 02 H HIGH Byte The internal inputs and outputs of the SPL logic are assigned using the following machine data Internal SPL inputs MD36980 MD36990 SGA A_INSI The SGAs are output signals of the SI function and can be mapped to the system variables A_INSI n These can in turn be read in the NCK SPL and used as inputs for the...

Page 374: ... KL_AS12_XZ AS A_INSE 7 DEFINE KL_AS12_C AS A_INSE 8 DEFINE TESTSTOP1E AS A_INSE 9 DEFINE TESTSTOP2E AS A_INSE 10 DEFINE TEST_STOPA AS A_INSE 11 DEFINE TEST_STOPC AS A_INSE 12 DEFINE TEST_STOPD AS A_INSE 13 DEFINE NOT_HALT2K AS A_OUTSE 1 DEFINE KL_663_XZ AS A_OUTSE 3 DEFINE KL_663_C AS A_OUTSE 4 Internal interfaces DEFINE IMP_FREI_XZ AS A_INSI 1 DEFINE IMP_FREI_C AS A_INSI 2 DEFINE STOP_A_ABWS AS ...

Page 375: ...2 SPL IMP_FREI_C DB18 DBX54 1 A_OUTSIP 1 SPL STOP_A_ABWS DB18 DBX38 0 DB33 DBX 32 2 A_OUTSIP 2 SPL STOP_A_ABWA DB18 DBX38 1 DB31 32 DBX 32 2 A_OUTSIP 3 SPL STOP_C_ABW DB18 DBX38 2 DB31 32 33 DBX 32 3 A_OUTSIP 4 SPL STOP_D_ABW DB18 DBX38 3 DB31 32 33 DBX 32 4 A_OUTSI P 5 SPL SBH_ABW DB18 DBX38 4 DB31 32 33 DBX 22 1 A_OUTSIP 6 SPL SG_BIT_0 DB18 DBX38 5 DB31 32 33 DBX 22 3 A_OUTSI P 7 DB18 DBX38 6 A_...

Page 376: ...ZUVER U E 76 3 EMERGENCY STOP acknowledgement SPL NOT_QUIT U E 76 5 SPL SCHLUESSEL Key operated switch SBH de selection The logic operations are located here SPL Supply SPL_DATA_OUTSEP I Os U SPL NOT_HALT1K EMERGENCY STOP 1K A 48 2 EMERGENCY STOP contactor K1 The same procedure is applied to the internal SPL inputs or outputs Internal SPL inputs DB18 DBX54 0 DB18 DBX57 7 A_INSIP 1 32 DB18 DBX58 0 ...

Page 377: ...face Drive X DB32 DBX 32 3 Drive interface Drive Z DB33 DBX 32 3 Drive interface Drive C U SPL STOP_D_ABW STOP D for Drives X Z C DB31 DBX 32 4 Drive interface Drive X DB32 DBX 32 4 Drive interface Drive Z DB33 DBX 32 4 Drive interface Drive C U SPL SBHABW SBH de selection DB31 DBX 22 1 SBH de selection Axis X DB32 DBX 22 1 SBH de selection Axis Z DB33 DBX 22 1 SBH de selection Spindle C U SPL SG_...

Page 378: ...d DB18 signals in the NCK system variables A_TIMERSI n Configuration example Assignment as shown in the table Note The individual timers NCK A_TIMERSI PLC freely selectable are not listed at his point refer to Chapter 7 3 10 SPL programs because they are not included in the crosswise data and result comparison For the PLC SPL the name SPL or also a variable type UDT18 can be assigned to DB18 in th...

Page 379: ... supplied to terminal AS1 either from terminal 9 or an external 24 V power supply depending on the cabinet configuration SIMODRIVE 611D Double axis module Axis X axis Z SIMODRIVE 611D Single axis module Spindle C 663 AS2 AS1 9 663 AS2 AS1 9 24V NCK I7 I8 NCK Q4 Q3 Fig 7 5 Circuit diagram The NCK SPL contains a copy procedure from the safe output signal pulse enable SGA INSI to an output OUTSE term...

Page 380: ...signment INSI SGA Pulses enabled Assignment INSI SGA Pulses enabled OUTSE terminal 663 U SPL KL_AS12_XZ Terminal AS1 AS2 SPL STAT_IMP_XZ Status pulses cancelled NOT SPL KL_663_XZ Terminal 663 SPL IMP_FREI_XZ Pulse enable X Z U SPL KL_AS12_C Terminal AS1 AS2 SPL STAT_IMP_C Status pulses cancelled NOT SPL KL_663_C Terminal 663 SPL IMP_FREI_C Pulse enable C 2nd alternative If a separate input and out...

Page 381: ... SI output devices Case 2 Mixed mode SI I Os without SPL and SI I Os with SPL As described above NCK inputs can be assigned a multiple number of times i e the input or its image can be used both for an assignment in the axial machine data MD 36970 MD 36978 and for the SPL I Os MD 10390 For the NCK outputs bytewise mixed operation is possible This means that if a byte of the sub module is defined a...

Page 382: ...r switch 0V ER_MODUL DSF Leading contact Fig 7 6 I R module The two main contacts of the Emergency Stop button are supplied with 24 V three terminal concept via the PLC output This PLC output is used for the forced checking procedure of the inputs and outputs refer to Chapter 7 3 6 Test stop The individual circuits of the Emergency Stop button are separately connected to the PLC and NCK inputs Cir...

Page 383: ...external actuators is disconnected in the cabinet using two contactors that are controlled redundantly by the PLC and the NC The power contacts are connected in series and therefore disconnect the power through two channels when an EMERGENCY STOP is initiated One signaling contact of each of the two contactors is connected in series to the input of the PLC This PLC input is also used for the force...

Page 384: ... acknowledgment button This is connected to the 24 V power supply The safety guidelines published by the German Institute for Occupational Safety state that this switch must be configured using two channels If additional checkback signals e g AS1 AS2 have to be included in the acknowledgement function then these contacts should be included in the 24 V power supply of the two channel acknowledgemen...

Page 385: ...A_S 0 These times must be carefully adapted for each of the drives of the machine If the machine configuration does not allow braking of any of the drives with STOP C e g a grinding wheel it is possible to make a distinction between the different types of drive and to brake the drives in question with STOP D brake along a path or STOP A pulse cancellation However a STOP C is the fastest braking me...

Page 386: ...nction chart starts in line N110 where the acknowledgement button and the EMERGENCY STOP button are logically combined They form the internal EMERGENCY_STOP signal STOP C is selected with EMERGENCY_STOP 0 N210 and the timers for the axes N120 N140 and the spindles N150 N170 are started When each of the timers has elapsed STOP A is triggered for the axes N180 and the spindles N200 STOP D is not use...

Page 387: ...PL STOP_C_ABW De select STOP C X Z C UN M 216 1 Test External STOP D FC97 UN M 218 7 STOP D dynamized FC 97 SPL STOP_D_ABW De select STOP D X Z C U SPL NOT_HALT EMERGENCY STOP pressed SPL NOT_HALT1K EMERGENCY STOP contactor K1 The structure of the PLC program is identical to that of the NCK SPL The additional acknowledgement of the EMERGENCY STOP SPL QUIT_MARKER DB18 DBX70 4 and the individual tes...

Page 388: ...ersion 1 Data transfer via the FC 21 An example using of the FC21 is provided in the FC97 for an automatic EMERGENCY STOP acknowledgment after test stop phase III The FC 21 is used to transfer a byte the smallest transferable data structure for the FC 21 from the PLC to the NCK via the dual port RAM DPR An equivalent method to this is to define for each test stop step test stop 1 test stop 2 test ...

Page 389: ...C TEST_STOPD are also combined into the STOP A STOP C STOP D de selection in a similar way to the SPL program of the configuration examples The byte in the dual port RAM A_DBB 5 TESTST_PLC is assigned the value for the actual test step via the FC 21 from the PLC program i e the transfer FC 21 is active for the test stops Version 2 Data transfer via the simulated NCK I Os It is also possible to rep...

Page 390: ...al Pulses safely disabled Drive X C DB3x DBX108 2 FC 60 internal yes no Canellation of test stop on NCK side FC 60 internal yes no yes no End of test stop phase 1 M 216 0 FUNKPLAN DSF Cancellation of test stop on PLC side FC 60 internal Cancellation of test stop on PLC side FC 60 internal Cancellation of test stop on NCK side FC 60 internal Checkback signal Pulses safely Drive X C DB3x DBX108 2 FC...

Page 391: ...211 1 Start test step 1 S M 211 0 Reset monitoring time CALL FC 60 start M 211 1 Start test stop 1 reset E 3 7 RESET MCP num_axis 2 Number of drives test_axis_1 1 Drive number Axis X test_axis_2 3 Drive number Spindle C After test stop step 1 has been completed the external STOPs are tested The test sequence is implemented by a simple sequence control in which the external STOPs D C A are triggere...

Page 392: ...9 3 Checkback signal STOP C active DB3x DBX111 5 STOP A is triggered on NCK side M 216 7 A 49 2 Checkback signal STOP A active DB3x DBX111 4 End of test stop phase 2 M217 1 No No No TESTS3_00 DSF Start No No Check STOP A not active DB3x DBX111 4 M 216 4 Check STOP A not active DB3x DBX111 4 M 217 0 Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Fig 7 13 Flowchart Note If the sequence control stops at...

Page 393: ...k Stop A PLC U M 216 4 Check STOP A PLC not active UN DB31 DBX 111 4 STOP A B active Axis X UN DB32 DBX 111 4 STOP A B active Axis Z UN DB33 DBX 111 4 STOP A B not active Spindle C S M 216 5 Initiate Stop D on the NCK side R M 216 4 Reset Check STOP A PLC U M 216 5 Initiate Stop D on the NCK side A 49 4 See circuit diagram and NCK SPL U M 216 5 Check Stop D on the NCK side U DB31 DBX 111 6 STOP D ...

Page 394: ...nt by PLC Acknowledgment by PLC SPL DB18 DBX70 4 End offset no yes A data byte is transferrred from the PLC with FC21 and evaluated by the NCK SPL Acknowledgment by NCK SPL QUIT_MARKER yes yes no no Backup time automatic automatic without acknowledgment Start STOP D triggered on PLC side Error diagnostics RESET error check Error corrected Fig 7 14 Flowchart Note If an EMERGENCY STOP is triggered d...

Page 395: ...checking procedure output R M 218 0 Check Emergency Stop inputs U T 22 After drop out time of contactor U E 3 7 RESET MCP U E 76 0 Emergency Stop PLC not actuated U E 76 4 Forced checking procedure input E76 4 1 S M 218 1 Start acknowledgement R M 218 0 Check EMERGENCY STOP inputs R M 218 7 Withdraw Stop D U M 218 1 Start acknowledgement L S5T 50MS Delay time for Emergency Stop inputs SE T 23 Set ...

Page 396: ... PLC FC 21 can only transfer data to the NC with a minimum length of one byte This byte can be read in the synchronous actions by system variable A_DBB n However the binary logic operations AND and OR cannot combine a bit with a byte so that the byte sent A_DBB 4 must be converted to a bit A_MARKERSI 3 QUIT_REQUEST lines N100 N101 As a result of lines N102 to 105 automatic acknowledgment is only p...

Page 397: ...e been sent in FC21 Note The time for timer 22 must be matched to the drop out time of the contactors used The times for timers 23 and 24 are dependent on the PLC cycle time and have to be appropriately adapted 7 3 7 Protective door interlocking In this example the two channel door switch checkback signal Door closed and interlocked is used and connected to one input of the NCK I Os and one input ...

Page 398: ... K2 This means that an output must be supplied in the PLC SPL A_OUTSEP n as well as in the NCK SPL A_OUTSE n that drops out when the door opens The checkback input must be checked every time the protective door is opened or even better integrated into the forced checking procedure of the inputs outputs error response STOP D from PLC if it is not certain that the door will be opened once within eig...

Page 399: ...KEYSWITCH FUNKPL03 DSF Fig 7 17 Function chart SBH de selection NCK SPL program excerpt SBH DE SELECTION VIA KEY OPERATED SWITCH N380 IDS 50 DO SBHABW KEY OR DOOR FC96 program excerpt SBH de selection using the key operated switch U SPL SCHLUESSEL Key operated switch O SPL TUERZUVER Door closed and interlocked SPL SBHABW SBH de selection The standstill tolerance is saved in the axis specific machi...

Page 400: ...n the protective door is closed SG stage 2 SG2 10 m min SG2 2000 RPM is active The speed limits are saved in the axis specific machine data and in the drive machine data FD MSD 36931 1331 SAFE_VELO_LIMIT 0 1 SG BIT 0 DOOR CLOSER FUNKPL04 DSF Fig 7 18 Function chart SG selection NCK SPL program excerpt SG selection via protective door N390 IDS 52 DO SG_BIT_O DOOR CLOSED FC96 program excerpt SG sele...

Page 401: ...A AS A_INSE 11 DEFINE TEST_STOPC AS A_INSE 12 DEFINE TEST_STOPD AS A_INSE 13 DEFINE NOT_HALT2K AS A_OUTSE 1 DEFINE KL_663_XZ AS A_OUTSE 3 DEFINE KL_663_C AS A_OUTSE 4 Internal interfaces DEFINE IMP_FREI_XZ AS A_INSI 1 DEFINE IMP_FREI_C AS A_INSI 2 DEFINE STOP_A_ABWS AS A_OUTSI 1 DEFINE STOP_A_ABWA AS A_OUTSI 2 DEFINE STOP_C_ABW AS A_OUTSI 3 DEFINE STOP_D_ABW AS A_OUTSI 4 DEFINE SBHABW AS A_OUTSI 5...

Page 402: ...ER1 1 0 AND NOT NOT_HALT DO TIMER1 1 STOP_A_A 0 N150 IDS 18 EVERY NOT_HALT 0 DO TIMER2 0 N160 IDS 20 EVERY NOT_HALT 1 DO STOP_A_S 1 TIMER2 1 N170 IDS 22 EVERY TIMER2 5 0 AND NOT NOT_HALT DO TIMER2 1 STOP_A_S 0 N180 IDS 24 DO STOP_A_ABWA STOP_A_A AND NOT TEST_STOPA N200 IDS 28 DO STOP_A_ABWS STOP_A_S AND NOT TEST_STOPA N210 IDS 30 DO STOP_C_ABW NOT_HALT AND NOT TEST_STOPC N220 IDS 32 DO STOP_D_ABW ...

Page 403: ...SUB Unit 1 Addr1 P DB120 DBX 34 0 BYTE 34 Program path Addr2 P DB120 DBX 0 0 BYTE 34 Program name WVar1 W 16 1 Interrupt number 1 WVar2 W 16 1 Priority 1 WVar3 W 16 0 LIFTFAST 0 WVar4 W 16 0 BLKSYNC Error DB120 DBX 68 0 Error occurred Done DB120 DBX 68 1 Task error free State DB120 DBW 70 Error code U DB120 DBX 68 1 Task successfully error free completed S M 210 4 Start ASUB R M 210 3 Reset PI ser...

Page 404: ...Load for 1 second SA T 20 After pressing U T 20 EMERGENCY STOP SPL STOP_A_A Intermediate marker STOP A for axes X Z U SPL NOT_HALT EMERGENCY STOP L S5T 5S Load for 5 seconds SA T 21 After pressing U T 21 EMERGENCY STOP SPL STOP_A_S Intermediate marker STOP A for spindle C U SPL STOP_A_A Intermediate marker STOP A for axes X Z UN M 216 3 Test external STOP A see FC97 SPL STOP_A_ABWA STOP A for axes...

Page 405: ...X32 3 Drive interface for drive Z DB33 DBX32 3 Drive interface for drive C U SPL STOP_D_ABW Select STOP D for axes X Z DB31 DBX32 4 Drive interface for drive X DB32 DBX32 4 Drive interface for drive Z DB33 DBX32 4 Drive interface for drive C U SPL SBHABW SBH de selection DB31 DBX22 1 SBH de selection axis X DB32 DBX22 1 SBH de selection axis Z DB33 DBX22 1 SBH de selection spindle C U SPL SG_BIT_0...

Page 406: ...ses not disabled X UN DB32 DBX 108 2 Pulses not cancelled Z UN DB33 DBX 108 2 Pulses not cancelled C U DB31 DBX 110 5 Axis X stopped U DB32 DBX 110 5 Axis Z stopped U DB33 DBX 110 5 Axis C stopped S M 211 0 Reset monitoring time of 8 hours S M 211 1 Start test stop 1 CALL FC 60 Test stop module start M 211 1 Start test stop 1 reset E 3 7 Reset by RESET MCP num_axis 2 Number of drives test_axis_1 1...

Page 407: ... D PLC U M 216 2 Check stop C on the PLC side U DB31 DBX 111 5 STOP C active axis X U DB32 DBX 111 5 STOP C active axis Z U DB33 DBX 111 5 STOP C active spindle C S M 216 3 Initiate Stop A on the PLC side FC96 R M 216 2 Reset check stop C PLC U M 216 3 Check stop A on the PLC side U DB31 DBX 111 4 STOP A B active axis X U DB32 DBX 111 4 STOP A B active axis Z U DB33 DBX 111 4 STOP A B active spind...

Page 408: ...RGENCY STOP inputs R M 217 1 Reset Start forced checking procedure R A 48 1 PLC forced checking procedure output U M 218 0 Check EMERGENCY STOP inputs L S5T 120MS Drop out time of contactor SE T 22 Timer 22 U T 22 After drop out time of contactor UN A 48 1 PLC forced checking procedure output UN E 76 4 Error case checkback input contactors 0 S M 218 7 Initiate Stop D see FC96 S A 48 1 PLC forced c...

Page 409: ... M 218 2 Acknowledge EMERGENCY STOP NCK SPB QUI1 Do not acknowledge NCK L 1 Load 1 T MB 194 Transfer marker byte 194 QUI1 UN M 218 3 Withdraw NCK acknowledgement SPB QUI2 L 0 Load 0 T MB 194 Transfer marker byte 194 QUI2 NOP 0 CALL FC 21 Enable SPL QUIT_MARKER Funct B 16 4 S7Var P M 194 0 BYTE 1 IVAR1 4 IVAR2 1 Error M 218 4 ErrCode MW 188 U M 218 3 Withdraw acknowledgement NCK U SPL NOT_HALT Ackn...

Page 410: ...7 Test_Stop_A_PLC M 216 3 BOOL Trigger stop A in PLC FC96 18 PLC_Stop_A_nicht_aktiv M 216 4 BOOL Stop A PLC check not active 19 Test_Stop_D_NCK M 216 5 BOOL Trigger stop D via A 49 4 PLC in NCK 20 Test_Stop_C_NCK M 216 6 BOOL Trigger stop C via A 49 3 PLC in NCK 21 Test_Stop_A_NCK M 216 7 BOOL Trigger stop A via A 49 2 PLC in NCK 22 NCK_Stop_A_nicht_aktiv M 217 0 BOOL Stop A NCK check not active 2...

Page 411: ...he PLC program of the configuration example Structure of PLC program call of user modules OB1 FC2 Basic program FC95 Start of NCK SPL FB4 instance DB 121 data DB 120 FC9 data DB 120 FC96 PLC SPL FC97 Forced dormant error detection FC60 test stop phase I Remaining user program Fig 7 19 Structure of the user program The following function overview is used to configure and commission SPL logic Symbol...

Page 412: ...arison monitoring 1s 10s In case of error STOP D is triggered if SPL is protected Monitoring cycles settable in MD Order of magnitude 81 MD 10090 Assignment to SPL inputs INSEP 1 64 DB18 DBX38 0 to DBX45 7 Assignment of SPL outputs OUTSEP 1 64 DB18 DBX46 0 to DBX53 7 FC XXX Logic OUTSIP 1 64 DB18 DBX62 0 to DB18 DBX69 7 Output variables SPL FC XXX Logik INSIP 1 64 DB18 DBX54 0 to DB18 DBX61 7 Inpu...

Page 413: ...s SPL 1 2 3 4 7 6 5 8 NCK I Os SGE input signals NCK SGA SGE signals Machine data Machine data Machine data Combinational logic with switches and contactors Switches light barriers indicator lamps etc NCK I Os BEI2_02 DSF Switches light barriers indicator lamps etc SGA output signals Fig 7 21 Function schematic of SI without SPL 7 4 1 Connecting up the drives The drives are connected up exactly in...

Page 414: ...on the infeed regenerative feedback module The drives brake with the maximum current this can be configured After a certain delay if for example the spindle has also braked and is stationary the internal line contactor in the NE module that is used to electrically isolate it from the power supply is opened via terminal 48 DIN EN 60204 1 The connection between terminals NS1 NS2 is opened as an addi...

Page 415: ...using a safety relay K1 3TK2805 When the EMERGENCY STOP button is pressed safety relay K1 drops out immediately and opens the NO contacts that are included in the connection between terminal 9 and terminal 64 on the infeed regenerative feedback module and in the supply path for delay module 3TK29 As soon as the selected delay time has elapsed delay module K2 3TK29 3 also drops out and opens the NO...

Page 416: ... L X3 X5 X4 L A1 L 0V EMERGENCY STOP K1 schalt03 dsf A2 L Fig 7 24 Connecting up the safety relay combination 7 4 3 Test stop For the test stop the first section of the test stop test can be taken from the PLC programming example with SPL The parameterization of the machine data directly refers to the DMP input modules X axis 36975 SAFE_STOP_REQUEST_INPUT 01060809H Spindle C 36975 SAFE_STOP_REQUES...

Page 417: ... operator If the protective door switch only activates and de activates Safety Integrated functions of the NC drives in the safety area and this is clearly confirmed by the risk analysis then the contacts of the door switch can be directly integrated into the switching logic for the SGEs NCK SPL see Fig 7 26 Safety Integrated monitors the door switch using the crosswise data comparison of the SGEs...

Page 418: ...indle C 36971 SAFE_SAFE_SS_DISABLE_INPUT 01040105H Safe operating stop is de selected when the protective door is closed and a changeover is made from safely reduced speed 1 personnel protection to safely reduced speed 2 machine protection X axis Z axis spindle C 36972 SAFE_SAFE_VELO_SELECT_INPUT 0 01040106H On the PLC side the switching states of the door and the key operated switch are logically...

Page 419: ...3 7 419 Program Program excerpt SBH selection using the protective door and using the key operated switch U E 32 5 Door closed and interlocked O E 32 6 DB31 DBX22 1 SBH de selection DB32 DBX22 1 SBH de selection DB33 DBX22 1 SBH de selection SG selection via the protective door U E 32 6 Door closed and interlocked DB31 DBX22 3 SG bit 0 DB32 DBX22 3 SG bit 0 DB33 DBX22 3 SG bit 0 ...

Page 420: ... block is 4 and the input module used is inserted into slot 1 in the terminal block Commissioning is explained step by step with reference to the previous sections in Chapter 7 1 Enable the function SBH SB monitoring and external STOPs for drives X Z C via the axis specific machine data 36901 SAFE_FUNCTION_ENABLE 41 H 2 Set the machine data 11602 ASUP_START_MASK 7 ASUB start in all operating state...

Page 421: ... STOP at the channel interface in the automatic mode 9 Implement the following NCK SPL in the standard cycle directory CST DIR under the name SAFE SPF _N_SAFE_SPF PATH _N_CST_DIR SAFE_CHECKSUM 000009C6H N100 IDS 01 DO A_OUTSI 1 1 Static de selection STOP A N110 M17 10 The NCK SPL start when the control runs up is described in Chapter 7 Starting the NCK SPL and PLC SPL 11 The first part of the test...

Page 422: ... 2 marker 216 0 Pulses for drives X Z C not safely disabled Trigger STOP C on PLC side Q 36 0 0 Checkback signal STOP C active DB3x DBX111 4 Start yes no no yes Trigger STOP C on NCK side Q 36 1 0 Checkback signal STOP C active DB3x DBX111 4 yes no End of test stop M 211 0 0 Cancel STOP C NCK side Q 36 1 1 Cancel STOP C on PLC side Q 36 0 1 Fig 7 28 Flowchart when testing external STOP C ...

Page 423: ...K 840D SIMODRIVE 611 digital SINUMERIK Safety Integrated FBSI Edition 11 03 7 423 Circuit diagram PLC NCK I32 0 I1 11 12 22 21 Light barrier analysis unit PLC Q36 0 PLC Q36 1 Fig 7 29 Wiring Note The drive cannot be operated until the SPL is started because the external STOP A is not supplied ...

Page 424: ... of the required hardware and software settings is not shown rather only the sections that differ when compared to previous SPL applications with two separate hardware I O branches NCK and PLC I Os 7 6 1 Functional scope of the application The safety relevant input signals read in from the F DI module and processed in the SPL are to be used to change over axis specific safety functions SBH SG exte...

Page 425: ...er settings are obtained in the hardware configuration under STEP 7 All of the sensor signals are connected through two channels EMERGENCY stop Type NC Contact 1 9 5 13 3 11 7 15 VS1 2 6 4 8 VS2 10 14 12 16 F DI BSP_FDI_Verdrahtung dsf Channel 4 Channel 0 Channel 6 Channel 2 Channel 7 Channel 3 Channel 5 Channel 1 Protective door closed Type NC Contact Enable button Type NC NO contact Drives ON Ty...

Page 426: ...encoder supplies must be used when the short circuit test is activated cf Chapter Configuration and wiring of the ET200S I Os Components of the node IM151 HF F DI module The exclusive OR sensor agreement button is an exception For this type of wiring the encoder supply VS1 must be used in conjunction with the short circuit test for both contacts The actuators that must be shut down in a safety rel...

Page 427: ...to individual actuators cf functionality of an F DO module on the other hand the third output channel DO 2 has an additional function Output channel DO2 is used to internally switch in or switch out the safety relevant i e via two voltage potentials power supply to or from the downstream standard DO or standard DI modules This means that the outputs on the DO modules can be controlled as single ch...

Page 428: ... has been acknowledged Table 7 1 Application functions Sensor State Axes spindles external devices Monitor function switching status Emergency Stop Not actuated Axes spindles SG3 maximum speed Protective door Closed Valve unit 1 Open position Agreement button Not applicable Valve unit 2 Open position Valve unit 3 Open position Case 1 Supply voltage DO Connected Emergency Stop Not actuated Axes spi...

Page 429: ... FM NCU X2 3 4 0 840D NCU 57x 4 8 IM 151 HWKonf_Bus dsf Fig 7 34 STEP 7 Hardware configuration Definition of the PROFIBUS system The system requirements regarding the NCU hardware and interface module must be observed cf Chapter 3 12 SI I Os using fail safe modules on PROFIBUS DP System requirements Note When describing how the F I Os are configured the associated parameters are only described to ...

Page 430: ...erzögerung Kurzschlusstest Aktiviert Auswertung der Geber Art der Geberverschaltung Diskrepanzzeit ms Kanal 2 6 Kanal 1 5 Kanal 3 7 2v2 Auswertung Zweikanalsensor 300 Aktiviert Auswertung der Geber Art der Geberverschaltung Diskrepanzzeit ms 2v2 Auswertung Antivalentsensor 300 OK Abbrechen Hilfe Fig 7 35 Parameter settings for the F DI module The parameters of the F DO module are explained below F...

Page 431: ...fer to Fig 7 34 Therefore the encoder evaluation is set to 2v2 evaluation for all 4 channel pairs Type of encoder connection The type of encoder connection depends on the encoder design For NC and NO contact pairs channels 0 4 channels 1 5 channels 3 7 the two channel sensor version must be set On the other hand for the exclusive OR agreement button one NC and one NO contact the exclusive OR senso...

Page 432: ...resse F Parameter Parameter 100 1111111101 1021 1 SI PLC315 2DP 2AF03 32 0 32 3 Eigenschaften PM E F DC24V 10A 2 F DO DC24V 2A R S7 Parameter Parameter Adressen Allgemein Wert Baugruppe Bestellnummer E Adre A Adres D Kommentar Diagnose Drahtbruch Aktiviert DO Kanal 3 Diagnose Drahtbruch Aktiviert DO Kanal 2 OK Abbrechen Hilfe Fig 7 36 Parameter settings for the F DO module The parameters of the F ...

Page 433: ...augruppenparameter F_Überwachungszeit ms DIL Schalterstellung 9 0 F_Ziel_Adresse F_Quell_Adresse F Parameter Parameter 100 1111111100 1020 1 SI PLC315 2DP 2AF03 32 0 32 3 Eigenschaften PM E F DC24V 10A 2 F DO DC24V 2A R S7 Parameter Parameter Adressen Allgemein Wert OK Abbrechen Hilfe Baugruppe Bestellnummer E Adre A Adres D Kommentar Fig 7 37 Parameter settings for the PM E F module The parameter...

Page 434: ...nel channel 2 in the example A_OUTSE P variables 1 4 are output to the F DO module MD 10387 MN_PROFISAFE_OUT_ADDRESS 0 05 00 03 FDH MD 10389 MN_PROFISAFE_OUT_ASSIGN 0 004 001 A_OUTSE P variables 5 7 are output to the PM E F module MD 10387 MN_PROFISAFE_OUT_ADDRESS 1 05 00 03 FCH MD 10389 MN_PROFISAFE_OUT_ASSIGN 0 007 005 A few definitions are now required in order to explain a safe programmable lo...

Page 435: ...387 10389 E n d D e s c r i p t i o n Cycle definition Suppress single block display N100 PROC SAFE SBLOF DISPLOF Declarations Definition of symbolic names for SPL variables Addressing of PROFIsafe input modules MD 10386 MN_PROFISAFE_IN_ADDRESS n Assignment of PROFIsafe signals to SPL MD 10388 MN_PROFISAFE_IN_ASSIGN n MD 10386 0 MD 10388 0 F DI NCK PLC DB18 N105 DEFINE IE_EMERGENCY_STOP AS A_INSE ...

Page 436: ...DEFINE OE_P1P2 AS A_OUTSE 07 DBX46 6 MARKERSI Internal status marker PLC DB18 N665 DEFINE MI_NO_E_STOP AS A_MARKERSI 01 DBX70 0 N670 DEFINE MI_AGREEMENT AS A_MARKERSI 02 DBX70 1 TIMERSI Internal timer PLC timer N742 DEFINE TI_RES_01 AS A_TIMERSI 01 T xxx not used for example PLCSIOUT Single channel data from PLC NCK PLC DB18 N800 DEFINE IPLC_RES_01 AS A_PLCSIOUT 01 DBX128 0 not used for example PL...

Page 437: ...Deselect STOP D Agreement mode IDS 06 DO MI_AGREEMENT NOT IE_PROT DOOR_CLOSED AND IE_AGREEMENT SBH de selection if protective door closed or for agreement mode IDS 07 DO OI_SBH_DESEL IE_PROT DOOR_CLOSED OR MI_AGREEMENT SG changeover select SG3 if protective door closed IDS 08 DO OI_SG_DESEL_B1 IE_PROT DOOR_CLOSED Valve unit 1 IDS 09 DO OE_VALVE1 MI_NO_E_STOP AND IE_PROT DOOR_CLOSED OR MI_AGREEMENT...

Page 438: ...P 06 46 6 OEP_P1P2 BOOL FALSE A_OUTSEP 07 62 0 OIP_SBH_ABWAHL BOOL FALSE A_OUTSIP 01 62 1 OIP_SG_AUSW_B1 BOOL FALSE A_OUTSIP 02 62 2 OIP_STOPA_ABW BOOL FALSE A_OUTSIP 03 62 3 OIP_STOPC_ABW BOOL FALSE A_OUTSIP 04 62 4 OIP_STOPD_ABW BOOL FALSE A_OUTSIP 05 70 0 MIP_KEIN_NOT_H ALT BOOL FALSE A_MARKERSIP 0 1 70 1 MIP_ZUSTIMMUNG BOOL FALSE A_MARKERSIP 0 2 BEGIN NETWORK TITLE map external inputs to A_INS...

Page 439: ...RGENCY_STOP R SPL MIP_NO_E_STOP Reset status marker IDS 04 STOP C De select U SPL IEP_PROT DOOR_CLOSED O SPL MIP_NO_E_STOP SPL OIP_STOPC_DESEL IDS 05 STOP D De select UN SPL IEP_PROT DOOR_CLOSED O SPL MIP_NO_E_STOP SPL OIP_STOPD_DESEL IDS 06 Agreement mode UN SPL IEP_PROT DOOR_CLOSED U SPL IEP_AGREEMENT SPL MIP_AGREEMENT IDS 07 SBH de selection if protective door closed or for agreement mode U SPL...

Page 440: ...mple describes only the interface of axis 1 De select SBH U SPL OIP_SBH_DESEL DB31 DBX 22 1 SG Changeover bit 1 U SPL OIP_SG_SEL_B1 DB31 DBX 22 4 De select external STOP A cf MD 36977 0 U SPL OIP_STOPA_DESEL DB31 DBX 32 2 De select external STOP C cf MD 36977 1 U SPL OIP_STOPC_DESEL DB31 DBX 32 3 De select external STOP D cf MD 36977 2 U SPL OIP_STOPD_DESEL DB31 DBX 32 4 NETWORK TITLE Output exter...

Page 441: ...nnels i e data crosswise comparison is no longer performed in the control for the A_INSE P variables The external SPL output signals of the DB18 interface A_OUTSEP variables are transferred within the system to the relevant PROFIsafe output modules Since only one signal state is transferred via PROFIsafe it is no longer possible to temporarily output a signal state for the PLC output that is diffe...

Page 442: ...ring example 11 03 7 6 SI I Os using fail safe modules connected to PROFIBUS DP Siemens AG 2003 All Rights Reserved 7 442 SINUMERIK 840D SIMODRIVE 611 digital SINUMERIK Safety Integrated FBSI Edition 11 03 Notes ...

Page 443: ...e PLC 8 444 8 2 Two channel brake control with SI SPL 8 445 8 3 Testing the function of the brake mechanical system 8 450 8 3 1 Applications 8 450 8 3 2 Parameterization 8 450 8 3 3 Sequence 8 452 8 3 4 Limitations 8 455 8 3 5 Activating 8 455 8 3 6 Examples 8 456 8 4 Safe cams at the modulo limit 8 457 8 5 SPL functionality without real drives 8 464 8 6 Direction detection when retracting from SE...

Page 444: ... comply with the safety requirements in the worst case the PLC can crash without resetting the outputs i e the axis could fall Secondly the application time of the holding brake is increased because the hardware relay has to be controlled and it also has an associated switching time In order to keep the switching time of the contactor as short as possible neither an interference suppression diode ...

Page 445: ... NCK output switches the P voltage 24 V to release the brake and a PLC output S7 relay module switches the M voltage P M control A checkback contact on the PLC side verifies that the two switching elements are operating correctly Controlling the NCK output relevant signals suggestion STOP A B active VA_DPE machine axis name power enable status axis specific available in software version 5 x and hi...

Page 446: ...se signals to the PLC output NCK part 1 Machine data MD 36990 0 SAFE_ACT_STOP_OUTPUT 04010101 for drive X1 2 SPL DEFINE STOP_A_B_aktiv AS A_INSI 1 DEFINE P_BREMSE_X1 AS A_OUTSE 1 DEFINE NOT_HALT_nicht_aktiv AS A_MARKERSI 1 IDS 1 DO P_BREMSE_X1 NOT STOP_A_B_aktiv AND VA_DPE X1 AND EMERGENCA_STOP_not_active PLC part U DB31 DBX111 4 STOP A B active DB18 DBX56 0 A_INSIP 1 UN DB18 DBX56 0 A_INSIP 1 UN ...

Page 447: ...rated FBSI Edition 11 03 8 447 Holding service brake actuation Current source link version with checkback Holding brake Relay outoutput Fig 8 2 Two channel brake control P M switching with SI Unlike the test routine described in Chapter 7 3 6 the test involves separately controlling the two outputs A1 and A2 and monitoring the resulting level change at test input E1 ...

Page 448: ...IVE 611 digital SINUMERIK Safety Integrated FBSI Edition 11 03 Bremsen3_00 DSF t2 t3 t4 t6 high high high low low low A1 NCK A2 PLC E1 PLC t1 t5 Fig 8 3 Test routine at power up The check can be integrated into the normal test routine Chapter 7 3 4 or can be performed separately The flowchart below shows the test procedure Description ...

Page 449: ...ircuit to current source or malfunction Test input level low Test input level high Check test input I1 time t 4 Test input level high Conductor D2 short circuit to current source or switching element Q2 short circuit to current source or malfunction Test input level low Check test input I1 time t 6 Test input level low Test input level high Error message Error message deactivate output Q1 Error me...

Page 450: ...izable monitoring window In this case traversing to fixed endstop is terminated so that the position controller can prevent the axis falling The brake test is then negatively acknowledged The brake test must always be started when the axis is at standstill also refer to Chapter 8 3 5 Activation The direction in which the drive produces force is specified by the PLC using a traversing motion via FC...

Page 451: ...olding torque required for the weight of the axis is measured internally mAct The drive must only provide the difference between this torque and the braking torque specified in MD MA_SAFE_BRAKETEST_TORQUE This torque is designated with a mDrive in Fig 8 5 The SIMODRIVE 611 digital drive locates its torque limit symmetrically around the torque specified in drive machine data 1192 This is the reason...

Page 452: ...t the fixed endstop has been reached This is a difference when compared to activating traversing to the fixed endstop from the part program The contour deviation that is determined is always used in the brake test to detect that the fixed endstop has been reached The parameterization in MA_FIXED_STOP_BY_SENSOR is therefore irrelevant The required threshold value must be set in MD MA_FIXED_STOP_THR...

Page 453: ...closed after the CloseBrake output was set TV_FeedCommand I S5TIME Monitoring time value output traversing command Check travel command after MoveAxis has been set TV_FXSreached I S5TIME Monitoring time value fixed endstop reached TV_FXShold I S5TIME Monitoring time value test brake CloseBrake O BOOL Request close brake MoveAxis O BOOL Request initiate traversing Done O BOOL Test successfully comp...

Page 454: ...d S M GND 110 7 Brake test running S M GND 110 6 Next step S DBX 8 4 Request neutral axis U DBX 68 6 Checkback signal axis is neutral U M GND 110 6 FP M GND 110 1 R M GND 110 6 S M GND 110 5 Next step R DBX 8 4 S DBX 28 7 Request PLC monitored axis U DBX 63 1 Checkback signal the PLC is monitoring the axis M GND 110 5 FP M GND 110 2 R M GND 110 5 S M GND 111 0 Start the brake test for FB CALL FB 1...

Page 455: ...raverse Z axis Start M 111 2 Start traversing motion Stop FALSE Funct B 16 5 Mode Axis mode Mode B 16 1 Traversing Incremental AxisNo 3 Axis number of the axis to be traversed Z axis Pos 5 000000e 000 Distance Minus 5 mm Frate 1 000000e 003 Feed rate 1000 mm min InPos M 113 0 Position reached Error M 113 1 Error has occurred State MB 114 Error status 8 3 4 Limitations During the brake test travers...

Page 456: ...3 6 Examples An example of incorrect parameterization that results in Alarm 20095 Axis 1 impermissible holding torque measured torque 2 is shown in the following diagram The torque due to weight in the drive machine data 1192 has been parameterized considerably lower than the measured torque mAct The calculated torque limit mFXS symmetrically around this MD would mean that the drive would not be a...

Page 457: ...ected A cam signal is to be generated for this purpose that has a high signal level between 89 5 and 90 5 pulse These positions are entered into the machine data 36936SAFE_CAM_POS_PLUS 0 90 5 degrees 36937SAFE_CAM_POS_MINUS 0 89 5 degrees 36905SAFE_MODULO_RANGE 360 degrees and are subsequently transferred into the FD MSD machine data The levels of the safe cam signals change as follows SN1 SN1 89 ...

Page 458: ... 0 04010101 The minimum logic Chapter 3 9 19 of the NCK safety channel is used for multiple assignment to an output or a system variable This includes the rounding off of the assigned signals This type of logic is not available in the form of parameter settings on the PLC side The negation on the NC side is not effective for the drive PLC side therefore the position detection has to be programmed ...

Page 459: ... 0 5 Modulo correction Position detection to be implemented SN1 Position detection 0 degrees SN1 Fig 8 9 Signal generation for modulo cam 1 Because of the modulo correction and the associated level changes of the safe cams the above method of rounding would have the effect that position detection 0 degrees would always be a low signal This problem can be solved by negating signal SN1 in the machin...

Page 460: ...are parameterized to A_INSI variables and logically combined in the SPL 36988 SAFE_CAM_PLUS_OUTPUT 0 84010101 A_INSI 1 36989 SAFE_CAM_MINUS_OUTPUT 0 04010102 A_INSI 2 IDS 1DO A_MARKERSI 1 A_INSI 1 OR A_INSI 2 PLC programming is analogous to that of the NCK SPL UN DB3x DBX109 0 SN1 inverted DB18 DBX62 0 A_INSIP 1 U DB3x DBX109 1 SN1 DB18 DBX62 1 A_INSIP 2 U DB18 DBX62 0 A_INSIP 1 O DB18 DBX62 1 A_I...

Page 461: ...toring in order that the two safety channels are switched in synchronism see also Section 3 7 This synchronization is necessary if the safe cam signals are to be processed in the SPL Consideration should be given to conditions which can affect the parameter settings and the effect of synchronization on position detection The position of the safe cams at the modulo limit must be aligned to the sele...

Page 462: ...ection the magnitude of the tolerance and the magnitude of the position deviations Example 2 linear axis pulse generation For a cam position of 100 mm and the following tolerances 36942 SAFE_POS_TOL 0 1mm max static deviation 36940 SAFE_CAM_POS_TOL 0 1mm 36936 SAFE_CAM_POS_PLUS 0 100 mm SN 36037 SAFE_CAM_POS_MINUS 0 99mm SN POSITION NCK at 0 mm 0 000 mm POSITION drive at 0 mm 0 040 mm static devia...

Page 463: ...chronized with hysteresis negation of a signal for SN1 via MD parameters SGA SN1 synchronized with hysteresis generated in same way as SN1 SAFE_CAM_TOL SAFE_CAM_TOL Use of cam signals signal pattern depending on traversing direction by mapping onto same signal HW INSI Traversing direction Traversing direction Cam synchronization SN1 SAFE_CAM_TOL SAFE_CAM_TOL SAFE_CAM_TOL Fig 8 12 Signal generation...

Page 464: ...ctual values 1 Run up the NCK with the standard machine data by selecting key position S3 1 and then activating power on 2 Switch S3 back to position 0 3 The password for protection level 2 Machine manufacturer must be active 4 Alternative 1 Readiin an NC archive file with an existing drive configuration continue with Point 11 5 Alternative 2 Commission one or more axes Drive configuration softkey...

Page 465: ...ive at the interface Both position measuring systems should be de activated Position measuring system 1 DB3x DBX1 5 0 parking axis Position measuring system 2 DB3x DBX1 6 0 parking axis 13 Commission Safety Integrated as described in Chapter 7 set MD 36915 SAFE_ENC_TYPE to 1 or 4 If terminals 663 or AS1 AS2 on the control card are already connected up then the supply must be made from the PLC side...

Page 466: ...on at this point The safe cam SI function is used for the solution A detailed description of this function is given in Chapter 3 7 The section below only describes how the function is used The retraction logic is based on the following considerations 1 SI function Safe cam The SGA signal assigned to the safe cam is only used on the PLC side it is not necessary to configure the machine data This me...

Page 467: ...SNx Traversing area program Fig 8 11 Example of retraction logic The minus cam of a cam pair for example cams SN1 SN4 can all be used is set up in the machine data at the position immediately in front of the left safe limit position SE It must be ensured that SN is passed if SE is passed This means that the difference should be kept as low as possible we recommend 0 0 1 mm A cam should be set up i...

Page 468: ...signal of SN It should be noted that the SGA for the cam signal is not available until the drive has powered up Example when using the 1st cam pair U DB10 DBX108 5 Drives in cyclic mode L S5T 50ms Transition period to avoid timing problems SE T100 Timer as input delay UN T100 While the time has still not SPB NOSN expired the HW limit switch signals are not supplied UN DB axis DBX109 0 SN1 DB axis ...

Page 469: ...referenced at least once adjustment between the actual position value of the NC and the SI actual values axis drive has been carried out Safe limit positions or Safe cams have been able to be used A motor or motor encoder must replaced under these limitations conditions In order to set the encoder the offset between the machine zero and the zero of the absolute encoder was determined and saved in ...

Page 470: ...00950 Axis not safely referenced are still present and indicate that the functions Safe limit positions and Safe cams are not active in this state For example if the Safe limit positions as being used as a substitute for hardware limit switches then they are not functioning at this time 2 Move the axis to the reference position after first setting MD 34010 REFP_CAM_DIR_ IS_MINUS according to the a...

Page 471: ...librate the encoder a reference point approach has been set up e g with reference point cams i e after the zero mark has been passed when leaving the cam the reference point is approached according to the offsets in 34080 REFP_MOVE_DIST and 34090 REFP_MOVE_DIST_CORR and the value of the reference point is set in MD 34100 REFP_SET_POS After the referencing operation Alarm messages 27000 300950 Axis...

Page 472: ... into the referenced state At this time the reference point value is taken over as the safe actual value for the axis and drive 5 Finally if the JOG REF machine mode is active on the MMC the user agreement softkey must be pressed and the user agreement for the axis involved must be reset Alarms 27000 300950 disappear and the functions Safe limit positions and Safe cams are safely active again Case...

Page 473: ...erized as follows at the machine the following doesn t provide a complete parameterization of the ESR function only that part required to obtain an understanding Parameterization of the channel specific ESR machine data NC controlled retraction MD 21380 MC_ESR_DELAY_TIME1 0 1 Continue to move for a short time MD 21381 MC_ESR_DELAY_TIME2 3 0 Time for the braking ramp Parameterizing the axis specifi...

Page 474: ...ors MD 10097 MN_SAFE_SPL_STOP_MODE 4 Default value 3 For errors in the crosswise data comparison of the SPL Alarm 27090 with the value 4 a Stop E is initiated instead of a Stop D At the same time bit DB18 DBX36 1 must be set in the PLC SET DB18 DBX36 1 enable Stop E MD 36901 MA_SAFE_FUNCTION_ENABLE AX1 51 X axis SG SBH external Stop E MD 36901 MA_SAFE_FUNCTION_ENABLE AX2 53 Y axis SG SBH SE extern...

Page 475: ...ted in the drive drive based function in this time This time should therefore be adapted to the parameterization of the drive MD MD_RETRACT_TIME in this particular example 200 ms In this example the system does not wait for this time in the following specific cases active SBH when an external Stop A is selected active SG1 For SG1 MA_SAFE_VELO_STOP_REACTION is parameterized so that when the bus fai...

Page 476: ...cts a Stop E IDS 250 WHENEVER AC_MARKER 20 1 AND A_STOPESI 0 DO AC_ESR_TRIGGER TRUE The retraction is automatically initiated if safety integrated has detected a problem associated with the actual value sensing Alarm 27001 with Codes 3 or 44 to 57 has occurred or a Stop F is present that will result in a subsequent stop B A ID 251 WHENEVER AC_MARKER 20 1 AND A_XFAULTSI 0 DO AC_ESR_TRIGGER TRUE Mar...

Page 477: ...Asynchronous subroutine Application Specific Integrated Circuit semiconductor module developed for special applications Mode group Stop in corresponding mode group Professional association in Germany Berufsgenossenschaftliches Institut für Arbeitssicherheit German Institute for Occupational Safety Configuration telegram Central Processing Unit Cyclic Redundancy Check D A converter Data block A AB ...

Page 478: ...I Os Direct Measuring System Digital Output Distributed I O DP master Dual Port RAM Data Right Data Word Number of encoder pulses Encoder Data interface for absolute encoder Part of an order code for absolute incremental encoders made by Heidenhain ElectroStatic Discharge Extended Stop and Retract Failsafe Failsafe input module Failsafe output module DI DKE AK DL DMP DMS DO DP DPM DPR DR DW ENC EN...

Page 479: ...ues Fixed Stop travel to fixed stop Handheld Unit High resolution Measuring System Hardware Infeed Regenerative Feedback Unit Input Byte Start up Pulse cancellation Indirect Measuring System Interpolator Interface signal Crosswise data comparison Leadscrew Error Compensation Least Significant Bit Fast retraction from contour Lower limit FD FOC FV FXS HHU HMS HW I RF IB IBN IMP IMS IPO IS KDV LEC L...

Page 480: ...chinery Directive Man Machine Communication operator interface for man machine communication Most Significant Bit Main Spindle Drive Machine Tool Numerical Control NC Kernel Line infeed module Operator Acknowledge Organization block Operator interface Operator panel Machine readable product designation Programmable Logic Controller Power Module Electronic Failsafe MD MDD Mixed IO MDIR MMC MSB MSD ...

Page 481: ...ute Safe operating stop Safe braking ramp Safe Limit Switch Safely reduced speed Safety relevant outputs Safety relevant inputs Safe standstill SINUMERIK Safety Integrated Safety Integrity Level Softkey Safe cams Safe Programmable Logic Stop response In the event of a fault the system reacts depending on the configured STOP response Software PS PSC QVK RPM SBH SBR SE SG SGA SGE SH SI SIL SK SN SPL...

Page 482: ...dix 11 03 Siemens AG 2003 All Rights Reserved A 482 SINUMERIK 840D SIMODRIVE 611 digital SINUMERIK Safety Integrated FBSI Edition 11 03 Tool Center Point Testing Data Active Gear Ratio Upper limit TCP TEA Ü UL ...

Page 483: ...me in Maschinen Schäfer M Umbreit M Antriebssysteme und CNC Steuerungen mit integrierter Sicherheit BIA Report Nr 4 97 Kategorien für sicherheitsbezogene Steuerungen nach EN 954 1 BIA Report 6 97 ZH1 419 Prüf und Zertifizierungsordnung der Prüf und Zertifizierungsstellen im BG Prüfzert Prüf und Zertifizierungsordnung Ausgabe 10 97 Reinert D Schäfer M Umbreit M Antriebe und CNC Steuerungen mit inte...

Page 484: ...2 SINUMERIK 840D 840Di 810D SIMODRIVE 611D Lists Order No 6FC5 297 6AB70 0BP3 SINUMERIK 840D 840Di 810D Description of Functions Basic Machine Part 1 Order No 6FC5 297 6AC20 0BP2 SINUMERIK 840D 840Di 810D CCU2 Description of Functions Extended Functions Part 2 Order No 6FC5 297 6AC30 0BP2 SINUMERIK 840D 840Di 810D CCU2 Description of Functions Special Functions Part 3 Order No 6FC5 297 6AC80 0BP1 ...

Page 485: ... 11 03 A 485 A 2 3 List of References for SIMODRIVE 611 SIMODRIVE 611 A 611 D Planning Guide Inverters Transistor PWM Inverters for AC Feed Drives and AC Main Spindle Drives Order No 6SN1197 0AA00 0BP5 SIMODRIVE Planning Guide Synchronous Build in Motors 1FE1 AC Motors for Main Spindle Drives Order No 6SN1 197 0AC00 0BP1 PJU PJFE ...

Page 487: ...ut assignment 4 230 Commissioning 840D First commissioning 5 277 Series commissioning 5 280 Communication NCK and PLC SPL 3 158 Comparison clock cycle 2 35 for 840D 4 210 4 215 Configuration for 840D 5 276 Connection of the drives 7 381 7 415 Control category 3 2 32 Control Category 3 2 49 Cross Monitoring 1 19 Crosswise data comparison 2 34 3 138 D D A converter output 5 283 Data altering 5 281 D...

Page 488: ...S 3 180 Incremental encoder 3 168 Initialization Safety relay 3 149 Integrated safety functions 1 20 Interface signals 4 256 from drive 4 261 to drive 4 257 K Keyswitch 7 400 L Limit frequency 3 96 Limiting the setpoint speed 3 99 Load standard motor data 4 242 Local inputs on the NCU 4 231 Local outputs on the NCU 4 234 Logbook 5 279 M Machine calibration 3 170 Machine data for 611 digital Overvi...

Page 489: ...4 Safe operating stop 3 89 De selection 3 92 Function features 3 89 Machine data 3 94 Prerequisites 3 90 Selecting 3 90 Safe operating stop test 5 287 Safe signal processing 3 129 Safe software cams Function features 3 115 Hysteresis 3 116 Machine data 3 123 Output assignment 3 117 Prerequisites 3 115 Special case 3 116 Specifying cam positions 3 116 Synchronization 3 116 Tolerance 3 116 Safe soft...

Page 490: ...inking to the I Os 3 145 SPL data on the PLC side 3 156 SPL start without axial safety enable 3 137 Standard monitoring functions 2 46 Standstill tolerance 3 89 Standstill via SGEs 3 80 Start SPL 3 144 STOP A Description 3 73 STOP B Description 3 73 STOP C Description 3 74 STOP D Description 3 75 STOP F Description 3 76 Stop response SG specific 3 102 Stop responses Assignment table 3 72 Overview ...

Page 491: ...ocu erlf siemens de SINUMERIK Safety Integrated Manufacturer Documentation From Name Description of Functions Order No 6FC5297 6AB80 0BP2 Edition 11 03 Company Dept Address Postal code ____________ City Phone __________ Fax ________ Should you come across any printing errors when reading this publication please notify us using this form Suggestions for improvement are also welcome Suggestions and ...

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Page 494: ...change without prior notice Order No 6FC5297 6AB80 0BP2 Printed in the Federal Republic of Germany Siemens AG Automation and Drives Motion Control Systems Postfach 3180 D 91050 Erlangen Bundesrepublik Deutschland www ad siemens de ...

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