SINUMERIK 840D sl. Service - Configuring Commissioning. Manual (2011-2020)

Safety Integrated

9.1 Safety Integrated terminology

EN ISO 13849-1 (SINUMERIK 840D sl)

EN 61800-5-2 (SINAMICS S120)

German

English

Abbr.

German

English

Abbr.

Sichere Software-

Safe Software Limit

Sicher begrenzte Lage

Safely-Limited Position

SLP

Endschalter

Switch

Sicheres

Safe Brake

SBM

Bremsenmanagement

Management

Sichere

Safe Brake Control

SBC

Sichere

Safe Brake Control

SBC

Bremsenansteuerung

Sicherer Bremsentest

Safe Brake Test

SBT

Sichere Software-

Safe Software Cam

Sichere Nocken

Safe Cam

SCA

Nocken

Sicherheitsgerichteter

n < nx

Sichere

Safe Speed Monitor

SSM

Ausgang n < nx

Geschwindigkeits-

überwachung

Sichere Bewegungs-

Safe Direction

SDI

/Drehrichtungsüberwac

hung

Sichere

Safe Programmable

SPL

programmierbare

Logic

Logik

Sicherheitsgerichtete

Safety-related I/O

SGE/SG

Failsafe Digital Input

F-DI

Ein-/Ausgabesignale

Failsafe Digital Output

F-DO

Integrierter

Abnahmetest

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Safety Integrated

9.2 SINAMICS Safety Integrated

9.2

SINAMICS Safety Integrated

9.2.1

Safety functions

All of the Safety Integrated functions (SI functions) available with SINAMICS S120 are listed

in this chapter.

The safety functions listed here conform to:

● Safety Integrity Level (SIL) 2 according to DIN EN 61508

● Category 3 according to DIN EN ISO 13849-1

● Performance level (PL) d according to DIN EN ISO 13849-1

The safety functions correspond to the functions according to DIN EN 61800-5-2.

SINAMICS makes a distinction between Safety Integrated Basic Functions and Safety

Integrated Extended Functions. Extended Functions, however, are not available with

SINUMERIK. For this reason, the information below will not address them in any further

detail.

Safety Integrated Basic Functions

These functions are part of the standard scope of the drive and can be used without

requiring an additional license. They are always available. They do not require an encoder

and/or do not place any special requirements on the encoder used.

Function

Abbr.

Meaning

Safe Torque Off

STO

Safe Torque Off is a safety function that prevents the drive from starting unexpectedly, in

accordance with EN 60204-1. STO prevents the motor from being supplied with energy

that can generate a torque, and corresponds to stop category 0.

Safe Stop 1

SS1

Safe Stop 1 is based on the "Safe Torque Off" function. This means that a category 1 stop

(according to EN 60204-1) can be implemented after a delay time (time-controlled).

Safe Brake Control

SBC

Safe Brake Control is used to control a holding brake safely.

Notes

1. The functions must be enabled using parameters.

2. It is possible to group the control terminals for the Safe Torque Off (STO) function.

3. The functions are drive-integrated, i.e. they are present for each drive and must be

individually brought into operation for each drive.

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9.2 SINAMICS Safety Integrated

9.2.2

Basic Functions

Note

Basic functions do not require an encoder

The Safety Integrated Basic Functions are functions for safely stopping the drive. You do not

require an encoder.

9.2.2.1

Safe Torque Off (STO)

Definition according to EN 61800-5-2:

"The STO function prevents energy from being

supplied to the motor, which can generate a

torque."

Principle of operation

The inverter recognizes

the selection of STO via

a fail-safe input or via

the safe communication

PROFIsafe.

The inverter then safely

switches off the torque

of the connected motor.

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Safety Integrated

9.2 SINAMICS Safety Integrated

Application examples

Example

Possible solution

After an Emergency Stop button has been pressed,

• Wire the Emergency Stop button with a fail-

the drive must be braked as quickly as possible and

safe input.

brought into the STO state.

• Select STO via the fail-safe input.

A central Emergency Stop button ensures that

• Evaluate an Emergency Stop button in a

several drives are braked as quickly as possible

central control.

and brought into the STO state.

• Select STO via PROFIsafe.

Controlling the Safe Torque Off (STO) safety function using terminals

The Safe Torque Off function is selected/deselected separately for each drive using a

specific terminal on the Control Unit and Motor Module.

● Control Unit

The desired input terminal for STO is selected via BICO interconnection (BI: p9620).

Digital input DI 0 ... DI 7 on the Control Unit can be used as a signal source (NCU). The

NX modules have DI 0 to DI 3 digital input.

● Motor Module

The input terminal for STO is the "EP" pulse enable (Enable Pulses) terminal.

Both terminals must be simultaneously energized, otherwise a fault will be issued.

Note

To enable safe control of the safety functions using terminals, an external safety control such

as a safety relay (3TK28...) or SIMATIC S7 F control (e.g. ET200S F-DO- P/M-switching)

conforming to EN 13849-1 must be provided.

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9.2 SINAMICS Safety Integrated

Figure 9-2

Safe Torque Off terminals; control using ET200S fail-safe output, for example

Grouping drives

If the function is to be initiated for several drives simultaneously, the terminals for the

corresponding drives must be grouped together:

● Control Unit

By appropriately interconnecting the binector input to a joint input terminal for the drives

to be combined to form a group.

● Motor Module

By appropriately connecting terminal "EP" for the individual Motor Modules belonging to a

group.

Note

The same grouping must be set in both monitoring channels.

If a fault in a drive leads to an STO, the other drives in the same group will not

automatically enter the STO state.

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Safety Integrated

9.2 SINAMICS Safety Integrated

Enabling the Safe Torque Off (STO) function

The Safe Torque Off function is enabled via the following parameters:

p9601.0

STO using terminals on the Control Unit

p9801.0

STO using terminals on the Motor Module

The Safe Torque Off function does not need to be enabled for applications that do not

require Safety Integrated. All input terminals on the Control Unit can be used.

The STO terminal on the Motor Module does not need to be used.

Selecting/Deselecting Safe Torque Off

The Safe Torque Off function must be selected/deselected simultaneously in both monitoring

channels using the input terminals and is only effective for the associated drive.

1 signal: Deselection of the function

0 signal: Selection of the function

Restart after the Safe Torque Off function has been selected

1. Deselect the function in each monitoring channel via the input terminals.

2. Issue drive enable signals.

3. Cancel the power-on inhibit and power-up again.

1/0 edge at input signal "ON/OFF1" (cancel power-on inhibit)

–

0/1 edge at input signal "ON/OFF1" (power-up drive)

4. Move/traverse the drives again.

Status for Safe Torque Off

The status of the Safe Torque Off function is displayed using the following parameters:

r9772

CO/BO: Safety Integrated Status (Control Unit)

r9872

CO/BO: Safety Integrated Status (Motor Module)

r9773

CO/BO: Safety Integrated Status (Control Unit + Motor Module)

r9774

CO/BO: Safety Integrated Status (Safe Torque Off group)

Further information

For further details and information on how to assign parameters for this function, see the

"SINAMICS S120, Safety Integrated" Function Manual.

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9.2 SINAMICS Safety Integrated

9.2.2.2

Safe Stop 1 (SS1)

Definition according to EN 61800-5-2:

"The function SS1 brakes the motor and

trips the function STO after a delay time."

Principle of operation

The drive brakes once "Safe Stop 1" has

been selected, and goes into the "Safe

Torque Off" (STO) state once the delay

time has expired.

Selecting SS1

As soon as the converter identifies that SS1 has been selected via a terminal or via

PROFIsafe safe communication, the following happens:

● If the motor has already been switched off when SS1 was selected, then the converter

safely switches off the motor torque (STO).

● If the motor is switched on when SS1 is selected, the converter brakes the motor with the

AUS3 ramp-down time.

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Safety Integrated

9.2 SINAMICS Safety Integrated

Application examples

Example

Possible solution

After an Emergency Stop button has been pressed,

• Wire the Emergency Stop button with a fail-

the drive must be braked as quickly as possible and

safe input.

brought into the STO state.

• Select SS1 via the fail-safe input.

A central Emergency Stop button ensures that

• Evaluate an Emergency Stop button in a

several drives are braked as quickly as possible

central control.

and brought into the STO state.

• Select SS1 via PROFIsafe.

Further information

For further details and information on how to assign parameters for this function, see the

"SINAMICS S120, Safety Integrated" Function Manual.

9.2.2.3

Safe Brake Control (SBC)

Principle of operation

The "Safe Brake Control" function (SBC) is used to control holding brakes that function

according to the closed-circuit principle (e.g. motor holding brake).

SBC is (if configured) initiated together with STO. The Motor Module / Safe Brake Relay /

Safe Brake Module then carries out the action and activates the outputs for the brake.

Brake activation via the brake connection on the Motor Module / Safe Brake Relay / Safe

Brake Module involves a safe, two-channel method.

Features

● SBC is executed when "Safe Torque Off" (STO) is selected.

● In contrast to conventional brake control, SBC is executed via two channels.

● SBC is executed regardless of the brake control or mode set in p1215. SBC is not

recommended, however, when 1215 = 0 or 3.

● When the state changes, electrical faults, such as a short-circuit in the brake winding or

wire breakage can be detected.

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9.2 SINAMICS Safety Integrated

Two-channel brake control

The brake is essentially controlled from the Control Unit. Two signal paths are available for

applying the brake.

Figure 9-5

Two-channel brake control, blocksize (example)

For the "Safe Brake Control" function, the Motor/Power Module assumes a monitoring

function to ensure that when the Control Unit fails or malfunctions the brake current is

interrupted therefore closing the brake.

The brake diagnostics can only reliably detect a malfunction in either of the switches (TB+,

TB-) when the status changes, i.e. when the brake is released or applied.

If the Motor Module or Control Unit detects a fault, the brake current is switched off and the

safe status is reached.

Note

The monitoring and the forced checking procedure of the brake outlet is only possible if the

brake is connected directly to the connection terminals, and not using a coupling relay!

Further information

For further details and information on how to assign parameters for this function, see the

"SINAMICS S120, Safety Integrated" Function Manual.

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Safety Integrated

9.3 SINUMERIK Safety Integrated

9.3

SINUMERIK Safety Integrated

9.3.1

Safety functions

SINUMERIK Safety Integrated provides integrated safety functions for monitoring standstill,

speed, and working area.

Table 9- 2

SINUMERIK 840D sl safety functions

Function

Abbr.

Meaning

Safe Stopping Process

SS1

Brakes the drives safely down to standstill if monitoring or a sensor is triggered.

Safe Acceleration Monitor

SBR

Monitors the speed characteristic. The speed must be reduced after a stop request

has been issued.

Safe Operating Stop

SBH

Monitors the drives during standstill (to ensure that they remain stationary). The

drives remain fully functional for position control.

Safe Standstill

The drive pulses are suppressed, allowing the energy feed to be safely and

electronically disconnected.

Safely Reduced Speed

Monitoring of configurable speed limits

Safety-Related Output

Safe speed detection for a drive

n < nx

Safe Software Limit Switch

Variable traversing range limits

Safe Software Cam

Range detection

Safety-Related Input/Output

SGE/

Interface with process

Signals

SGA

Safe Programmable Logic

SPL

Direct connection of all safety-related signals and their internal logical operations

Safe Brake Management

SBM

•

2-channel brake control (SBC) (integrated into Motor Module)

• Cyclic brake test (SBT)

Safety-related

• Connection of distributed I/O for process and safety signals via PROFIBUS or

communication via standard

PROFINET using the PROFIsafe protocol

bus

• Safety-related CPU - CPU communication via PROFIBUS or PROFINET

Integrated acceptance test

Partially automated acceptance test for all safety-related functions. Simple

operation of the test process, automatic configuration of trace functions, and

automatic generation of an acceptance report.

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9.3 SINUMERIK Safety Integrated

Note

External safety-related process signals are connected via safe input/output modules of the

ET200S, ET200M, ET200eco, or ET200pro, and connected to SINUMERIK 840D sl via

PROFIBUS or PROFINET.

The safe sensors and actuators are processed within the safe programmable logic, which

means that external safety relays are no longer required.

Note

Further information

You can find a detailed description of the individual safety functions in the SINUMERIK

Safety Integrated Function Manual (FBSI sl).

9.3.2

Connecting safe sensors and actuators to the SINUMERIK

The following example illustrates the wiring possibilities of the ET200S PROFIsafe

component.

No complete plant with all required hardware and software settings is shown. Only the data

always required for the application is described for each of the used ET200S components. A

detailed description is contained in the associated product/function manuals.

The sensor/actuator connection for SINUMERIK Safety Integrated is established using

PROFIBUS or PROFINET with PROFIsafe profile and PROFIsafe-compliant I/O modules

(e.g. ET200S, ET200eco, ET200pro, or ET200M).

Overview of the ET200S peripheral connection to the NCU

Figure 9-6

Overview of the ET200S peripheral connection to the NCU

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Safety Integrated

9.3 SINUMERIK Safety Integrated

Signal assignment and significance

Part of the signal assignment and significance for the PROFIsafe modules is explained in the

following section:

4/8 F-DI 24 VDC PROFIsafe electronic module

The safety-related I/O input signals are connected to this module. These sensors in the

example are optionally exclusive OR with two break contacts (Emergency Stop actuator and

protective door interlocked state), i.e. provided with a break contact and a make contact

(agreement button) or with two make contacts (<drive on> button).

All of the sensor signals are connected through two channels.

Figure 9-7

Signal assignment, electronics module, 4/8F-DI, 24 VDC, PROFIsafe

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9.3 SINUMERIK Safety Integrated

Meaning and use of the individual signals

Emergency Stop actuator [F-DI terminal 1 (channel 0), terminal 9 (channel 4)]

Signal state channel 0 = "1" and channel 4 = "1":

Emergency Stop actuator not pressed.

Signal state channel 0 = "0" and channel 4 = "0":

Emergency Stop actuator pressed.

Protective door interlocked state [F-DI terminal 5 (channel 1), terminal 13 (channel 5)]

The door switch only interlocks if the actuator is inserted. The contacts of the monitoring

circuit then signal the status "closed and interlocked"

Signal state channel 1 = "1" and channel 5 = "1":

Protective door closed and interlocked.

Signal state channel 1 = "0" and channel 5 = "0":

Protective door not closed or not interlocked.

Agreement button [F-DI terminal 3 (channel 2), terminal 11 (channel 6)]

Signal state channel 2 = "1" and channel 6 = "0":

Acknowledgment button pressed.

Signal state channel 2 = "0" and channel 6 = "1":

Acknowledgment button not pressed.

Drives On button [F-DI terminal 7 (channel 3), terminal 15 (channel 7)]

Signal state channel 3 = "0" and channel 7 = "0":

Drives On button not pressed.

Signal state channel 3 = "1" and channel 7 = "1":

Drives On button pressed.

VS1: internal sensor supply for channel 0 to 3

VS2: internal sensor supply for channel 4 to 7

These two sensor supplies must be used when the short-circuit test is activated. The

exclusive OR sensor agreement button is an exception. For this sensor variant, in

conjunction with the short-circuit test, the VS1 sensor supply must be used for both contacts.

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Safety Integrated

9.3 SINUMERIK Safety Integrated

Electronics module 4 F-DO 24 VDC/2 A PROFIsafe

The actuators that must be shut-down in a safety-related fashion are connected through two

channels. Each output channel can be separately shutdown.

Two valve units are connected in the configuration example. These are used to control the

motion of the supplementary pneumatic axis.

Figure 9-8

Signal assignment electronics module, 4F-DO, 24 VDC_2 A, PROFIsafe

Meaning and use of the individual signals

Valve unit 1 F-DO terminal 1,2 (channel 0 P/M)

Signal state channel 0 = "0"

Valve in the locked neutral position

Signal state channel 0 = "1"

Valve in the flow position

Not assigned [F-DO terminal 5,6 (channel 1 P/M)]

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9.3 SINUMERIK Safety Integrated

Valve unit 2 [F-DO terminal 9,10 (channel 2 P/M)]

Signal state channel 2 = "0"

Valve in the locked neutral position

Signal state channel 2 = "1"

Valve in the flow position

Not assigned [F-DO terminal 13.14 (channel 3 P/M)]

Power Module PM-E F

This module combines two functions. Not only can individual actuators (comparable with the

functionality of an F-DO module) be connected to all three two-channel output channels, but

the third DO2 output channel also has a further function.

The DO2 output channel is used to internally (no external wiring required) disconnect safety-

oriented (i.e. with two potentials) to supply power for the subsequent standard DO or also

standard DI modules. Namely, the outputs on the DO modules can not only be controlled

using a single channel in the PLC for the "normal" function, but also a safety-oriented

shutdown of the power supply for all DO modules following the PM-E F module is possible.

Power Module PM-D F 24 V DC PROFIsafe

The Power Module can switch off the SG 1 to SG 6 voltage buses in a fail-safe way using six

digital outputs. The outputs are implemented using two P switches in each case. There is a

main switch for all six shutdown groups and six subsequent (downstream) individual

switches for each shutdown group.

The voltage bus U 1 (electronics power supply for the motor starter) is supplied with 24 VDC.

In the event of an overvoltage or undervoltage condition, U 1 is shut down by two P switches

and the subsequent (downstream) motor starters are deactivated. If the motor starter is

safely shutdown, U 1 is not shutdown.

With the six available shutdown groups (SG1...SG6), the Power Module is suitable for tasks

including supplying fail-safe motor starters such as F-DS1e-x and F-RS1e-x.

Fail-safe direct starters F-DS1e-x

The fail-safe direct starter with electronic overload protection can either power-up or power-

down the connected motor (implemented in the application through the PLC I/O interface).

Further, when the SG signal is missing at the upstream PM-D F, the PM module can

shutdown the motor in a safety-related fashion.

Depending on the type, three-phase motors up to 7.5 kW can be connected and operated

with integrated protection against overload and short-circuit.

On the one hand, the SG 1...SG 6 safe shutdown group will be assigned to the fail-safe

motor starter using the STEP 7 hardware configuration. On the other hand, the assignment

is realized using the coding connector on the terminal module of the motor starter. Both

assignments must match one another.

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Activate/Deactivate Drive System

12.2 Drive Group with Several Axes

12.2

Drive Group with Several Axes

The Motor Module is controlled via terminals -X21, -X22 and the DRIVE-CLiQ interfaces -

X200/-X201/-X202/-X203 (-X22 and -X203 are only available with Double Motor Modules).

You can find a detailed function description for the individual signals and control/status

words in the following document:

\LH1\SINAMICS S120/S150 List Manual

To enable the Motor Module, the "infeed ready" signal must be connected from the Line

Module.

The following function diagrams show how the individual signals interact.

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Activate/Deactivate Drive System

12.2 Drive Group with Several Axes

Note

Applies to CU320; with integrated drive solutions (e.g. NCU, NX, etc.), some signals are

already processed by means of internal communication

Off responses

● OFF1

- The immediate specification of n_set = 0 at the ramp generator return ramp (p1121)

causes the drive to be braked.

- When zero speed is detected, the motor holding brake (if parameterized) is closed

(p1215). The pulses are suppressed when the closing time (p1217) expires. The zero

speed is detected when the speed actual value is lower than the speed threshold

(p1226) or when the monitoring time (p1227) started when speed setpoint ≤ speed

threshold (p1226) has expired.

● OFF2

- Immediate pulse suppression, the drive coasts to standstill.

- The motor holding brake (if parameterized) is closed immediately.

- Closing lockout is activated.

● OFF3

- The immediate specification of n_set = 0 at the OFF3 return ramp (p1135) causes the

drive to be braked.

- When zero speed is detected, the motor holding brake (if parameterized) is closed.

The pulses are suppressed when the closing time of the holding brake (p1217)

expires. The zero speed is detected when the speed actual value is lower than the

speed threshold (p1226) or when the monitoring time (p1227) started when speed

setpoint ≤ speed threshold (p1226) has expired.

- Closing lockout is activated.

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Activate/Deactivate Drive System

12.2 Drive Group with Several Axes

Control and status signals

Table 12- 1 Switching on/switching off the control system

Signal name

Internal control word

Binector input

PROFIBUS message

VDI interface (PLC)

frame 2 … 106

0 = OFF1

STWA.00

p0840 ON/OFF1

STW1.0

DB(AX).DBX2.1

STWAE.00

(controller enable)

DB(AX).DBX1.5/6

(measuring system

selected and OK)

DB(AX).DBX21.7

(pulse enable)

0 = OFF2

STWA.01

p0844 1. OFF2

STW1.1

STWAE.01

p0845 2. OFF2

0 = OFF3

STWA.02

p0848 1. OFF3

STW1.2

P0849 2. OFF3

Enable operation

STWA.03

p0852 operation

STW1.3

DBX21.7

STWAE.03

enabled

Table 12- 2 Activate/deactivate status signals

Signal name

Internal status word

Parameter

PROFIBUS message frame 2 … 106

Ready to start

ZSWA.00

r0899.0

ZSW1.0

ZSWAE.00

Ready

ZSWA.01

r0899.1

ZSW1.1

ZSWAE.01

Operation enabled

ZSWA.02

r0899.2

ZSW1.2

ZSWAE.02

Closing lockout

ZSWA.06

r0899.6

ZSW1.6

ZSWAE.06

Pulses enabled

ZSWA.11

r0899.11

ZSW1.11

Function block diagram overview (see SINAMICS S List Manual)

●

2610 sequence control - sequencer

●

2634 missing enables, line contactor control

●

8732 basic infeed - sequencer

●

8832 smart infeed - sequencer

●

8932 active infeed - sequencer

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Appendix

A.1

Screw terminals

The type of screw terminal can be taken from the interface description of the particular

component.

Table A- 1 Connectable conductor cross-sections and tightening torques for screw terminals

Screw terminal type

Connectable conductor cross-

Rigid, flexible

0.08 mm² to 1.5 mm²

sections

With wire end ferrule, without plastic sleeve

0.25 mm² to 1.5 mm²

With wire end ferrule, with plastic sleeve

0.25 mm² to 0.5 mm²

Stripping length

7 mm

Tool

Screwdriver 0.4 x 2.0 mm

Tightening torque

0.22 to 0.25 Nm

1_1

Connectable conductor cross-

Rigid, flexible

0.14 mm² to 1.5 mm²

sections

With wire end ferrule, without plastic sleeve

0.25 mm² to 1.5 mm²

With wire end ferrule, with plastic sleeve

0.25 mm² to 0.5 mm²

Stripping length

7 mm

Tool

Screwdriver 0.4 x 2.5 mm

Tightening torque

0.22 to 0.25 Nm

Connectable conductor cross-

Rigid, flexible

0.08 mm² to 2.5 mm²

sections

With wire end ferrule, without plastic sleeve

0.5 mm² to 2.5 mm²

With wire end ferrule, with plastic sleeve

0.5 mm² to 1.5 mm²

Stripping length

7 mm

Tool

Screwdriver 0.6 x 3.5 mm

Tightening torque

0.5 to 0.6 Nm

Connectable conductor cross-

Flexible

0.2 mm² to 2.5 mm²

sections

With wire end ferrule, without plastic sleeve

0.25 mm² to 1 mm²

With wire end ferrule, with plastic sleeve

0.25 mm² to 1 mm²

Stripping length

9 mm

Tool

Screwdriver 0.6 x 3.5 mm

Tightening torque

0.5 to 0.6 Nm

Connectable conductor cross-

Flexible

0.2 mm² to 4 mm²

sections

With wire end ferrule, without plastic sleeve

0.25 mm² to 4 mm²

With wire end ferrule, with plastic sleeve

0.25 mm² to 4 mm²

Stripping length

7 mm

Tool

Screwdriver 0.6 x 3.5 mm

Tightening torque

0.5 to 0.6 Nm

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Appendix

A.1 Screw terminals

Screw terminal type

Connectable conductor cross-

Flexible

0.5 mm² to 6 mm²

sections

With wire end ferrule, without plastic sleeve

0.5 mm² to 6 mm²

With wire end ferrule, with plastic sleeve

0.5 mm² to 6 mm²

Stripping length

12 mm

Tool

Screwdriver 1.0 x 4.0 mm

Tightening torque

1.2 to 1.5 Nm

Connectable conductor cross-

Flexible

0.5 mm² to 10 mm²

sections

With wire end ferrule, without plastic sleeve

0.5 mm² to 10 mm²

With wire end ferrule, with plastic sleeve

0.5 mm² to 10 mm²

Stripping length

11 mm

Tool

Screwdriver 1.0 x 4.0 mm

Tightening torque

1.5 to 1.8 Nm

Connectable conductor cross-

0.5 mm² to 16 mm²

sections

Stripping length

14 mm

Tool

Screwdriver 1.0 x 4.0 mm

Tightening torque

1.5 to 1.7 Nm

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Appendix

A.2 Spring-loaded terminals

A.2

Spring-loaded terminals

The type of spring-loaded terminal can be taken from the interface description of the

particular component.

Table A- 2 Connectable conductor cross-sections for spring-loaded terminals

Spring-loaded terminal type

Connectable conductor cross-

Rigid

0.14 mm² to 0.5 mm²

sections

Flexible

0.14 mm² to 0.5 mm²

Flexible with end sleeve without plastic sleeve

0.25 mm² to 0.5 mm²

AWG/kcmil

26 to 20

Stripping length

8 mm

Connectable conductor cross-

Flexible

0.08 mm² to 2.5 mm²

sections

Stripping length

8 to 9 mm

Connectable conductor cross-

Rigid

0.2 mm² to 1 mm²

sections

Flexible

0.2 mm² to 1.5 mm²

Flexible with end sleeve without plastic sleeve

0.25 mm² to 1.5 mm²

Flexible with end sleeve with plastic sleeve

0.25 mm² to 0.75 mm²

AWG/kcmil

24 to 16

Stripping length

8 mm

3_1

Connectable conductor cross-

Rigid

0.2 mm² to 1.5 mm²

sections

Flexible

0.2 mm² to 1.5 mm²

Flexible with end sleeve without plastic sleeve

0.25 mm² to 1.5 mm²

Flexible with end sleeve with plastic sleeve

0.25 mm² to 0.75 mm²

AWG/kcmil

24 to 16

Stripping length

10 mm

Connectable conductor cross-

25 mm² to 95 mm²

sections

AWG 4 to 4/0

Stripping length

35 mm

Connectable conductor cross-

Rigid

0.2 mm² to 10 mm²

sections

Flexible

0.2 mm² to 6 mm²

Flexible with end sleeve without plastic sleeve

0.25 mm² to 6 mm²

Flexible with end sleeve with plastic sleeve

0.25 mm² to 4 mm²

AWG/kcmil

24 to 8

Stripping length

15 mm

Guidelines for machine configuration

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515

Appendix

A.3 Power loss of components

A.3

Power loss of components

A.3.1

Power Loss of the SINUMERIK Components

The following power losses apply to operation with rated power:

Table A- 3 List of power losses

Component

Power loss

NCU 710.2

22 W

NCU 720.2

25 W

NCU 720.2 PN

55 W

NCU 730.2

55 W

NCU 730.2 PN

65 W

NX1x.x

20 W

A.3.2

Power loss of SINAMICS components

The tables below provide an overview of the power loss of all components during rated

operation. The characteristic values apply for the following conditions:

● Line voltage for Line Modules 400 V

● Pulse frequency of the Motor Modules 4 kHz

● Rated pulse frequency of the Active Line Modules 8 kHz

● Operating components at their rated power

The total losses of the relevant power unit (Line Module, Motor Module) are calculated from

the power loss and the corresponding electronics loss of the power unit.

A.3.2.1

Power loss for Control Units, Sensor Modules, and other system components

Table A- 4 Overview of power loss during rated operation for Control Units, Sensor Modules, and

other system components

Unit

Power loss

Control Units and Option Boards

CU320-2

CBC10

< 3

CBE20

2.8

Sensor Modules

SMC10

< 10

SMC20

< 10

SMC30

< 10

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Appendix

A.3 Power loss of components

Unit

Power loss

SME20/25

≤ 4

SME120/125

≤ 4.5

Terminal Modules

TM15

< 3

TM41

TM120

2.4

DC link components

Braking Module Booksize

Braking Module Booksize Compact

< 40

Capacitor Module

Control Supply Module

Line

DC link

Voltage Clamping Module

A.3.2.2

Power loss for line filters and line reactors

Table A- 5 Overview of power loss during rated operation for line filters and line reactors

Unit

Power loss

Basic Line Filters for Active Line Modules

16 kW

36 kW

55 kW

80 kW

120 kW

Basic Line Filter for Active Line Modules with Active Interface Module

16 kW

36 kW

55 kW

80 kW

120 kW

Wideband Line Filter for Active Line Modules

16 kW

36 kW

55 kW

110

80 kW

150

120 kW

200

Basic Line Filter for Smart Line Modules

5 kW

10 kW

16 kW

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Appendix

A.3 Power loss of components

Unit

Power loss

36 kW

55 kW

Basic Line Filter for Basic Line Modules

20 kW

40 kW

100 kW

Active Interface Modules

16 kW

270 ¹⁾

36 kW

340 ¹⁾

55 kW

380 ¹⁾

80 kW

490 ¹⁾

120 kW

585 ¹⁾

Line reactors for Active Line Modules

16 kW

170

36 kW

250

55 kW

350

80 kW

450

120 kW

590

Line reactors for Smart Line Modules

5 kW

10 kW

116

16 kW

110

36 kW

170

55 kW

200

Line reactors for Basic Line Modules

20 kW

130

40 kW

270

100 kW

480

1) Referred to VDC link 600 V

A.3.2.3

Power loss for power units with internal air cooling

Table A- 6 Overview of power loss at rated operation for power units with internal air cooling

(including electronics losses)

Unit

Power loss

Active Line Modules

16 kW

282.8

36 kW

666

55 kW

945.6

80 kW

1383.6

120 kW

2243.2

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Appendix

A.3 Power loss of components

Unit

Power loss

Smart Line Modules Booksize

5 kW

79.2

10 kW

141.6

16 kW

187.8

36 kW

406

55 kW

665.6

Smart Line Modules Booksize Compact

16 kW

187.8

Basic Line Modules

20 kW

144

40 kW

283.6

100 kW

628

Single Motor Modules Booksize

3 A

50.4

5 A

73.4

9 A

100.4

18 A

185.4

30 A

309.2

45 A

455.2

60 A

615.2

85 A

786

132 A

1270.4

200 A

2070.4

Single Motor Modules Booksize Compact

3 A

68 ¹⁾

5 A

98 ¹⁾

9 A

100.4

18 A

185.4

Double Motor Modules Booksize

3 A

97.6

5 A

132.6

9 A

187.6

18 A

351.2

Double Motor Modules Booksize Compact

1.7 A

114 ¹⁾

3 A

134 ¹⁾

5 A

194 ¹⁾

1) Power loss at 8 kHz

Guidelines for machine configuration

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519

Appendix

A.3 Power loss of components

A.3.2.4

Power loss for power units with external air cooling

Table A- 7 Overview of power loss at rated operation for power units with external air cooling (including electronics

losses)

Unit

Internal

External power loss

Total power loss

Power loss ¹⁾

Active Line Modules

16 kW

82.8 (60 + 22,8)

200

282.8

36 kW

171 (135 + 36,0)

495

666

55 kW

245.6 (200 + 45,6)

700

945.6

80 kW

338.6 (305 + 33,6)

1045

1383.6

120 kW

533.2 (490 + 43,2)

1710

2243.2

Smart Line Modules

5 kW

41.2 (22 + 19,2)

79.2

10 kW

66.6 (45 + 21,6)

141.6

16 kW

64.8 (42 + 22,8)

123

187.8

36 kW

116 (80 + 36)

290

406

55 kW

185.6 (140 + 45,6)

480

665.6

Single Motor Modules

3 A

35.4 (15 + 20,4)

50.4

5 A

43.4 (23 + 20,4)

73.4

9 A

55.4 (35 + 20,4)

100.4

18 A

95.4 (75 + 20,4)

185.4

30 A

99.2 (80 + 19,2)

210

309.2

45 A

135.2 (110 + 25,2)

320

455.2

60 A

160.2 (135 + 25,2)

455

615.2

85 A

196 (160 + 36,0)

590

786

132 A

270.4 (250 + 20,4)

1000

1270.4

200 A

455.4 (435 + 20,4)

1615

2070.4

Double Motor Modules

3 A

62.6 (35 + 27,6)

97.6

5 A

72.6 (45 + 27,6)

132.6

9 A

92.6 (65 + 27,6)

187.6

18 A

111.2 (80 + 31,2)

240

351.2

1) Power loss of the power electronics + power loss of the 24 V electronics

Guidelines for machine configuration

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Appendix

A.3 Power loss of components

A.3.2.5

Power loss for power units with cold plate

With cold-plate cooling, only part of the power loss remains in the cabinet.

The table below shows the internal and external power loss of the components.

Table A- 8 Overview of power loss at rated operation for power units with cold plate (including electronics losses)

Unit

Internal power loss ¹⁾

External power loss

Total power loss

Active Line Modules

16 kW

70.4 (50 + 20,4)

210

280.4

36 kW

135.2 (110 + 25,2)

520

655.2

55 kW

187.6 (160 + 27,6)

740

927.6

80 kW

283.6 (250 + 33,6)

1100

1383.6

120 kW

443.2 (400 + 43,2)

1800

2243.2

Smart Line Modules Booksize

5 kW

34.4 (20 + 14,4)

74.4

10 kW

56.8 (40 + 16,8)

136.8

Smart Line Modules Booksize Compact

16 kW

56.6 (36,2 + 20,4)

130

186.6

Basic Line Modules

20 kW

46.6 (25 + 21,6)

141.6

40 kW

71.4 (45 + 26,4)

205

276.4

100 kW

168.4 (130 + 38,4)

450

618.4

Single Motor Modules Booksize

3 A

27.6 (12 + 15,6)

45.6

5 A

35.6 (20 + 15,6)

70.6

9 A

45.6 (30 + 15,6)

95.6

18 A

80.6 (65 + 15,6)

100

180.6

30 A

85.6 (70 + 15,6)

220

305.6

45 A

108 (90 + 18,0)

340

448

60 A

128 (110 + 18,0)

480

608

85 A

149.2 (130 + 19,2)

620

769.2

132 A

220.4 (200 + 20,4)

1050

1270.4

200 A

370.4 (350 + 20,4)

1700

2070.4

Single Motor Modules Booksize Compact

3 A

25.6 (10 + 15,6)

65.6

5 A

30.6 (15 + 15,6)

95.6

9 A

45.6 (30 + 15,6)

95.6

18 A

80.6 (65 + 15,6)

100

180.6

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Appendix

A.3 Power loss of components

Unit

Internal power loss ¹⁾

External power loss

Total power loss

Double Motor Modules Booksize

2x3 A

55.6 (34 + 21,6)

91.6

2x5 A

61.6 (40 + 21,6)

126.6

2x9 A

81.6 (60 + 21,6)

100

181.6

2x18 A

95.2 (70 + 25,2)

250

345.2

Double Motor Modules Booksize Compact

2x1.7 A

42 (20,4 + 21,6)

114

2x3 A

44 (22,4 + 21,6)

134

2x5 A

59 (37,4 + 21,6)

135

194

1) Power loss of the power electronics + power loss of the 24 V electronics

Note

Lower average power losses are obtained for intermittent duty.

A.3.2.6

Power loss for liquid-cooled power units

Table A- 9 Overview of power loss during rated operation for liquid-cooled power units (including electronics losses)

Unit

Internal power loss ¹⁾

External power loss

Total power loss

Active Line Modules

120 kW

443.2 (400 + 43,2)

1800

2243.2

Single Motor Modules

200 A

370.4 (350 + 20,4)

1700

2070.4

1) Power loss of the power electronics + power loss of the 24 V electronics

Guidelines for machine configuration

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Appendix

A.3 Power loss of components

A.3.3

Electronics losses of power units

Table A- 10 Electronics losses for power units with internal/external air cooling

Component

Internal/external air cooling

Power loss [W]

Single Motor Modules

3 A

20.4

5 A

20.4

9 A

20.4

18 A

20.4

30 A

19.2

45 A

25.2

60 A

25.2

85 A

36.0

132 A

20.4

200 A

20.4

Single Motor Modules Booksize

3 A

20.4

Compact

5 A

20.4

9 A

20.4

18 A

20.4

Double Motor Modules

3 A

27.6

5 A

27.6

9 A

27.6

18 A

31.2

Double Motor Modules Booksize

1.7 A

27.6

Compact

3 A

27.6

5 A

27.6

Active Line Modules

16 kW

22.8

36 kW

36.0

55 kW

45.6

80 kW

33.6

120 kW

43.2

Basic Line Modules

20 kW

40 kW

33.6

100 kW

Smart Line Module

5 kW

19.2

10 kW

21.6

16 kW

22.8

36 kW

36.0

55 kW

45.6

Smart Line Module Booksize Compact

16 kW

22.8

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Appendix

A.3 Power loss of components

Table A- 11 Electronics losses for power units with cold plate

Component

Cold plate

Power loss [W]

Motor Modules Booksize

3 A

15.6

5 A

15.6

9 A

15.6

18 A

15.6

30 A

15.6

45 A

18.0

60 A

18.0

85 A

19.2

132 A

20.4

200 A

20.4

2x3 A

21.6

2x5 A

21.6

2x9 A

21.6

2x18 A

25.2

Motor Modules Booksize Compact

3 A

15.6

5 A

15.6

9 A

15.6

18 A

15.6

2x1.7 A

21.6

2x3 A

21.6

2x5 A

21.6

Active Line Modules

16 kW

20.4

36 kW

25.2

55 kW

27.6

80 kW

33.6

120 kW

43.2

Smart Line Module Booksize

5 kW

14.4

10 kW

16.8

Smart Line Module Booksize Compact

16 kW

20.4

Basic Line Modules

20 kW

21.6

40 kW

26.4

100 kW

38.4

Table A- 12 Electronics losses for liquid-cooled power units

Component

Liquid cooled

Power loss [W]

Motor Module

200 A

20.4

Active Line Module

120 kW

43.2

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Appendix

A.3 Power loss of components

A.3.5

Typical power losses for Motor Modules

The information on the power losses in the previous chapters are maximum values, which

occur in the most unfavorable case. For typical applications, the losses are lower.

The following applies as typical application:

● Maximum motor cable length, 30 m

●

4 kHz pulse frequency

● DC link voltage 540 V - 600 V

The power loss for typical applications can be calculated using the following formula:

PV [W] = a + S1 • (I1 + I2) + S2 • (I12 + I22)

Electronics losses of the Motor Module

S1, S2

Coefficients to calculate power loss

Current (arithmetic mean value) of the 1st axis

Current (arithmetic mean value) of the 2nd axis

Overview of required coefficients

Table A- 13 Coefficients to calculate the power loss in the control cabinet for internally cooled Motor

Modules for typical applications

Motor Module

a [W]

S1 [W/A]

S2 [W/A²]

Single Motor Module 3 A

3.29

0.205

Single Motor Module 5 A

3.29

0.205

Single Motor Module 9 A

3.29

0.205

Single Motor Module 18 A

3.29

0.205

Single Motor Module 30 A

4.71

0.113

Single Motor Module 45 A

5.50

0.054

Single Motor Module 60 A

5.50

0.054

Single Motor Module 85 A

6.11

0.030

Single Motor Module 132 A

150

6.01

0.018

Single Motor Module 200 A

150

6.01

0.017

Double Motor Module 3 A

5.20

0.200

Double Motor Module 5 A

5.20

0.200

Double Motor Module 9 A

5.18

0.247

Double Motor Module 18 A

5.57

0.091

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Appendix

A.3 Power loss of components

Table A- 14 Coefficients to calculate the power loss in the control cabinet for externally cooled Motor

Modules for typical applications

Motor Module

a [W]

S1 [W/A]

S2 [W/A²]

Single Motor Module 3 A

2.30

0.100

Single Motor Module 5 A

2.30

0.100

Single Motor Module 9 A

2.30

0.100

Single Motor Module 18 A

2.34

0.101

Single Motor Module 30 A

1.29

0.057

Single Motor Module 45 A

1.31

0.015

Single Motor Module 60 A

1.37

0.006

Single Motor Module 85 A

1.37

0.006

Single Motor Module 132 A

1.06

0.004

Single Motor Module 200 A

1.06

0.004

Double Motor Module 3 A

1.37

0.240

Double Motor Module 5 A

1.37

0.240

Double Motor Module 9 A

1.37

0.240

Double Motor Module 18 A

1.56

0.056

Overview of typical power losses at the rated operating point

Table A- 15 Typical power losses in the control cabinet for operation at the rated operating point for

internally and externally cooled Motor Modules

Motor Module

PVn [W]

internal air cooling

external air cooling

Single Motor Module 3 A

Single Motor Module 5 A

Single Motor Module 9 A

Single Motor Module 18 A

140

Single Motor Module 30 A

263

106

Single Motor Module 45 A

382

110

Single Motor Module 60 A

550

130

Single Motor Module 85 A

772

192

Single Motor Module 132 A

1257

260

Single Motor Module 200 A

2032

422

Double Motor Module 3 A

Double Motor Module 5 A

Double Motor Module 9 A

152

Double Motor Module 18 A

281

110

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527

Appendix

A.4 Abbreviations

A.4

Abbreviations

Table A- 16 Abbreviations and meanings, German/English

Abbreviation

German meaning

English meaning

Wechselstrom

Alternating current

ALM

Active Line Module

CBC

Communication Board CAN

CBE

Communication Board Ethernet

CPU

Zentrale Recheneinheit

Central Processing Unit

CSM

Control Supply Module

Control Unit

Gleichstrom

Direct Current

Antriebsobjekt

Drive Object

Dezentrale Peripherie

Decentralized Peripherals

DRIVE-CLiQ

Drive Component Link with IQ

Impulsfreigabe

Enable Pulses

EMC

Elektromagnetische Verträglichkeit

Electromagnetic Compatibility (EMC)

Europäische Norm

European Standard

Fehlerstrom-Schutzschalter

Earth Leakage Circuit Breaker (ELCB)

HMI

Mensch-Maschine-Schnittstelle

Human Machine Interface

IEC

Internationale Norm in der Elektrotechnik

International Electrotechnical Commission

Drehstromversorgungsnetz ungeerdet

Insulated three-phase supply network

LED

Leuchtdiode

Light Emitting Diode

LM :

Line Module

Numerische Steuerung

Numerical Control

NCK

Numerik-Kern mit Satzaufbereitung,

Numerical Control Kernel

Verfahrbereich usw.

NCU

Numerical Control Unit

Numerical Extension

Bedientafelfront

Operator Panel

Schutzerde

Protective Earth

PLC

Speicherprogrammierbare Steuerung (SPS)

Programmable Logic Controller

SBC

Safe Brake Control

Sicherer Halt

Safe standstill

SIL

Sicherheitsintegritätsgrad

Safety Integrity Level

SLM

Smart Line Module

SMC

Sensor Module Cabinet

SME

Sensor Module External

SPL

Sichere Programmierbare Logik

Safe Programmable Logic

STW

Steuerwort

Control word

TCU

Thin Client Unit

Terminal Module

Guidelines for machine configuration

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System Manual, MA 01/2013, 6FC5397-6CP10-0BA2

Preface

SINUMERIK documentation

The SINUMERIK documentation is organized into the following categories:

• General documentation/catalogs

• User documentation

• Manufacturer/service documentation

Additional information

You can find information on the following topics at the following address (https://

support.industry.siemens.com/cs/de/en/view/108464614):

• Ordering documentation/overview of documentation

• Additional links to download documents

• Using documentation online (find and search in manuals/information)

If you have any questions regarding the technical documentation (e.g. suggestions,

corrections), please send an e-mail to the following address

(mailto:docu.motioncontrol@siemens.com).

mySupport/Documentation

At the following address (https://support.industry.siemens.com/My/ww/en/documentation ),

you can find information on how to create your own individual documentation based on

Siemens' content, and adapt it for your own machine documentation.

Training

At the following address (http://www.siemens.com/sitrain ), you can find information about

SITRAIN (Siemens training on products, systems and solutions for automation and drives).

FAQs

You can find Frequently Asked Questions in the Service&Support pages under Product Support

(https://support.industry.siemens.com/cs/de/en/ps/faq ).

SINUMERIK

You can find information about SINUMERIK at the following address (http://www.siemens.com/

sinumerik).

Basesoftware and operating software

Commissioning Manual, 10/2020, 6FC5397-1DP40-6BA4

Preface

Target group

This documentation is intended for commissioning personnel.

The plant or system is readily assembled and wired. For the

following steps, e.g. configuring the individual components,

the Commissioning Manual contains all necessary information or at least references.

Benefits

The intended target group can use the Commissioning Manual to test and commission the

system or the plant correctly and safely.

Utilization phase: Setup and commissioning phase

Standard scope

This documentation only describes the functionality of the standard version. Additions or

revisions made by the machine manufacturer are documented by the machine manufacturer.

Other functions not described in this documentation might be executable in the control. This

does not, however, represent an obligation to supply such functions with a new control or when

servicing.

For the sake of simplicity, this documentation does not contain all detailed information about all

types of the product and cannot cover every conceivable case of installation, operation, or

maintenance.

Note regarding the General Data Protection Regulation

Siemens observes standard data protection principles, in particular the principle of privacy by

design. That means that

this product does not process / store any personal data, only technical functional data (e.g. time

stamps). If a user links this data with other data (e.g. a shift schedule) or stores personal data on

the same storage medium (e.g. hard drive) and thus establishes a link to a person or persons,

then the user is responsible for ensuring compliance with the relevant data protection

regulations.

Technical Support

Country-specific telephone numbers for technical support are provided on the Internet at the

following address (https://support.industry.siemens.com/cs/ww/en/sc/2090 ) in the "Contact"

area.

If you have any technical questions, use the online form in the "Support Request" area.

Basesoftware and operating software

Commissioning Manual, 10/2020, 6FC5397-1DP40-6BA4

Preface

CompactFlash Cards

• Do not remove the memory card while it is being accessed. This can lead to damage of the

memory card and the SINUMERIK as well as the data on the memory card.

• Insert the memory card carefully and the right way round into the memory card slot (observe

indicators such as arrow or similar). This way you avoid mechanical damage to the memory

card or the device.

• Only use memory cards that have been approved by Siemens for use with SINUMERIK. Even

though SINUMERIK follows general industry standards for memory cards, it is possible that

memory cards from some manufacturers will not function perfectly in this device or are not

completely compatible with it (you can obtain information on compatibility from the

memory card manufacturer or supplier).

• For further information on handling CompactFlash cards, please refer to the NCU manuals.

Basesoftware and operating software

Commissioning Manual, 10/2020, 6FC5397-1DP40-6BA4

Table of contents

Preface

Fundamental safety instructions

1.1

General safety instructions

1.2

Equipment damage due to electric fields or electrostatic discharge

1.3

Warranty and liability for application examples

1.4

Security information

1.5

Residual risks of power drive systems

SINUMERIK Operate

Easy XML

615

SINUMERIK Integrate Run MyScreens

885

NCU operating system

1239

Appendix

1341

A.1

Documentation overview

1341

Basesoftware and operating software

Commissioning Manual, 10/2020, 6FC5397-1DP40-6BA4

Fundamental safety instructions

1.1

General safety instructions

WARNING

Electric shock and danger to life due to other energy sources

Touching live components can result in death or severe injury.

• Only work on electrical devices when you are qualified for this job.

• Always observe the country-specific safety rules.

Generally, the following steps apply when establishing safety:

1. Prepare for disconnection. Notify all those who will be affected by the procedure.

2. Isolate the drive system from the power supply and take measures to prevent it being

switched back on again.

3. Wait until the discharge time specified on the warning labels has elapsed.

4. Check that there is no voltage between any of the power connections, and between any of

the power connections and the protective conductor connection.

5. Check whether the existing auxiliary supply circuits are de-energized.

6. Ensure that the motors cannot move.

7. Identify all other dangerous energy sources, e.g. compressed air, hydraulic systems, or

water. Switch the energy sources to a safe state.

8. Check that the correct drive system is completely locked.

After you have completed the work, restore the operational readiness in the inverse sequence.

WARNING

Electric shock due to connection to an unsuitable power supply

When equipment is connected to an unsuitable power supply, exposed components may carry

a hazardous voltage. Contact with hazardous voltage can result in severe injury or death.

• Only use power supplies that provide SELV (Safety Extra Low Voltage) or PELV- (Protective

Extra Low Voltage) output voltages for all connections and terminals of the electronics

modules.

Basesoftware and operating software

Commissioning Manual, 10/2020, 6FC5397-1DP40-6BA4

Fundamental safety instructions

1.1 General safety instructions

WARNING

Electric shock due to equipment damage

Improper handling may cause damage to equipment. For damaged devices, hazardous

voltages can be present at the enclosure or at exposed components; if touched, this can result

in death or severe injury.

• Ensure compliance with the limit values specified in the technical data during transport,

storage and operation.

• Do not use any damaged devices.

WARNING

Electric shock due to unconnected cable shields

Hazardous touch voltages can occur through capacitive cross-coupling due to unconnected

cable shields.

• As a minimum, connect cable shields and the cores of cables that are not used at one end

at the grounded housing potential.

WARNING

Electric shock if there is no ground connection

For missing or incorrectly implemented protective conductor connection for devices with

protection class I, high voltages can be present at open, exposed parts, which when touched,

can result in death or severe injury.

• Ground the device in compliance with the applicable regulations.

NOTICE

Damage to equipment due to unsuitable tightening tools.

Unsuitable tightening tools or fastening methods can damage the screws of the equipment.

• Be sure to only use screwdrivers which exactly match the heads of the screws.

• Tighten the screws with the torque specified in the technical documentation.

• Use a torque wrench or a mechanical precision nut runner with a dynamic torque sensor and

speed limitation system.

Basesoftware and operating software

Commissioning Manual, 10/2020, 6FC5397-1DP40-6BA4

Fundamental safety instructions

1.1 General safety instructions

WARNING

Spread of fire from built-in devices

In the event of fire outbreak, the enclosures of built-in devices cannot prevent the escape of

fire and smoke. This can result in serious personal injury or property damage.

• Install built-in units in a suitable metal cabinet in such a way that personnel are protected

against fire and smoke, or take other appropriate measures to protect personnel.

• Ensure that smoke can only escape via controlled and monitored paths.

WARNING

Unexpected movement of machines caused by radio devices or mobile phones

Using radio devices or mobile telephones in the immediate vicinity of the components can

result in equipment malfunction. Malfunctions may impair the functional safety of machines

and can therefore put people in danger or lead to property damage.

• Therefore, if you move closer than 20 cm to the components, be sure to switch off radio

devices or mobile telephones.

• Use the "SIEMENS Industry Online Support app" only on equipment that has already been

switched off.

WARNING

Fire due to inadequate ventilation clearances

Inadequate ventilation clearances can cause overheating of components with subsequent fire

and smoke. This can cause severe injury or even death. This can also result in increased

downtime and reduced service lives for devices/systems.

• Ensure compliance with the specified minimum clearance as ventilation clearance for the

respective component.

NOTICE

Overheating due to inadmissible mounting position

The device may overheat and therefore be damaged if mounted in an inadmissible position.

• Only operate the device in admissible mounting positions.

Basesoftware and operating software

Commissioning Manual, 10/2020, 6FC5397-1DP40-6BA4

Fundamental safety instructions

1.1 General safety instructions

WARNING

Unexpected movement of machines caused by inactive safety functions

Inactive or non-adapted safety functions can trigger unexpected machine movements that

may result in serious injury or death.

• Observe the information in the appropriate product documentation before commissioning.

• Carry out a safety inspection for functions relevant to safety on the entire system, including

all safety-related components.

• Ensure that the safety functions used in your drives and automation tasks are adjusted and

activated through appropriate parameterizing.

• Perform a function test.

• Only put your plant into live operation once you have guaranteed that the functions

relevant to safety are running correctly.

Note

Important safety notices for Safety Integrated functions

If you want to use Safety Integrated functions, you must observe the safety notices in the Safety

Integrated manuals.

WARNING

Malfunctions of the machine as a result of incorrect or changed parameter settings

As a result of incorrect or changed parameterization, machines can malfunction, which in turn

can lead to injuries or death.

• Protect the parameterization against unauthorized access.

• Handle possible malfunctions by taking suitable measures, e.g. emergency stop or

emergency off.

Basesoftware and operating software

Commissioning Manual, 10/2020, 6FC5397-1DP40-6BA4

Fundamental safety instructions

1.2 Equipment damage due to electric fields or electrostatic discharge

1.2

Equipment damage due to electric fields or electrostatic discharge

Electrostatic sensitive devices (ESD) are individual components, integrated circuits, modules or

devices that may be damaged by either electric fields or electrostatic discharge.

NOTICE

Equipment damage due to electric fields or electrostatic discharge

Electric fields or electrostatic discharge can cause malfunctions through damaged individual

components, integrated circuits, modules or devices.

• Only pack, store, transport and send electronic components, modules or devices in their

original packaging or in other suitable materials, e.g conductive foam rubber of aluminum

foil.

• Only touch components, modules and devices when you are grounded by one of the

following methods:

- Wearing an ESD wrist strap

- Wearing ESD shoes or ESD grounding straps in ESD areas with conductive flooring

• Only place electronic components, modules or devices on conductive surfaces (table with

ESD surface, conductive ESD foam, ESD packaging, ESD transport container).

Basesoftware and operating software

Commissioning Manual, 10/2020, 6FC5397-1DP40-6BA4

Fundamental safety instructions

1.3 Warranty and liability for application examples

1.3

Warranty and liability for application examples

Application examples are not binding and do not claim to be complete regarding configuration,

equipment or any eventuality which may arise. Application examples do not represent specific

customer solutions, but are only intended to provide support for typical tasks.

As the user you yourself are responsible for ensuring that the products described are operated

correctly. Application examples do not relieve you of your responsibility for safe handling when

using, installing, operating and maintaining the equipment.

Basesoftware and operating software

Commissioning Manual, 10/2020, 6FC5397-1DP40-6BA4

Fundamental safety instructions

1.4 Security information

1.4

Security information

Siemens provides products and solutions with industrial security functions that support the

secure operation of plants, systems, machines and networks.

In order to protect plants, systems, machines and networks against cyber threats, it is necessary

to implement - and continuously maintain - a holistic, state-of-the-art industrial security

concept. Siemens’ products and solutions constitute one element of such a concept.

Customers are responsible for preventing unauthorized access to their plants, systems,

machines and networks. Such systems, machines and components should only be connected to

an enterprise network or the internet if and to the extent such a connection is necessary and only

when appropriate security measures (e.g. firewalls and/or network segmentation) are in place.

For additional information on industrial security measures that may be implemented, please

visit

https://www.siemens.com/industrialsecurity https://www.siemens.com/industrialsecurity ).

Siemens’ products and solutions undergo continuous development to make them more secure.

Siemens strongly recommends that product updates are applied as soon as they are available

and that the latest product versions are used. Use of product versions that are no longer

supported, and failure to apply the latest updates may increase customer’s exposure to cyber

threats.

To stay informed about product updates, subscribe to the Siemens Industrial Security RSS Feed

under

https://www.siemens.com/industrialsecurity https://new.siemens.com/global/en/products/

services/cert.html#Subscriptions).

Further information is provided on the Internet:

Industrial Security Configuration Manual (https://support.industry.siemens.com/cs/ww/en/

view/108862708)

WARNING

Unsafe operating states resulting from software manipulation

Software manipulations, e.g. viruses, Trojans, or worms, can cause unsafe operating states in

your system that may lead to death, serious injury, and property damage.

• Keep the software up to date.

• Incorporate the automation and drive components into a holistic, state-of-the-art industrial

security concept for the installation or machine.

• Make sure that you include all installed products into the holistic industrial security concept.

• Protect files stored on exchangeable storage media from malicious software by with suitable

protection measures, e.g. virus scanners.

• On completion of commissioning, check all security-related settings.

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Commissioning Manual, 10/2020, 6FC5397-1DP40-6BA4

Fundamental safety instructions

1.5 Residual risks of power drive systems

1.5

Residual risks of power drive systems

When assessing the machine- or system-related risk in accordance with the respective local

regulations (e.g., EC Machinery Directive), the machine manufacturer or system installer must

take into account the following residual risks emanating from the control and drive components

of a drive system:

Unintentional movements of driven machine or system components during commissioning,

operation, maintenance, and repairs caused by, for example,

- Hardware and/or software errors in the sensors, control system, actuators, and cables and

connections

- Response times of the control system and of the drive

- Operation and/or environmental conditions outside the specification

- Condensation/conductive contamination

- Parameterization, programming, cabling, and installation errors

- Use of wireless devices/mobile phones in the immediate vicinity of electronic components

- External influences/damage

- X-ray, ionizing radiation and cosmic radiation

Unusually high temperatures, including open flames, as well as emissions of light, noise,

particles, gases, etc., can occur inside and outside the components under fault conditions

caused by, for example:

- Component failure

- Software errors

- Operation and/or environmental conditions outside the specification

- External influences/damage

Hazardous shock voltages caused by, for example:

- Component failure

- Influence during electrostatic charging

- Induction of voltages in moving motors

- Operation and/or environmental conditions outside the specification

- Condensation/conductive contamination

- External influences/damage

Electrical, magnetic and electromagnetic fields generated in operation that can pose a risk to

people with a pacemaker, implants or metal replacement joints, etc., if they are too close

Release of environmental pollutants or emissions as a result of improper operation of the

system and/or failure to dispose of components safely and correctly

Influence of network-connected communication systems, e.g. ripple-control transmitters or

data communication via the network

For more information about the residual risks of the drive system components, see the relevant

sections in the technical user documentation.

Basesoftware and operating software

Commissioning Manual, 10/2020, 6FC5397-1DP40-6BA4

Preface

Fundamental safety

instructions

System overview

SINUMERIK

Principles of start-up

SINUMERIK 840D sl

SINUMERIK Operate

General settings

Licensing

Commissioning Manual

Creating drive connections

Channel menu

Machine and setting data

Customizing the "Machine"

operating area

Simulation and

simultaneous recording

Spindle functions

Drive system

Configuring alarms

Valid for

Control:

Data backup

SINUMERIK 840D sl/840DE sl

Software:

CNC software

V4.94

SINUMERIK Operate V4.94

Configuring the network

10/2020

Continued on next page

6FC5397-1DP40-6BA4

Legal information

Warning notice system

This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage

to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices

referring only to property damage have no safety alert symbol. These notices shown below are graded according to

the degree of danger.

DANGER

indicates that death or severe personal injury will result if proper precautions are not taken.

WARNING

indicates that death or severe personal injury may result if proper precautions are not taken.

CAUTION

indicates that minor personal injury can result if proper precautions are not taken.

NOTICE

indicates that property damage can result if proper precautions are not taken.

If more than one degree of danger is present, the warning notice representing the highest degree of danger will be

used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property

damage.

Qualified Personnel

The product/system described in this documentation may be operated only by personnel qualified for the specific

task in accordance with the relevant documentation, in particular its warning notices and safety instructions.

Qualified personnel are those who, based on their training and experience, are capable of identifying risks and

avoiding potential hazards when working with these products/systems.

Proper use of Siemens products

Note the following:

WARNING

Siemens products may only be used for the applications described in the catalog and in the relevant technical

documentation. If products and components from other manufacturers are used, these must be recommended or

approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance

are required to ensure that the products operate safely and without any problems. The permissible ambient

conditions must be complied with. The information in the relevant documentation must be observed.

Trademarks

All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication may

be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

Disclaimer of Liability

We have reviewed the contents of this publication to ensure consistency with the hardware and software described.

Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this

publication is reviewed regularly and any necessary corrections are included in subsequent editions.

Siemens AG

Document order number: 6FC5397-1DP40-6BA4

Digital Industries

Ⓟ 10/2020 Subject to change

Postfach 48 48

90026 NÜRNBERG

GERMANY

Preface

SINUMERIK documentation

The SINUMERIK documentation is organized into the following categories:

• General documentation/catalogs

• User documentation

• Manufacturer/service documentation

Additional information

You can find information on the following topics at the following address (https://

support.industry.siemens.com/cs/de/en/view/108464614):

• Ordering documentation/overview of documentation

• Additional links to download documents

• Using documentation online (find and search in manuals/information)

If you have any questions regarding the technical documentation (e.g. suggestions,

corrections), please send an e-mail to the following address

(mailto:docu.motioncontrol@siemens.com).

mySupport/Documentation

At the following address (https://support.industry.siemens.com/My/ww/en/documentation ),

you can find information on how to create your own individual documentation based on

Siemens' content, and adapt it for your own machine documentation.

Training

At the following address (http://www.siemens.com/sitrain ), you can find information about

SITRAIN (Siemens training on products, systems and solutions for automation and drives).

FAQs

You can find Frequently Asked Questions in the Service&Support pages under Product Support

(https://support.industry.siemens.com/cs/de/en/ps/faq ).

SINUMERIK

You can find information about SINUMERIK at the following address (http://www.siemens.com/

sinumerik).

SINUMERIK Operate

Commissioning Manual, 10/2020, 6FC5397-1DP40-6BA4

Preface

Target group

This documentation is intended for commissioning personnel.

The plant or system is readily assembled and wired. For the

following steps, e.g. configuring the individual components,

the Commissioning Manual contains all necessary information or at least references.

Benefits

The intended target group can use the Commissioning Manual to test and commission the

system or the plant correctly and safely.

Utilization phase: Setup and commissioning phase

Standard scope

This documentation only describes the functionality of the standard version. Additions or

revisions made by the machine manufacturer are documented by the machine manufacturer.

Other functions not described in this documentation might be executable in the control. This

does not, however, represent an obligation to supply such functions with a new control or when

servicing.

For the sake of simplicity, this documentation does not contain all detailed information about all

types of the product and cannot cover every conceivable case of installation, operation, or

maintenance.

Note regarding the General Data Protection Regulation

Siemens observes standard data protection principles, in particular the principle of privacy by

design. That means that

this product does not process / store any personal data, only technical functional data (e.g. time

stamps). If a user links this data with other data (e.g. a shift schedule) or stores personal data on

the same storage medium (e.g. hard drive) and thus establishes a link to a person or persons,

then the user is responsible for ensuring compliance with the relevant data protection

regulations.

Technical Support

Country-specific telephone numbers for technical support are provided on the Internet at the

following address (https://support.industry.siemens.com/cs/ww/en/sc/2090 ) in the "Contact"

area.

If you have any technical questions, use the online form in the "Support Request" area.

SINUMERIK Operate

Commissioning Manual, 10/2020, 6FC5397-1DP40-6BA4

Preface

CompactFlash Cards

• Do not remove the memory card while it is being accessed. This can lead to damage of the

memory card and the SINUMERIK as well as the data on the memory card.

• Insert the memory card carefully and the right way round into the memory card slot (observe

indicators such as arrow or similar). This way you avoid mechanical damage to the memory

card or the device.

• Only use memory cards that have been approved by Siemens for use with SINUMERIK. Even

though SINUMERIK follows general industry standards for memory cards, it is possible that

memory cards from some manufacturers will not function perfectly in this device or are not

completely compatible with it (you can obtain information on compatibility from the

memory card manufacturer or supplier).

• For further information on handling CompactFlash cards, please refer to the NCU manuals.

SINUMERIK Operate

Commissioning Manual, 10/2020, 6FC5397-1DP40-6BA4

Table of contents

Preface

Fundamental safety instructions

1.1

General safety instructions

1.2

Equipment damage due to electric fields or electrostatic discharge

1.3

Warranty and liability for application examples

1.4

Security information

1.5

Residual risks of power drive systems

System overview

2.1

System overview

2.2

System requirements

Principles of start-up

3.1

Data structure of SINUMERIK Operate

3.2

Editing files

3.2.1

Editing the file at the controller

3.2.2

Editing a file externally

General settings

4.1

Changing the language

4.2

Set date/time

4.3

Using the time server

4.4

Use time zone

4.5

Device registration

4.6

Activation of the display for the remaining time of spindle utilization

4.7

Configuring Caps Lock

4.8

Activating/deactivating the virtual keyboard

4.9

Defining the access rights for the "HMI restart" softkey

4.10

Setting OEM functions for the softkeys "HMI restart" and "EXIT"

4.11

Changing the skin design

4.12

Setting the screensaver

4.13

Setting cleaning mode for the operator panel

4.14

Inserting a user-specific run up screen

4.15

Using user interfaces in parallel

4.16

Setting how login data (credentials) are handled when archiving

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Table of contents

4.17

VNC remote connections

4.18

Setting the WEB browser

4.19

Access levels

4.19.1

Definition of access levels

4.19.2

Modifying the access levels password

4.19.3

Work station safety

4.19.4

Access levels for programs

4.19.5

Access rights for files

4.19.6

Access levels for softkeys

4.19.7

This is how you define new access levels for softkeys

4.19.8

Setting the MDA program access via protection level

4.20

Program selection

4.20.1

Displaying the softkey

4.21

Activate and configure the Sidescreen window

4.21.1

Activate Sidescreen

4.21.2

Display Sidescreen ABC keyboard

4.21.3

Display Sidescreen machine control panel

4.21.3.1

Configuring your own keys on the machine control panel

4.21.3.2

Create own translations of texts for the machine control panel

4.21.4

Display sidescreen camera

4.22

SINUMERIK Operate Display Manager

4.22.1

Display configurations

4.22.2

Creating your own display configurations

4.22.2.1

Displays

4.22.2.2

Frames

4.22.2.3

Menus

4.22.2.4

Menu actions

4.22.2.5

Applications

4.22.2.6

Global settings

Licensing

5.1

Determining the license requirement

5.2

Activating the test license

100

5.3

Exporting license requirements

101

5.4

Reading in the license key

101

5.5

Backing up the license of a new CompactFlash card

102

Creating drive connections

105

6.1

Setting up drives

105

6.2

Setting EXTCALL

106

6.3

Creating a global part program memory

107

Channel menu

109

7.1

Configuring a channel menu

109

7.2

Constraints

110

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Table of contents

7.3

General structure of the channel menu

110

7.4

Defining channel groups in the "netnames.ini" file

111

7.5

Configuring operating stations in the "config.ini" file

112

7.6

Example: Settings for 1:N

113

7.7

Distribution via job lists in the case of 1:N

115

Machine and setting data

119

8.1

Machine and setting data

119

8.2

Displaying/editing machine data

119

8.3

Displaying/editing display machine data

122

8.4

Displaying/editing setting data

122

8.5

Displaying/editing drive parameters

124

8.6

Machine data display options

126

8.7

Editing machine data and drive parameters

128

8.7.1

Editing hexadecimal values

128

8.7.2

Editing BICO values

128

8.7.3

Editing enum values

129

8.8

Searching for data

130

8.9

Data admin

131

8.10

User views

134

8.10.1

Creating a user view

135

8.10.2

Editing the user view

136

8.10.3

Deleting a user view

138

8.11

Plain texts for machine and setting data

138

Customizing the "Machine" operating area

141

9.1

Setting the font size of the actual value display

141

9.2

Inserting a user-specific logo

142

9.3

Configuring the display of the G-code groups

143

9.4

Configuring the channel operational message

145

9.5

Deactivating program test

147

9.6

Display articulated joint position STAT and rotary axis position TU

147

9.7

Activating the "Teach In" function

148

9.8

Block search

149

9.8.1

Activating block search mode

149

9.8.2

Accelerated block search for execution from external

151

9.9

Multi-channel support

151

9.10

Manual machine

153

9.11

User status display (OEM)

155

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9.12

Configuring the offset display

157

9.13

Activate machining time recording

157

Simulation and simultaneous recording

159

10.1

Simulation overview

159

10.2

Setting the technology for simulation

161

10.3

Simultaneous recording overview

163

10.4

Clamping a blank

165

Spindle functions

169

11.1

Spindle control

169

11.2

Analog spindle

170

11.3

Spindle diagnostics

171

11.3.1

Spindle diagnostics

171

11.3.2

Temperatures

173

11.3.3

Motor temperature sensor

175

11.3.4

Additional temperature sensor

175

11.3.5

Temperature histograms

176

11.3.6

Speed/torque

176

11.3.7

Clamping system

177

11.3.8

Clamping system: Speed limits

179

11.3.9

Clamping system: Diagnostic statistics

180

11.3.10

Clamping system: Clamping time statistics

181

11.3.11

Fetching the logistics data

181

Drive system

183

12.1

Commissioning of drives

183

Configuring alarms

185

13.1

Creating alarm and message texts via the user interface

185

13.2

Configuring alarm and message texts via alarm text files

187

13.2.1

Creating in-house alarm texts

188

13.2.2

Creating texts for indexed alarm parameters

190

13.2.3

Creating part program message texts

192

13.2.4

Changing alarm attributes

196

13.2.5

Replacing standard alarm texts

200

13.2.6

Range of alarms

204

13.2.7

Parameter specifications in alarm texts

205

13.2.8

Opening error file

206

13.3

Configuring an alarm log

206

13.3.1

Setting alarm logs from the user interface

208

13.3.2

Loading alarm log via configuration file

208

13.4

PLC alarms with parameters

212

13.4.1

Definition of a parameter of the octet string data type

213

13.4.2

Definition of the language-dependent formatting

215

13.5

Deactivating a warning

216

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SINUMERIK 840D sl. Service - Configuring Commissioning. Manual (2011-2020) - page 35