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Focused approach for more safety
As machine builder and company operating machines, your topmost priority is
to guarantee the safety of man and the environment when your machines are
being used and to boost productivity. We can support you in achieving this goal
with integrated safety functions in our drives and more than 100 years of
experience in industrial safety systems.
2
The prevention of accidents must be seen not as
a regulation prescribed by law but as a dictate of
human obligation and sound economic sense.
If this is not fully possible, or if not all of the Normally, a safety function comprises three subfunctions:
risks can be avoided by taking the appropriate
Detect (position switch, Emergency Stop, light curtain etc.)
design measures, then the appropriate
protective measures must be implemented. Evaluate (fail-safe control, safety relays, modular safety systems etc.)
For example, by embedding one or several
safety functions in the system. React (drives, motor starters, motor management systems)
Together, these subfunctions must create a safe and effective chain.
IEC 62061 or ISO 13849 can be applied to structurally configure the
safety functions. We recommend that products certified according to
these standards are used.
Machinery directive
Defining the safety integrity:
(2006/42/EC)
Safe design
3
Safety functions according to IEC 61800-5-2
integrated in the drive
Automated operation of plants and machinery assumes that suitable safety functions are
available, so that operating and maintenance personnel can always work safely in any situation.
For SINAMICS with Safety Integrated, these functions are already integrated in the drive.
Safety functions in SINAMICS drives can be split up into four categories:
SBC
t t t
Function: STO safely sets the drive into Function: The drive is quickly stopped Function: A holding brake is safely
a torque-free condition; an undesirable and safely monitored, especially for high controlled and monitored, especially for
restart is safely prevented. STO acts directly. moments of inertia vertical axes; is always activated in parallel
After STO has been deselected, the drive Application: Drive is quickly stopped with with STO
can quickly restart as the DC link remains subsequent transition into the STO state. Application: In conjunction with STO or
active Typical examples include: saws, grinding SS1 functions, an axis in the torque-free
Application: for example, operating and machines, centrifuges, storage and retrieval state is prevented from moving, e.g. as
maintenance personnel can safely work machines, winders a result of gravity
with the protective door open (restart Benefits: The productivity of a machine is Benefits: The monitored brake operates
inhibit) increased as a result of the lower safety safely, even in the no-current state without
Benefits: No wearing parts as a result of clearances; no mechanical braking that requiring external components and wiring;
the electronic shutdown. The converter involves intensive wear is required this prevents vertical/pulling loads from
remains connected to the line supply and sagging
can still be fully diagnosed
Safe operating stop Safe stop 2 Safe brake test
(SOS) (SS2) (SBT)
t
t t t
Function: The position is safely held and Function: A motor is quickly and safely Function: Using the SBT diagnostic
monitored at standstill for each drive control stopped and then SOS is activated function, up to two brakes per axis can
Application: For certain work, the machine (Safe Operating Stop) be cyclically tested
or parts of the machines must be safely at Application: The drive independently Application: Can be used for vertical axes
standstill however, the drive can still pro- brakes the motor along a emergency stop and suspended loads, e.g. for gantry cranes
vide a holding torque. Typical applications ramp; however, the motor can provide the and presses; in conjunction with SBC, it is
include: Winders, converting and packaging full torque to maintain standstill suitable for implementing a safe brake
machines as well as machine tools Benefits: Safe standstill monitoring; Benefits: Faults and wear can be detected
Benefits: Shorter equipping and down- productive operation is immediately in the mechanical system of a brake.
times thanks to permanently active resumed without referencing; Automatically testing the braking effective-
closed-loop position control. A motor is high degree of productivity and ness reduces maintenance costs and
quickly restarted short equipping and downtimes increases the safety and availability of
the system/machine
4
Functions for safely monitoring
drive motion
v SLS
v v
t
1
SDI
t
0
t
Function: A specific speed/velocity limit Function: Supplies a safety-related signal Function: It is safely monitored that the
of a drive is safely monitored as long as the drive operates below a drive can only move in the permissible
and a configurable fault response initiated specified speed/feed velocity direction; if the drive moves in the incorrect
when a limit value is violated Application: When a non-critical speed is direction, then a configured stop response
Application: If the safety of personnel reached, for example, a protective door can integrated in the drive is initiated
when carrying out maintenance or setting-up be released or a centrifuge filled Application: Allows material to be fed/
work is only guaranteed when operating at Benefits: Depending on the particular workpieces to be removed as long as the
reduced speed/velocity (e.g. manually situation, different response options to the machine moves in the safe direction,
threading material in a winder etc.) safe feedback signal, evaluation using a namely away from the operator
Benefits: Downtimes are shortened, setup safety-related control Benefits: Higher productivity/shorter cycle
is simplified, higher productivity and times, mechanical damage to the machine
system availability; an external speed is prevented when tools move with different
monitor is not required directions of rotation, e.g. for processing
machines
s
SCA 3
SP SCA 2
s
SLP SCA 1
S2 o 1
S1 o
t
S2 u 0
S1 u t
Function: Protective zones are safely Function: The SP function transfers safe Function: Supplies a safety-related signal
monitored using defined traversing ranges position actual values of the drive to the as long as the drive operates within a
Application: Wherever traversing ranges Fcontrol for further processing via specified position range
cannot be (completely) secured using PROFIsafe. Complex monitoring functions Application: Can be used with a high
protective doors or protective measures, can be implemented when required degree of versatility for safety-related,
e.g. for storage and retrieval machines, Application: Can be used with a high axis-specific range identification or working
gantry cranes, machining centers degree of versatility for cam sequencers, area/protective area demarcation
Benefits: Safety software limit switches are cross-axis safety concepts, multidimensional Benefits: Used to implement safe
implemented using SLP; mechanical limit protective areas and zone concepts. electronic cam sequencers without
switches can be eliminated Additional sensors and/or external safe requiring any hardware cams
transmitters/encoders, their installation
and evaluation are not required
Benefits: Suitable for machines where
flexible safety functions are required.
Engineering customized safety concepts
based on SIMATIC F controls
5
Safety Integrated
simply better
We have equipped our SINAMICS drives with Safety Integrated, as this functionality
directly supports you in building better machines. Based on Safety Integrated,
your machines provide an increased level of safety with low associated costs
today, and also when the system is expanded in the future.
Frequency
converter SINAMICS
A basic Emergency Stop application with external inter- As a comparison, the same application but this time imple-
connection is shown in the diagram. The Emergency Stop mented using a SINAMICS converter with Safety Integrated.
push button signal is evaluated using a safety relay. In this case, the signal from the SIRIUS EMERGENCY STOP
The converter is isolated from the line supply and motor push button is directly read into the converter, where it is
using two contactors. To start the application, the power evaluated. When initiating the Emergency Stop, STO is
circuit must be re-closed by switching the contactors and activated in the converter, for example. The converter is
the converter DC link pre-charged again. This takes time immediately switched into a no-torque condition, is safely
and involves switching operations of the electromechanical protected against an undesirable restart and does not
components. have to be electromechanically isolated from the line
supply. The application can be immediately restarted after
the Emergency Stop push button has been released. Here,
a higher productivity can be achieved as a result of the
shorter downtimes.
6
Conventional safety technology Safety Integrated
Fail-safe
control
Contactors
PROFINET / PROFIsafe
Fieldbus
React
Frequency
converter
Contactors SINAMICS
Evaluate React
A safety application involving Emergency Stop and setting-up The situation is completely different for a solution based on
operation where the speed is monitored is demonstrated a SINAMICS drive with Safety Integrated. In this case, the
in this example. Using conventional safety technology, this automation and safety solutions are merged to create a
application would be implemented in a separate circuit. fully integrated solution. The signals from the SIRIUS
The Emergency Stop push button signal is evaluated using a EMERGENCY STOP push button as well as the protective
safety relay. The converter is isolated from the line supply door monitoring are read into a fail-safe SIMATIC S7-1500 F
and motor using two contactors. For setting-up operation, control, and evaluated in the safety program. SINAMICS
a protective door monitoring function is evaluated, and the Safety Integrated functions for Emergency Stop (STO or
drive speed sensed using an encoder. If the speed limit is SS1) as well as speed monitoring (SLS) are controlled via
violated, the converter is isolated from the line supply and the existing fieldbus and fail-safe communication with
brought into a safe state. The converter is connected to the PROFIsafe. All of the necessary resources, such as standard-
automation control via a fieldbus. ized safety blocks for the safety program up to the precon-
figured PROFIsafe telegrams are available in the TIA Portal.
7
Safety Integrated
just get started
You can quickly find the solution for your drive and safety
application in the extensive SINAMICS portfolio with
Safety Integrated it is simple to implement, straight-
forward to commission and future-proof in operation.
Emergency Stop
v STO
Setting-up opera-
tion with safely- v SLS
limited speed
Objective reached in just a few steps Further, when the protective door is
SINAMICS with Safety Integrated open, the drive should not exceed
means that you can very simply and a velocity/speed configured by the
reliably engineer your safety functions. user when setting up the machine.
In a typical application for SINAMICS The diagram shows the concept of
with Safety Integrated, the Emergency the two safety functions and its
Stop signal should safely stop the implementation.
machine and protect against an
undesirable restart.
8
Basic stand-alone safety solution 1. Connect the sensors and operating devices directly to the drive.
with SINAMICS G120 2. Parameterize the functions in SINAMICS Startdrive.
A stand-alone solution based on Standard default values for most of the parameters are already
SINAMICS G120 can be realized preconfigured. Application-related parameters still have to be set,
in just a few steps: for example, the SS1 delay time.
The fail-safe system is now active.
Step 1 Step 2
1 t
2500,00 ms
n_is
Velocity
monitoring Stufe 1
n_max
500,00
Integrated safety solution with 1. Connect the sensors and operating devices of your integrated safety
SINAMICS G120 solution with the SIMATIC I/O. The signals can then be processed in
The integrated safety solution with the safety program (F program) of the control.
SIMATIC via safe communication based 2. In the hardware configuration in the TIA Portal, select the components
on PROFIsafe also only involves just a and the preconfigured PROFIsafe telegram. Then generate the safety
few steps: program (F program) using preconfigured blocks from the library.
3. Parameterize the functions in SINAMICS Startdrive.
Standard default values for most of the parameters are already
preconfigured. Application-related parameters still have to be set,
for example, the SS1 delay time.
The fail-safe system is now active.
1 t
2500,00 ms
n_is
Velocity
monitoring Stufe 1
n_max
500,00
9
Integrated safety
with SINUMERIK
SINAMICS drives teamed up with SINUMERIK controls
equipped with Safety Integrated also offer a wealth of
advantages for machine tools: lower engineering costs,
less external wiring, faster commissioning and all of
this with customized safety functions.
Integrated and ready-to-run Perfect interaction with SINUMERIK The practical examples on this page
This is all possible as the safety Simply program your own customized clearly demonstrate the advantages
functions integrated in the system safe logic: A wide range of safety of SINAMICS with Safety Integrated
are ready-to-run and fulfill the concepts is available for perfect teamed up with SINUMERIK.
requirements of Category 3/SIL 2/PL d. interaction between SINAMICS with
Safety Integrated and SINUMERIK. You
Documentation is part of the solution
can individually adapt, change and
The partially automated acceptance
expand these, so that you can imple-
test is yet another advantage. It
ment your own individual safety
simplifies commissioning and with
concept with minimum associated
all of the required reports to verify the
costs.
safety provides you with all of the
documentation you require.
Drive-based Basic
safety functions
10
2. Complex machine with
SINUMERIK 840D sl and SINAMICS
All safety functions are integrated
in the SINUMERIK 840D and the
SINAMICS drive (ready-to-run) with
this solution for complex machines.
Communication between the control,
SINUMERIK 840D sl
SINAMICS S120
via PROFIBUS or PROFINET; the safe
actuators and sensors are connected
e.g. CU320
via ET 200SP, for example. This con-
cept facilitates extensive adaptation
and expansion options and can be System-integrated Drive-based
simply commissioned and documented. safety functions Extended safety functions
11
Optimum support
for every safety task
With Safety Integrated in SINAMICS drives, you are not only selecting an outstanding
technical solution, but also perfect support relating to all safety issues. This starts with
the seamless integration of safety technology in SINAMICS drives and SIMATIC or
SINUMERIK and SIMOTION controls and continues in the accompanying work steps,
for instance, engineering in the TIA Portal or the documentation in-line with the stan-
dards using the Safety Evaluation Tool.
12
Scalable solutions for every safety task SIRIUS Safety Integrated seamless and safe
A significant advantage of our portfolio of Safety Integrated Completely safe functioning is absolutely mandatory when
products is the fact that you can scale your own individual it comes to implementing safety-related systems. This is
solution to practically any degree of complexity and each the reason that our SIRIUS Safety Integrated switchgear
machine and/or system size, and more precisely, with technology is specialized to address seamlessly integrated
standard components. This is complemented by the safety applications in your machines and systems to sense,
straightforward and seamless integration data exchange command and signal, to monitor and evaluate or to safely
via PROFINET and PROFIsafe. Benefit from this unique level shut down. SIRIUS products offer high system availability
of integrated seamlessness over the complete portfolio. and optimum protection for man, machine and the environ-
ment. In conjunction with standard fieldbus systems, such
www.siemens.com/safety-integrated
as AS Interface and PROFIBUS, also in networked, more
complex automation landscapes.
www.siemens.com/safety-relays
SIMATIC Safety Integrated the safe automation Complete holistic solutions with TIA
solution Safety and productivity with just one tool Safety Integrated
SIMATIC Safety Integrated allows you to seamlessly inte- is an integral part of Totally Integrated Automation.
grate machine safety into the SIMATIC automation solution. TIA seamlessly integrates our innovative products to create
This means that you use just one system for your standard homogeneous, highly specialized automation solutions.
automation and your fail-safe automation. The advantages: These begin with our SINAMICS drives with Safety Integrated,
high cost-effectiveness and reliability, less hardware, through space-saving controls for standard and safety-
simplified engineering, lower stock inventory costs to related communication up to ET 200SP motor starters.
name just a few. This is how SIMATIC Safety Integrated
supports you, for example, by reducing the amount of
cabling. This is achieved by being able to utilize the existing
network infrastructure including the WLAN plug connectors
for the fail-safe communication.
www.siemens.com/simatic-safety
13
We started by planning the hardware
and simply added the safety functions
using a memory card.
We were able to engineer our systems as usual
and commission them 30% faster.
SINAMICS Safety
simply safe, twice the efficiency
Machine builders and users both enjoy con-
siderable benefits by integrating the safety
functions into the drives: The machine or
system becomes safer, but the costs to
achieve this drop and the reliability of the
solution has been proven around the world
in many thousands of successful applica-
tions. You can also profit from the simplified
engineering, faster commissioning and
increased availability with lower mainte-
nance costs. Or put another way: You can
benefit from higher productivity, reduced
costs and increased competitiveness of the
machine.
More space lower costs
SINAMICS with Safety Integrated are not
only packed with functions, but they reduce
the amount of installation work and space
in the electrical cabinet. With SINAMICS,
you can simply activate the safety functions
instead of having to install and wire individ-
ual components a tedious task. Not only
this, you can be absolutely secure knowing
that these functions work perfectly.
14
SINAMICS V90 SINAMICS G110M/G120C
15
Variable-speed drive applications
SINAMICS G120 SINAMICS G120D SINAMICS G130/G150
The modular converter for single-motor drives Modular, distributed converters for Converters for variable-speed single-motor drives
with low up to medium power ratings variable-speed single-motor drives with average up to high power ratings
with a high degree of protection
Conveyor technology Conveyor technology and many more Pumps and fans
Handling equipment for high-performance solutions Compressors
Extruders, mixers Extruders and mixers
Pumps and fans Mills
Compressors
SIL 2 acc. to IEC 61508, Cat. 3 or PL d according to EN ISO 13849-1
16
High-performance and motion control applications
SINAMICS S110 SINAMICS S120 SINAMICS S150
Single-axis positioning drive Modular drive system Converters for demanding variable-speed
for demanding single-axis/multi-axis applications single-motor drives
17
Numeric control in processing machines
SIMOTION D SINUMERIK 840D sl SINUMERIK 828
18
Specific advantages of drives
with Safety Integrated
Essential safety functions are simply activated instead of having
to tediously create them using additional components
Certified system solution in compliance with the applicable
standards, including documentation
Fewer components, simplified engineering, lower system costs
No additional wiring costs, less space required in the
electrical cabinet
Faster commissioning/maintenance
Drive response in-line with the situation, faster restart for a
high degree of productivity
19
Published by
Siemens AG 2017
Digital Factory
P.O. Box 31 80
91050 Erlangen, Germany
Article No. E20001-A510-P670-X-7600
Printed in Germany
Dispo 21500
W/2847 WS 05173.0
Subject to changes and errors. The information given in this document only
contains general descriptions and/or performance features which may not
always specifically reflect those described, or which may undergo modifica-
tion in the course of further development of the products. The requested
performance features are binding only when they are expressly agreed upon
in the concluded contract. All product designations may be trademarks or
product names of SiemensAG or supplier companies whose use by third
parties for their own purposes could violate the rights of the owners.
To secure plants, systems and machines as well as networks against cyber-
attacks, a holistic industrial security concept must be implemented (and
continuously updated) corresponding to current state-of-the-art technology.
Products and solutions from Siemens are just one component of such a
concept. You can find additional information about industrial security at
siemens.com/industrialsecurity.