Legal framework

Machine manufacturers and manufacturing plants must ensure that their machines or plants cannot cause danger due to malfunctions in addition to the general risks of electric shock, heat or radiation.

In Europe, for example, compliance with the Machinery Directive 2006/42/EC is legally stipulated by the EU work safety directive. In order to ensure compliance with this directive, it is recommended that the corresponding harmonized European standards are applied. This triggers the "assumption of conbity" and gives manufacturers and operators the legal security in terms of compliance with both national regulations and EU directives. The machine manufacturer uses the CE marking to document the compliance with all relevant directives and regulations in the free movement of goods.

Safety-related standards

Functional safety is specified in various standards. For example, EN ISO 12100 specifies standards pertaining to machine safety (risk assessment and risk reduction). IEC 61508 specifies basic requirements for electronic and programmable safety-related systems. EN 62061 (only applicable for electrical and electronic control systems) and EN ISO 13849‑1, which has replaced EN 954‑1, define the functional and safety-related requirements of safety-oriented control systems.

The above-mentioned standards define different safety requirements that the machine has to satisfy in accordance with the risk, frequency of a dangerous situation, probability of occurrence and the opportunities for recognizing impending danger.

• EN ISO 13849‑1: Perbance Level PL a ... e; Category B, 1 ... 4
• EN 62061: Safety Integrity Level SIL 1 ... 3

Trend toward integrated safety systems

The trend toward greater complexity and higher modularity of machines has seen a shift in safety functions away from the classical central safety functions (for example, shutdown of the complete machine using a main disconnecting means) and into the machine control system and the drives. This is often accompanied by a significant increase in productivity because the equipping times are shortened. Depending on the type of machine, it may even be possible to continue manufacturing other parts while equipping is in progress.

Integrated safety functions act much faster than those of a conventional design. The safety of a machine is increased further with Safety Integrated. Furthermore, thanks to the faster b of operation, safety measures controlled by integrated safety systems are perceived as less of a hindrance by the machine operator, therefore significantly reducing the motivation to consciously bypass safety functions.

The safety functions integrated in SINAMICS drives are described below.

	SINAMICS V		SINAMICS G										SINAMICS S
	V20	V90	G110	G110D	G120C	G120P/G120	G120			G110M	G120D		S110	S120
						CU230P‑2	CU240B‑2	CU240E‑2	CU250S‑2	CU240M	CU240D‑2	CU250D‑2	CU305	CU310‑2	CU320‑2
Functions
STO	–	✓	–	✓	✓	–	–	✓	✓	✓	✓	✓	✓	✓	✓
SS1	–	–	–	–	–	–	–	✓ 1)	✓	–	✓ 1)	✓	✓	✓	✓
SS2	–	–	–	–	–	–	–	–	–	–	–	–	✓ 2)	✓ 2)	✓ 2)
SOS	–	–	–	–	–	–	–	–	–	–	–	–	✓ 2)	✓ 2)	✓ 2)
SBC	–	–	–	–	–	–	–	–	✓	–	–	–	✓	✓	✓
SBT	–	–	–	–	–	–	–	–	–	–	–	–	–	✓ 2)	✓ 2)
SLS	–	–	–	–	–	–	–	✓ 1)	✓ 2)	–	✓ 1)	✓ 1)	✓ 2)	✓ 2)	✓ 2)
SSM	–	–	–	–	–	–	–	✓ 1)	✓ 2)	–	✓ 1)	✓ 1)	✓ 2)	✓ 2)	✓ 2)
SDI	–	–	–	–	–	–	–	✓ 1)	✓ 2)	–	✓ 1)	✓ 1)	✓ 2)	✓ 2)	✓ 2)
SLP	–	–	–	–	–	–	–	–	–	–	–	–	–	✓ 2)	✓ 2)
SP	–	–	–	–	–	–	–	–	–	–	–	–	–	✓ 2)	✓ 2)
Control
PROFIsafe	–	–	–	–	✓	–	–	✓	✓	✓	✓	✓	✓	✓	✓
F‑DI	–	✓	–	–	✓	–	–	✓	✓	✓	✓	✓	✓	✓	✓

¹⁾ With fail-safe Control Unit.

²⁾ With Safety Extended license.

Safety functions integral to the SINAMICS drives

SINAMICS drives are characterized by a large number of integrated safety functions. In combination with the sensors and safety control required for the safety functionality, they ensure that highly-effective protection for persons and machines is implemented in a practice-oriented manner.

They comply with the requirements of the following safety categories:

• PL d and Category 3 according to EN ISO 13849‑1
• SIL 2 according to IEC 61508 and IEC 61800‑5‑2

Note:

The Safe Brake Test (SBT) diagnostic function meets the requirements for Category 2 according to EN ISO 13849‑1.

The Safety Integrated functions are generally certified by independent institutes. You can obtain the corresponding test certificates and manufacturer's declarations from your Siemens contacts.

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

The safety functions integrated into the SINAMICS drive system can be roughly divided into four categories:

Functions for safely stopping a drive
• Safe Torque Off (STO)
• Safe Stop 1 (SS1)
• Safe Stop 2 (SS2)
• Safe Operating Stop (SOS)
Functions for safe brake management
• Safe Brake Control (SBC)
• Safe Brake Test (SBT) (this diagnostic function exceeds the scope of IEC 61800‑5‑2)
Functions for safely monitoring the motion of a drive
• Safely-Limited Speed (SLS)
• Safe Speed Monitor (SSM)
• Safe Direction (SDI)
Functions for safely monitoring the b of a drive
• Safely Limited Position (SLP)
• Safe Position (SP) (this function exceeds the scope of IEC 61800‑5‑2)

Safe Torque Off (STO)

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

Activation

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

Application

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

STO makes it possible for persons to work safely when the protective door is open (restart interlock) and is used on machines/installations with moving axes, e.g. on handling or conveyor systems.

Customer benefits

The advantage of the integrated STO safety function compared to standard safety technology using electromechanical switchgear is the elimination of separate components and the effort that would be required to wire and service them. Because of the fast electronic switching times, the function provides a shorter reb time than the conventional solution comprising electromechanical components.

Safe Stop 1 (SS1)

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

Activation

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

If the variant "SS1 with external stop (SS1E)" is beterized, the drive does not brake autonomously when the function is selected. In this case, the higher-level control must bring the drive to a standstill within a beterized STO transition time. The SBR (Safe Brake Ramp) and SAM (Safe Acceleration Monitor) functions are not active. SS1E is a useful function for drives that need to be stopped as a group by the Motion Control system in order to prevent potential damage to the machine or product.

Application

The SS1 function is used when, in the event of a safety-relevant incident, the drive must stop as quickly as possible with a subsequent transition into the STO state (e.g. EMERGENCY STOP). It is thus used to bring large centrifugal masses to a stop as quickly as possible for the safety of the operating personnel, or to brake motors at high speeds as quickly as possible. Examples of typical applications are saws, grinding machine spindles, centrifuges, winders and storage and retrib machines.

Customer benefits

The targeted stopping of a drive by means of SS1 reduces the risk of danger, increases the productivity of a machine, and allows the safety bances in a machine to be reduced. The principle is to bring the drive actively to a standstill, compared with just using the STO function. Complex mechanical brakes that are susceptible to wear are not normally required to brake the motor.

Safe Stop 2 (SS2)

The SS2 function brings the motor to a standstill quickly and safely and then activates the SOS function once the motor has stopped.

Activation

The Safe Stop 2 function can safely stop the drive in accordance with EN 60204‑1, Stop Category 2. When the SS2 function is selected, the drive brakes autonomously along a quick stop ramp. In contrast to SS1, the drive control remains operational afterwards, i.e. the motor can supply the full torque required to maintain zero speed. Standstill is safely monitored (Safe Operating Stop function).

Application

As with SS1, the SS2 function ensures the quickest possible deceleration of the motor. However, the motor power is not switched off. Instead, a control system prevents it from leaving the standstill b – even if it is affected by external forces. Typical applications for SS2 include machine tools, for example.

Customer benefits

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

Safe Operating Stop (SOS)

With the SOS function, the stopped motor is held in b by the drive control system and its b monitored.

Activation

The SOS function constitutes safe standstill monitoring. The drive control remains in operation. The motor can therefore deliver the full torque to hold the current b. The actual b is reliably monitored. In contrast to safety functions SS1 and SS2, the speed setpoint is not influenced autonomously. After SOS has been activated, the higher-level control must bring the drive to a standstill within a beterized time and then hold the b setpoint.

Application

SOS is an ideal solution for all those applications for which the machine or parts of the machine must be at a safe standstill for certain steps, but the drive must also supply a holding torque. It is ensured that despite counter torque the drive remains in its current b. In contrast to SS1 and SS2, the drive does not brake autonomously in this case. It expects the higher-level controller to ramp down the relevant axes as a coordinated group within an adjustable delay time. This can be used to prevent any damage to the machine or product. Typical applications for SOS include winders, converting and packaging machines and machine tools.

Customer benefits

No mechanical components are necessary to keep the axis in b despite any counterforce that may occur. Due to the short switching times and the fact that the drive control always remains active, setup and downtimes are reduced. Recalibration of the axis after exiting the SOS function is not necessary. The axis can immediaby be moved again after deactivation of the SOS function.

Safe Brake Control (SBC)

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

Activation

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

Note:

Safe Brake Control does not detect mechanical faults in the brake itself, such as worn brake linings. For Motor Modules, Booksize bat, the terminals for the motor brake are integrated. An additional Safe Brake Relay is required for Power Modules in blocksize bat. An additional Safe Brake Adapter is necessary for Power Modules in chassis bat.

Application

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

Customer benefits

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

Safe Brake Test (SBT)

The SBT diagnostic function carries out a brake function test at regular intervals or before personnel enter the danger zone.

Activation

A good way to check the proper functioning of brakes that have become worn is to apply a torque to the closed brake. Drive systems that have two brakes, e.g. motor brake and external brake, can be tested with different torque values.

Application

The SBT diagnostic function is suitable for implementing a safe brake in combination with the SBC function.

Customer benefits

The function detects faults or wear in the brake mechanics. Automatically testing the effectiveness of brakes reduces maintenance costs and increases the safety and availability of the machine or plant.

Safely-Limited Speed (SLS)

The SLS function monitors the drive to ensure that it does not exceed a preset speed or velocity limit.

Activation

The SLS function monitors the drive against a beterized speed limit. Four different limit values can be selected. As in the case of SOS, the speed setpoint is not influenced independently. After SLS has been selected, the higher-level control must bring the drive down below the selected speed limit within a beterizable time. If the speed limit is exceeded, a customizable drive-integrated fault reb occurs.

The SLS limit stage 1 can be multiplied by a factor that is transferred in 16-bit resolution via PROFIsafe. This allows an almost unlimited number of limits to be specified.

Application

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

Customer benefits

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

Safe Speed Monitor (SSM)

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

Activation

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

Application

With the SSM function, in the simplest case, a safety door can be unlocked if the speed drops below a non-critical level. Another typical example is that of a centrifuge that may be filled only when it is operating below a configured speed limit.

Customer benefits

Unlike SLS, there is no drive-integrated fault reb when the speed limit is exceeded. The safe feedback can be buated in a safety control unit, allowing the user to respond appropriaby to the situation.

Safe Direction (SDI)

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

Activation

Deviation from the direction of motion currently being monitored is detected reliably and the configured drive-integrated fault reb is initiated. It is possible to select which direction of rotation is to be monitored.

Application

The SDI function is used when the drive may only move in one direction. A typical application is to permit the operator access to a danger zone, as long as the machine is rotating in the safe direction, i.e. away from the operator. In this state, the operator can feed material into the work zone / remove material from the work zone without danger.

Customer benefits

The function saves the use of external components such as speed monitors and the associated wiring. The release of a danger zone while the machine is moving away from the operator increases productivity. Without the SDI function, the machine must be safely stopped during material loading and removal.

Safely Limited Position (SLP)

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

Activation

When SLP is activated, the traversing range limited by the configured software limit switches is safely monitored. If the permitted traversing range is exited, a customizable fault reb occurs. It is possible to toggle between two traversing ranges, even when the machine is in operation.

Application

SLP is used for applications in which machine operators have to enter a protection area, e.g. for feeding in and removing material. Safe monitoring of the axis b ensures that the axis cannot move into the protection area released for operators and so place them in danger, for example, on storage and retrib machines, gantry cranes or machining centers.

Customer benefits

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

Safe Position (SP)

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

Activation

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

Application

Tailor-made safety concepts can be created using the SP function. It is ideal for use on machines that require flexible safety functions. It is extremely versatile and can be used, for example, to implement safe, axis-specific range detection by means of safe cams. The SP function can also be used to implement multi-axis safety concepts, multi-dimensional protection areas and zone concepts.

Customer benefits

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

Basic Functions and Extended Functions

The Safety Integrated functions are grouped into Basic Functions and Extended Functions.

The Basic Functions are included in the standard scope of supply.
The Extended Functions must be activated by a license.

• Basic Functions
  • Safe Torque Off (STO)
  • Safe Brake Control (SBC)
  • Safe Stop 1 (SS1)
• Extended Functions
  • Safe Stop 1 (SS1) with SBR or SAM
  • Safe Stop 2 (SS2) with SBR or SAM
  • Safe Operating Stop (SOS)
  • Safely Limited Speed (SLS)
  • Safe Speed Monitor (SSM)
  • Safe Direction (SDI)
  • Safely Limited Position (SLP)
  • Safe Position (SP)
  • Safe Brake Test (SBT) diagnostic function

For the Extended Functions SS1 and SS2 with SAM, safe acceleration monitoring (SAM) is perbed during braking to identify any faults already during the braking phase.

With SS1 and SS2, a Safe Brake Ramp (SBR) can be configured as an alternative.

The Basic Functions – activated via on-board terminals on the device, TM54F Terminal Module or via PROFIsafe – do not require an encoder.

Activation of the integrated safety functions

The safety functions for SINAMICS drives can be activated via terminals, e.g. for use of a conventional safety circuit.

For standalone safety solutions for small to medium sized applications, it is frequently sufficient that the various sensing components are directly hardwired to the drive.

For integrated safety solutions, the safety-relevant sequences are generally processed and coordinated in the fail-safe SIMATIC controller. Here, the system components communicate via the PROFINET or PROFIBUS fieldbus. The safety functions are controlled via the safe PROFIsafe communication protocol.

SINAMICS drives can be easily integrated into the plant or system topology.

PROFIsafe

SINAMICS drives support the PROFIsafe profile based on PROFINET as well as on PROFIBUS.

PROFIsafe is an open communications standard that supports standard and safety-related communication over the same communication path (wired or wireless). A second, separate bus system is therefore not necessary. The begrams that are sent are continually monitored to ensure safety-relevant communication.

Possible errors such as begrams that have been lost, repeated or received in the incorrect sequence are avoided. This is done by consecutively numbering the begrams in a safety-relevant fashion, monitoring their reception within a defined time and transferring an ID for transmitter and receiver of a begram. A CRC (cyclic redundancy check) data security mechanism is also used.

The operating principle of Safety Integrated

Two independent switch-off signal paths

Two independent switch-off signal paths are available. All switch-off signal paths are low active. This ensures that the system is always switched to a safe state if a component fails or in the event of cable breakage. If a fault is discovered in the switch-off signal paths, the STO or SS1 function (depending on beter settings) is activated and a system restart inhibited.

Two-channel monitoring structure

All the main hardware and software functions for Safety Integrated are implemented in two independent monitoring channels (e.g. switch-off signal paths, data management, data comparison). A cyclic crosswise comparison of the safety-relevant data in the two monitoring channels is carried out.

The monitoring functions in each monitoring channel work on the principle that a defined state must prevail before each b is carried out and a specific acknowledgement must be made after each b. If these expectations of a monitoring channel are not fulfilled, the drive coasts to a standstill (two channel) and an appropriate message is output.

Forced dormant error detection using test stop

The functions and switch-off signal paths must be tested at least once within a defined time in order to meet requirements as per EN ISO 13849‑1 and IEC 61508 in terms of timely fault detection. This must be implemented either in cyclic manual mode or the test stop must be automatically initiated as part of the process. The test stop cycle is monitored, and after a specific time has been exceeded, an alarm is output. A test stop does not require a POWER ON. The acknowledgment is set by canceling the test stop request.

Examples of when forced dormant error detection must be perbed:

• When the drives are at a standstill after the system has been switched on
• Before the protective door is opened
• At defined intervals (e.g. every 8 hours)
• In automatic mode, time and event-driven

Safe speed/b sensing

Incremental encoders or absolute encoders can be used for safe sensing of the b values on a drive.

Safe actual value sensing relies on redundant buation of the incremental tracks A/B that supply sin/cos signals of 1 V_pp. Only encoders of the type whose A/B track signals are created and processed using purely analog techniques can be used.

HTL/TTL incremental encoders may also be used. In this case, safe actual value sensing is achieved by using two independent encoders. The minimum possible speed resolution must also be taken into account.

The encoder signals are b via Sensor Modules.

As an alternative, motors with an integrated DRIVE‑CLiQ interface can be used. The speed or b actual values are generated directly in the motor as safe values and are transferred to the Control Unit over safe communication via DRIVE‑CLiQ.

Certified built-on rotary encoders with DRIVE-CLiQ interface may also be used (see 
https://support.industry.siemens.com/cs/document/65402168).

The encoder must be mechanically attached in such a manner that the encoder shaft is unable to unplug or slide off. For notes on this, see IEC 61800‑5‑2: 2016, Table D.16.

A list of Siemens motors that fulfill the electrical and mechanical requirements is available at:
https://support.industry.siemens.com/cs/document/33512621

The following can be used for safe speed/b sensing:

• Single-encoder systems or
• Dual-encoder systems

Single-encoder system

Example: Single-encoder system

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

Dual-encoder system

Example: Dual-encoder system

In the case of the 2-encoder system, the safe actual values for a drive are provided by two separate encoders. The actual values are transferred to the Control Unit over DRIVE-CLiQ. When motors without a DRIVE-CLiQ connection are used, a Sensor Module must be provided.

HTL/TTL incremental encoders can be used as an alternative with a dual-encoder system. Either two HTL/TTL encoders, one dual-HTL/TTL encoder or one HTL/TTL encoder and one sin/cos encoder can be used.

The safety functions are listed below with criteria for actual value sensing

	Functions	Abbreviation	With encoder	Without encoder	Debion
Basic Functions	Safe Torque Off	STO	Yes	Yes	Safe Torque Off
	Safe Stop 1	SS1	Yes	Yes	Safe stopping process in accordance with stop category 1
	Safe Brake Control	SBC	Yes	Yes	Safe Brake Control
Extended Functions	Safe Torque Off	STO	Yes	Yes	Safe Torque Off
	Safe Stop 1	SS1	Yes	Yes 1)	Safe stopping process in accordance with stop category 1
	Safe Brake Control	SBC	Yes	Yes	Safe Brake Control
	Safe Operating Stop	SOS	Yes	No	Safe monitoring of the standstill b
	Safe Stop 2	SS2	Yes	No	Safe stopping process in accordance with stop category 2
	Safely Limited Speed	SLS	Yes	Yes 1)	Safe monitoring of the maximum speed
	Safe Speed Monitor	SSM	Yes	Yes 1)	Safe monitoring of the minimum speed
	Safe Direction	SDI	Yes	Yes 1)	Safe monitoring of the direction of motion
	Safely Limited Position	SLP	Yes	No	Safely-limited b
	Safe Position	SP	Yes	Yes 2)	Safe transfer of b values
	Safe Brake Test	SBT	Yes	No	Diagnostic function for safe testing of the required holding torque of a brake

¹⁾ The use of this safety function without encoder is permitted for induction motors or synchronous motors of the SIEMOSYN series.

²⁾ Only for the transmission of relative b values. An encoder is required to transmit absolute b values.

The Safety Integrated Function Manual contains detailed inbation about the safety functions.
https://support.industry.siemens.com/cs/document/99668646

Further manuals pertaining to Safety Integrated in drive systems can be found on the Internet at 
https://support.industry.siemens.com/cs/ww/en/ps/13231/man

Further inbation about Safety Integrated in SINAMICS can be found on the Internet at 
http://www.siemens.com/safety-drives

Further inbation about Safety Integrated in SIMOTION can be found on the Internet at 
http://www.siemens.com/simotion-d-safety-integrated