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Function Example No. MC-FE-I-011-V10-DE

SIMOTION with SINAMICS S120

Safety Integrated Extended FunctionsFailsafe Drives on SIMOTION D435

with PROFIsafe Control viaPROFIBUS Data Exchange Broadcast

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SIMOTION mit SINAMICS S120 Fehlersichere Antriebe Article ID: 38701812

I DT Safety Integrated Page 2/74 MC-FE-I-011-V10-DE

Copyright

SiemensAG2009Allrightsreserved

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Preliminary remarks

The Functional Examples dealing with Safety Integrated are fully

functional and tested automation configurations based on I DT & IAstandard products for simple, fast and inexpensive implementation ofautomation tasks in safety engineering. Each of these Functional Examplescovers a frequently occurring subtask of a typical customer problem insafety engineering.

Aside from a list of all required software and hardware components and adescription of the way they are connected to each other, the FunctionalExamples include the tested and commented code. This ensures that thefunctionalities described here can be reset in a short period of time andthus also be used as a basis for individual expansions.

Important note

The Safety Functional Examples are not binding and do not claim to becomplete regarding the circuits shown, equipping and any eventuality. TheSafety Functional do not represent customer-specific solutions. They areonly intended to provide support for typeical applications. You areresponsible for ensuring that the described products are correctly used.

These Safety Functional Examples do not relieve you of the responsibilityin safely and professionally using, installing, operating and servicingequipment. When using these Safety Functional Examples, you recognizethat Siemens cannot be made liable for any damage/claims beyond the

liability clause described. We reserve the right to make changes to theseSafety Functional Examples at any time without prior notice. If there areany deviations between the recommendations provided in these SafetyFunctional Examples and other Siemens publications - e.g. Catalogs - thenthe contents of the other documents have priority.

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Contents

1 Warranty, Liability and Support ................................................................... 52 Automation Function .................................................................................... 62.1 Function Example Description......................................................................... 62.2 Advantages / Customer Benefits..................................................................... 93 Components Required................................................................................ 103.1 Hardware Components ................................................................................. 103.2 Software Components................................................................................... 113.2.1 Engineering software .................................................................................... 113.2.2 Firmware....................................................................................................... 114 Configuration and Wiring ........................................................................... 124.1 Overview of the Hardware Configuration....................................................... 124.2 Hardware Component Wiring ........................................................................ 134.2.1 Control voltage wiring.................................................................................... 134.2.2 DRIVE-CLiQ wiring ....................................................................................... 144.3 Major Hardware Component Settings............................................................ 154.3.1 Bus interfaces ............................................................................................... 154.3.2 Bus topology ................................................................................................. 185 Overview and Operation............................................................................. 195.1 Operating Description ................................................................................... 195.2 List of Input Signals....................................................................................... 216 Sample Project ............................................................................................ 226.1 Passwords .................................................................................................... 226.2 Basic Configurations ..................................................................................... 236.2.1 Hardware configuration of the failsafe SIMATIC Controller............................ 236.2.2 Inserting SIMOTION in the existing SIMATIC project .................................... 286.2.3 Basic commissioning of the SINAMICS drives (without safety)...................... 346.2.4 Telegram configuration.................................................................................. 386.2.5 Inserting F-CPU in the SIMOTION HW Config and connecting it................... 406.3 Programming the Failsafe Controller............................................................. 456.4

Parameterizing the Safety Functions in SINAMICS....................................... 51

6.4.1 Configuring the safety functions on the drives............................................... 516.4.2 Configuring the safety data block on SINAMICS ........................................... 556.5 SIMOTION .................................................................................................... 576.5.1 Creating SIMOTION axes ............................................................................. 576.5.2 SIMOTION programs .................................................................................... 656.5.3 Runtime system configuration....................................................................... 686.5.4 SIMOTION messages................................................................................... 706.6 Downloading the Sample Project .................................................................. 706.6.1 Loading the S7-F-CPU configuration............................................................. 706.6.2 Loading the SIMOTION and SINAMICS configuration................................... 72

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6.7 Acceptance Test ........................................................................................... 747 History ......................................................................................................... 74

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1 Warranty, Liability and Support

We do not accept any liability for the information contained in this docu-

ment.

Any claims against us - based on whatever legal reason - resulting from theuse of the examples, information, programs, engineering and performancedata etc., described in this Safety Functional Example shall be excluded.Such an exclusion shall not apply in the case of mandatory liability, e.g. un-der the German Product Liability Act (Produkthaftungsgesetz), in case ofintent, gross negligence, or injury of life, body or health, guarantee for thequality of a product, fraudulent concealment of a deficiency or breach of acondition which goes to the root of the contract (wesentliche Ver-tragspflichten). However, claims arising from a breach of a condition whichgoes to the root of the contract shall be limited to the foreseeable damage

which is intrinsic to the contract, unless caused by intent or gross negli-gence or based on mandatory liability for injury of life, body or health. Theabove provisions do not imply a change in the burden of proof to your det-riment

Copyright 2009 Siemens I DT. It is not permissible to transfer or copy the-se standard applications or excerpts of them without first having prior au-thorization from Siemens I DT in writing.

For questions regarding this article please contact us at the following

e-mail address:

[email protected]

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2 Automation Function

2.1 Function Example Description

The following safety functions have been integrated in SINAMICS S120drives according to IEC 61800-5-2:

Name Function Description

STO Safe Torque Off Failsafe disconnection of the torque-formingpower supply from the motor.

Restarting is blocked via the switch-on in-hibit (stop function category 0 according toEN 60204-1).

SBC Safe Brake

Control

SBC is only used with existing motor brake

which is connected to the power connectorvia the outputs. SBC always responds in combination with

STO or when the internal safety monitorsrespond with failsafe pulse suppression.

SS1 Safe Stop 1 Fast and safely monitored drive standstillalong the OFF3 ramp.

Upon expiry of a delay time or reaching thecuttoff speed, transition to STO (stop func-tion category 1 according to EN 60204-1).

SS2 Safe Stop 2 Fast and safely monitored drive standstillalong the OFF3 ramp.

Upon expiry of a delay time, transition toSOS; the drive is controlled (stop functioncategory 2 according to EN 60204-1).

SOS Safe OperatingStop

This function serves to safely monitor thestandstill position of a drive; the drive is con-trolled.

SLS Safely-LimitedSpeed

Safe drive speed monitoring. Parameterizable cutoff reaction in case of

limit value violation.

SSM Safe SpeedMonitor

Safe display of speed limit violation (n < nx).

These extended safety functions can be activated both via PROFIsafe withPROFIBUS and via a terminal extension module TM54F. In the presentexample, the safety functions are activated from a SIMATIC F-CPU usingthe PROFIsafe telegram.

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Task

A system equipped with SINAMICS S120 drives is controlled by a

SIMOTION D435. Various safety functions must be used on this system.The SIMOTION does not comprise any safety functions and uses the ex-tended safety functions integrated in SINAMICS S120 drives.

These drive-integrated safety functions shall be activated from the F-CPUusing the PROFIsafe telegram via PROFIBUS data exchange broadcast.The safety signals acquired via a failsafe digital input module are proc-essed by the F-CPU and transferred to the drives using the above-statedtelegram. In this case, the SIMOTION serves as PROFIBUS master andthe F-CPU as I slave. The PROFIdrive communication is established be-tween the SIMOTION and the SINAMICS, the PROFIsafe telegrams areexchanged between the F-CPU and the SINAMICS via PROFIBUS data

exchange broadcast.This function example is based on the SIMOTION D435 training case(6ZB2 470-0AE00), the SINAMICS training case (6ZB2 480-0BA00) andthe SAFETY training case.

The following figure provides a sample overview of the assumed machineconfiguration.

Further considerations are based on the following safety functions.

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Safetyfunction

Description Reaction

SF1Actuation of the emergencystop button

Fast controlled stopping ofdrive 1 -> followed by pulsesuppression (SS1)

Stopping of drive 2 withimmediate pulse suppression(STO)

SF2

The drive 1 must be quicklystopped when opening theprotective door 1. The drive 1must then be stopped withspeed setpoint = 0 and the

standstill position safelymonitored.

The SIMOTION deceleratesthe drive 1 with position control.Upon expiry of a waiting time,the standstill position is safely

monitored (SOS)

SF3With open protective door 2,the drive 2 may not exeed amaximum speed

Speed monitoring on drive 2(SLS)

Solution

Hardware overview

This function example shows the activation of the safety functions STO,SS1, SOS and SLS via the PROFIsafe telegram using the PROFIBUS dataexchange broadcast on a SIMOTION D435 with SINAMICS S120 drive

group.

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The drive group in Booksize format comprises an infeed unit and a DoubleMotor Module. Motion Control is performed via a SIMOTION D435 and themotor control via a SINAMICS S120. The Double Motor Module controls

the two mutually independent servo motors. A Smart Line Module is usedas infeed unit.

The safety-related signals are acquired via failsafe ET200M inputs andlogically processed in the F-CPU. The F-CPU uses the failsafe data tocreate a PROFIsafe telegram for each drive. This is transferred via thePROFIBUS data exchange broadcast to the SINAMICS drives where itactivates the safety functions.

Upon emergency stop request, the drive 1 is stopped with the drive-integrated safety function SS1 and the drive 2 with STO.

Two switches in the Safety training case simulate one protective door each

for drive 1 and 2. When opening the protective door 1, the drive 1 is decel-erated by the SIMOTION until it stops. Upon expiry of a configurable timeperiod, the standstill position is safely monitored (activation of the SOSfunction). When the door is closed, the axis 1 is restarted (deactivation ofthe SOS function). When the protective door 2 is opened, the speed fordrive 2 is monitored for a configurable maximum value (SLS function). Thesetpoint speed is limited to 80% of the selected SLS step. When closing thesimulated door, the speed limitation is canceled without influencing theother drive.

2.2 Advantages / Customer Benefits

Convenient activation of the safety functions integrated in the drive.

Convenient setup through standardized technology.

The existing system can be extended quickly and conveniently.

Space-saving and cost-efficient setup through integrated safety func-tions no additional hardware required.

The SIMOTION system provides convenient evaluation and diagnosticinformation

Complex safety concepts can thus be realized.

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3 Components Required

This section describes the hardware components and software versions re-

quired to implement the function example.

3.1 Hardware Components

SAFETY training case (major components)

Component Type MLFB / Order Data No. Manufacturer

SITOP power supply SITOP SMART 120W 6EP1 333-2AA01 1 Siemens

CPU 315F-2 PN/DP 6ES7 315-2FH13-0AB0 1 Siemens

SIMATIC S7-300 CPU SIMATIC Micro Memory Card,512KB

6ES7 953-8LJ20-0AA0 1 Siemens

SIMATIC S7 failsafeinput module

SM 326 F-DI 24 6ES7 326-1BK01-0AB0 1 Siemens

SIMATIC S7 failsafeoutput module

SM 326 F-DO 8 6ES7 326-1BF40-0AB0 1 Siemens

SINAMICS failsafeTerminal Module

TM54F 6SL3055-0AA00-3BA0 1 Siemens

Drive-CLiQ Cable, gray, metallic plug 6FX2002-1DC00-1AC0 1 Siemens

Toggle switch 0-I, latching,16mm, black

3SB2000-2AB01 2 SiemensProtective doorsimulation switches

S2 and S3 Holder with solder pins 3SB2908-0AB 2 Siemens

Mushroom pushbutton, red,16mm 3SB2000-1AC01 1 SiemensEmergency stopcontrol deviceS1 Holder with solder pins 3SB2908-0AB 1 Siemens

Pushbutton, flat pushbutton,16mm, white

3SB2000-0AG01 1 SiemensReset button

S4 Holder with lamp socket, lampand solder pins

3SB2455-1B 1 Siemens

Load resistors

R1 .. R81kOhm 1W

Type PO595-0 Style 0207Power Metaloxide film

resistors1

YageoEurope

ST 2,5-QUATTRO-TG 3038451 8PhoenixContactTerminals for load resistors

(R1..R8)Component plug P-CO 3036796 8

PhoenixContact

Load resistor R9 SMA0207 1K2 1% TKWID_MET_SHT_1K2_+-1%_600mW_+50ppm_02

071 Beyschlag

TERMINALS_ACCESS_DUMMYPLUG_TYPE1_GRAY

280-801 1 WAGOTerminals for load resistor(R9)

TERMINAL_4-WIRE_GRAY 280-686 1 WAGO

SIMOTION training case


SIMOTION training case D435 6ZB2 470-0AE00 1 SIEMENS

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SINAMICS training case


SINAMICS training case S120 CU320 6ZB2 480-0BA00 1 SIEMENS

Note The function example has been tested using the hardware componentslisted. Alternatively, you can use other, functionally equivalentcomponents. In such cases, you may have to use another componentparameterization resp. wiring. Components highlighted in yellow are notrelevant for this function example.

3.2 Software Components

3.2.1 Engineering software


STEP 7 V5.4 SP4 6ES7810-4CC08-0YA5 1 Siemens

S7 Distributed SafetyProgramming

V5.4 SP4 6ES7833-1FC+02-0YA5 1 Siemens

S7 F Configuration Pack V5.5 SP5 1 Siemens

SIMOTION SCOUT V4.1 SP4 6AU1810-1BA41-2XA0 1 Siemens

3.2.2 Firmware

The Firmware Version V2.6 SP2 (or later) must be installed on allSINAMICS components.

The SIMOTION must be used with Firmware Version V4.1 SP4 HF 1 (orlater).

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4 Configuration and Wiring

4.1 Overview of the Hardware Configuration

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4.2 Hardware Component Wiring

4.2.1 Control voltage wiring

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4.2.2 DRIVE-CLiQ wiring

The SINAMICS devices must be connected using a DRIVE-CLiQ cable as

displayed in the following figure.

DRIVE-CLiQ wiring

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4.3 Major Hardware Component Settings

In this example, the PROFIBUS is used to activate the safety functions inthe drives. For this, control and status signals are exchanged between thedrives and the F-CPU via the PROFIsafe telegram. The drives are con-trolled by the SIMOTION via the PROFIBUS.

Further, the PROFIBUS is used to configure the F-CPU, SINAMICS andSIMOTION.

4.3.1 Bus interfaces

Programming device / PC

PROFIBUS address = 0

Since the SIMOTION used is the bus master, the PROFIBUS interfaceof the programming device may not be the only master that is config-ured on the bus (the field PG/PC is the only master on the bus may notbe ticked). After increasing the transfer speed in the HW Config to12Mbit/s and downloading this, the transfer speed must also be in-creased on the PG interface.

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SIMOTION D435


The PROFIBUS address is set via the HW Config.

SINAMICS S120 CU320


The PROFIBUS address is set via the HW Config and must coincidewith the setting of the DIP switch on the CU 320.

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SIMATIC 315F-2 PN/DP CPU


The PROFIBUS address is set via the HW Config.

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4.3.2 Bus topology

View in NetPro

Prerequisites for operation

The SIMATIC components have been installed and interconnected. The

PROFIsafe addresses of the failsafe input and output modules must beset via the DIL switch; see section 6.2.1 Hardware configuration of thefailsafe SIMATIC controller.

All components are connected according to section 4.2 Hardware Com-ponent Wiring.

The DRIVE-CliQ topology of the SINAMICS components is compliedwith.

The motors are connected to the Motor Module via power and encodercable.

The Motor Module has been properly connected to the infeed unit (dclink and control voltage DC 24 V).

The infeed unit is connected to the power supply.

The components are supplied with DC 24 V.

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5 Overview and Operation

5.1 Operating Description

Hardware overview

Before you can move the drives, you have to switch the SIMOTION to theRUN state. In the example, this is done via the SCOUT. For this, mark theobject D435 and press the right mouse button. Make the following selec-tion: Target device -> operating status.

A screen is displayed where you can set the operating status of theSIMOTION. Set the toggle switch to the RUN position.

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The switches -S1 to -S4 are located on a switchbox included in the Safetytraining case which is used to activate the different safety functions. Theswitches -S5 to -S10 are located on a switchbox included in the SINAMICS

training case. These switches are used to switch axis enables, start travers-ing programs, trigger the test function of safety functions and acknowledgepending errors. In this example, the switches on the SIMOTION trainingcase are not used.

Unlock the emergency stop button -S1 to traverse the drives.

The switch -S5 activates the axis enable for drive 1 (upper motor). -S6starts and stops the related traversing program. The axis 2 (lower motor) isenabled via -S7 and the traversing program activated resp. deactivated with-S8. Pending alarms on the SIMOTION and drive alarms can be acknowl-edged with -S9. This does not apply to safety alarms which must be ac-knowledged failsafe via -S4. The test stop of the safety functions in the

drives which must be performed cyclically is activated via -S10.

When pressing the emergency stop button -S1, the safety function SS1 isactivated for drive 1 (upper motor); that means the drive is deceleratedalong the OFF3 ramp and STO activated. STO is directly triggered withdrive 2 (lower motor), that means the drive coasts down. When triggeringthe emergency stop, the drive 1 stops earlier than the drive 2.

The drive 1 can be traversed with closed protective door 1 (toggle switch -S2). The safety function SOS is activated when opening -S2; that meansthe drive is decelerated by the SIMOTION until it stops. Upon expiry of aconfigurable time period, the standstill position is safely monitored by thedrive. The traversing program is restarted when closing the simulated pro-

tective door -S2. An ON command is not required.

With closed protective door 2 (toggle switch -S3), the drive 2 can be trav-ersed at an arbitrary speed. When opening -S3, the traversing speed is lim-ited by the SIMOTION to 80% of the speed limit value of step 1 of thesafety function SLS. Upon expiry of a defined time period, this limit value ismonitored by the safety function SLS. When closing -S3, the SLS is deacti-vated and the speed limitation canceled on the SIMOTION. The drive cannow be traversed at the configured speed.

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5.2 List of Input Signals

Digital inputs of the SINAMICS at the SIMOTION D435

DI0 -S5 Drive 1 Set / remove axis enables

DI1 -S6 Drive 1Start / stop traversingprogram

DI2 -S7 Drive 2 Set / remove axis enables

DI3 -S8 Drive 2Start / stop traversingprogram

DI6 -S9

Drive 1 / Drive 2 /

SIMOTION Acknowledge alarms

DI7 -S10 Drive 1 / Drive 2 Trigger test stop

Failsafe inputs on the F-DI module

F-DI0 -S1 Emergency stop buttonDrive 1: SS1

Drive 2: STO

F-DI1 -S2Protective door 1(for drive 1)

SOS

F-DI2 -S3Protective door 2(for drive 2)

SLS

F-DI3 -S4 Acknowledgement button

Failsafe acknowledgement(drive 1 & 2) anddepassivation (all Fslaves)

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6 Sample Project

This section describes how to parameterize the individual components.

SIMOTION SCOUT is used as engineering software for the SIMOTION andSINAMICS S120. Distributed safety is required to program the F-CPU.

The following section describes how the software project belonging to thisfunction example has been set up.

6.1 Passwords

To simplify matters, we have used a common safety password for programand hardware regarding the SIMATIC components used in the project. Apassword is also used for the safety configuration of the SINAMICS com-ponents (drives).

Safety password for F-CPU: "0"

Safety password for SINAMICS components: "1"

Change these passwords in real applications!

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6.2 Basic Configurations

6.2.1 Hardware configuration of the failsafe SIMATIC Controller

Description Remark

In the SIMATICManager, insert aSIMATIC 300 station inthe project.

In the HW Config, cre-ate and parameterizethe complete station.

For this, move the mo-dules included in theparts list fromChap. 3.1 Hardware

Components viaDrag&Drop from thecatalog screen to theconfiguration screen.

Make address settingsfor the DP interface asdescribed in Chap. 4.3.

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Description Remark

Configuring the F-CPU

In the Propertiesscreen of the F-CPU inthe Protection tab,activate the accessprotection for the F-CPU and protect it by apassword.

Activate safetyprogram ("CPUcontains safetyprogram.")

Configuring the F-DI

module.

Configuring thePROFIsafe addressaccording to the DILswitches.

Configuring the F-DImodule.

Configuring F-DI 0(Channel 0, 12)

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Description Remark

Configuring the F-DImodule.

Configuring F-DI 1

(Channel 1, 13)




Configuring the F-DOmodule.

Configuring thePROFIsafe addressaccording to the DILswitches.

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Description Remark

Configuring the F-DOmodule.

Configuring F-DO 7

Save and compile HWConfig

Configuring the DPinterface as slave(step 1)

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Description Remark

Configure the DP inter-face as slave (step 2).

Press the button Newto open a secondscreen.Press the button OKto accept the defaultsetting.Note:This link is automati-cally inserted here bythe system to allow aproper compilation ofthe HW Config.This link is not required

for the example andcan be deleted after-wards (after creatingthe F-link).

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6.2.2 Inserting SIMOTION in the existing SIMATIC project

Description Remark

Insert anotherSIMATIC 300 station inthe existing object.

Then rename (ifrequired) the station;e.g. into

SIMOTION D

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Description Remark

Select thecorrespondingSIMOTION componentfrom the catalog andenter it in the workingarea (Drag&Drop).

Configure and networkthe DP interface of the

SIMOTION.DP2 is used in theexample (see alsosection 4.3.2 Bustopology)

Save and compile.Then load the HWConfig into theSIMOTION. You cannow close the HWConfig.

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Description Remark

Save and compile theHW Config.

Load the HW Configinto the SIMOTION.

Insert the PC in NetProto generate the routinginformation required to

access the SINAMICSonline.

From the folderStations, move theobject PC/PG into theworking area.

Double click theProperties screen.

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Description Remark

Select the tabInterfaces and pressthe button New.

In the following screen,select PROFIBUSandconfirm with OK.

Set the PG PROFIBUSaddress to the value 0and establish theconnection using thealready configuredPROFIBUS (selectionPROFIBUS(1))

Confirm settings withOK.

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Description Remark

Assign the interface onthe PC/PG.

In the example, thecomputer is equippedwith the CP5512interface which shall beconnected to thePROFIBUS(1).

Press the buttonAssign to set up theconnection.

Check whether the

interface has been setto active.

Press OK to close thescreen.

The PG now comprisesthe active interface.

Store and compile theproject and load it intothe CPU (place focuson the SIMATIC CPU).

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Description Remark

The SIMOTION is nowintegrated in theexisting project.

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6.2.3 Basic commissioning of the SINAMICS drives (without safety)

Description Remark

Open the SCOUT /STARTER from theSIMATIC project (->Double-clickCommissioning)

Go online.

Start automatic driveconfiguration.

Select Servo modefor both drives.

Go offline and Store

and compile

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Description Remark

ReconfiguringDrive 1

In the projectnavigator, open theconfiguration screenfor drive 1(SERVO_02).

Configure DDS startsthe guided reconfigu-ration.

Note: The following

section only describesthe screens to bechanged.

Reconfiguring bothdrives

Configure a signal forInfeed in progress(p0864).

The fixed binector 1 isused in the example.

Note: In realapplications, youshould not use thefixed binector 1 as thesignal for Infeed

in progress (p0864).

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Description Remark


The second drive hasno Drive-CLiQ en-coder; the motor mustbe selected manually.

The motor used in theexample has type1FK7022 - 5AK71 -1AG0.


Analogously to themotor, you mustmanually select theencoder. For this, also

use the type number(MLFB).

Save configuration, goonline and load themodified project intothe SINAMICS.

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Description Remark

Via the Project Naviga-tor, open the Speedcontrollerscreen withthe object SERVO_02.

For both drives, thespeed controller hasbeen set as follows inthe example:P gain = 0.1 Nms/radReset time = 10ms

On both drives, adaptsome parameters inthe expert list.

Adaptation to the 230Voperation.

Configuring the OFF3ramp.

Interconnect alarmacknowledgement with-S9 (= DI 6).

p2101 = r722.6 in the CU expert list

Copy RAM to ROM (onSINAMICS), load con-figuration onto the PGand save.

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6.2.4 Telegram configuration

Description Remark

In the SCOUT(offline!), open thescreen for configuringthe PROFIdrivetelegram. Selecttelegram type 105 forboth drives.

Create PROFIsafe slotfor both drives via thebutton Insert line andPROFIsafe.

Select telegram type390 for CU.

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Description Remark

Insert telegramextension for the so-

called safety datablock.

Three words arerequired to transferdata from the drive tothe SIMOTION (inputdata). The SIMOTIONdoes not transfer datato the drive (outputdata)

Insert this telegramextension for both

drives.

Enter changes in theHW Config.

The telegramconfiguration shouldlook as displayed here(same addressassignment assumed).

Save, go online andload the configuration.

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6.2.5 Inserting F-CPU in the SIMOTION HW Config and connecting it

Description Remark

Open the HW Config ofthe SIMOTION andenter the F-CPU.

For this, enter theobject CPU 31X fromthe folder alreadyconfigured stations inthe working area.

The screen displayed

is automaticallyopened.

Press the Connectbutton.

After closing and

reopening theProperties screen ofthe DP slave, it shouldlook as displayed here.The default connectioncan be deleted.

Another tab Fconfiguration isdisplayed. Select thistab and press thebutton New.

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Description Remark

Create the F-connection for the first

drive.

Settings in theexample:

Address (LADDR) = 15

Input address= 76

Exit the screen withOK and create thesecond F-connectionvia the button New inthe Properties screen.

Note:The drive 1 has thePROFIsafe address76. The F-program,however, accesses thedrive via the address15. The address 76 isonly required for dataexchange broadcast.

Create the F-connection for the

second drive.

Settings in theexample:

Address (LADDR) = 21

Input address= 82

Exit the screen withOK and create thesecond F-connectionvia the button New inthe Properties screen.

Note:The drive 2 has thePROFIsafe address82. The F program,however, accesses thedrive via the address21. The address 82 isonly required for dataexchange broadcast.

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Description Remark

Save and compile theHW Config and load it

onto the SIMOTION.

To check the correctconfiguration of thePROFIsafe setting ofthe drives, open thescreen DP Slaveproperties of the

SINAMICS.The tab DataExchange Broadcast -overview shows thedata exchangebroadcast setting.

In the tabConfiguration, pressthe button Activate.

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Description Remark

Place focus on object 1resp. 2 (first resp.second line) and pressthe buttonPROFIsafe.

The following screensare opened for the Fparameters of the twodrives.

This screen shows thePROFIsafe settings ofthe first drive. Nochanges are required.

F_Dest_Adddesignates thePROFIsafe address ofthe first drive. This islater required for thesafety configuration ofthe drives. The value is3FEhex (= 1022 dez).

Note:The watchdog time(F_WD_Time =150msec) must match

the OB35 cycle. In theexample, this is100msec.

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Description Remark

This screen displays

the PROFIsafe settingsof the second drive. Nochanges are required.

F_Dest_Adddesignates thePROFIsafe address ofthe second drive. Thisis later required for thesafety configuration ofthe drives. The value is3FDhex (= 1021 dez).

Note:The watchdog time(F_WD_Time =150msec) must matchthe OB35 cycle. In theexample, this is100msec.

Set the clocksynchronization in thetab clocksynchronization.

For this, checkmarkSynchronize drive toequidistant DP cycle,set the DP cycle to3ms and confirm withthe button Align.

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Description Remark

Then open the HWConfig of the F-CPUffnen. The Propertiesscreen of the MPI/DPinterface should alsodisplay the connection.

The setting made inthe tab Configurationis displayed. Nochanges are required.

The settings made inthe tab Fconfiguration aredisplayed. No changesare required.

Save, compile andload the HW Config ofthe F-CPU.

6.3 Programming the Failsafe Controller

We have intentionally selected a very easy safety program. In the presentcase, it is the main task of the safety program to compose the PROFIsafecontrol words for the drives using the signals to the F-DIs. These are trans-ferred via the PROFIsafe telegram to the drives where they activate the

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safety functions. First, you have to create the blocks required for the safetyprogram.

Notice:This program may not be used for real applications.

Start with the F-Call block. This is required to call up the safety program.For this, insert a function (here FC1) in the block folder using the genera-tion language F-Call. The cyclic interrupt OB35 is required to cyclically callup the safety program.

In this example, the safety program is processed in a function block (hereFB1); that means the FB 1 must be inserted with the generation languageF-KOP (F-LAD) or F-FUP (F-FBD).

Description Remark

Programming OB35

Calling up the safetyprogram

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Description Remark

Programming FB1

Network 1:Activate automaticacknowledgement

Network 2:

-S4 is used foracknowledgement (forerrors which cannot beacknowledgedautomatically)

Programming FB1

PROFIsafe controlword for drive 1; A15and A16 (LOW/HIGHbyte)

Network 3:A15.0 (STO) ispermanentlydeactivated with VKE1.

Network 4:-S1 is connected toA15.1 (SS1).

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Description Remark

Programming FB1

PROFIsafe controlword for drive 1; A15and A16 (LOW-/HIGHbyte)

Network 5:A15.2 (SS2) ispermanentlydeactivated with VKE1.

Network 6:-S2 is connected toA15.3 (SOS). Inversionrequired because -S2is wired as NOcontact/NC contact.

Network 7:

A15.4 (SLS) ispermanentlydeactivated with VKE1.

Network 8:- S4 is connected toA15.7 (failsafeacknowledgement).

Networks 9 and 10:The VKE0 isconnected to A16.1

and A16.2 and the SLSstep 1 permanentlyactivated.

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Description Remark

Programming FB1

PROFIsafe controlword for drive 2; A21and A22 (LOW-/HIGHbyte)

Network 11:-S1 is connected to

A21.0 (STO).



Network 14:A21.3 (SOS) ispermanentlydeactivated with VKE1.

Network 15:-S3 is connected toA21.4 (SLS).

Network 16:- S4 is connected toA21.7 (failsafe

acknowledgement).

Networks 17 and 18:The VKE0 isconnected to A22.1and A22.2 and the SLSstep 1 permanentlyactivated.

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Description Remark

The checkback signal

SSM from the safetystatus word of bothdrives is AND-ed andconnected to the lampin S4 via DO7.

Creating new Fruntime group

Here, the safetyprogram (FB1) isassigned to the FC1and the related I-DBdefined.

Then generate thesafety program andload it into the CPU.

In addition, load thestandard blocks intothe F-CPU.

Note:We recommend that you also integrate the blocks OB82 and OB86 to toler-ate I/O failure (e.g. of the drives upon Power On reset) without causing theF-CPU to change to the operating status STOP.

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6.4 Parameterizing the Safety Functions in SINAMICS

6.4.1 Configuring the safety functions on the drives

Note:

The safety functions must be configured online on the drives.

We have only described the screens that are subject to parameterchanges.

On both drives, the safety functions STO, SS1, SS2, SOS, SLS and SSMare commissioned such that they can be activated. This example only de-scribes the activation of SS1 and SOS for the drive 1. For the drive 2, STOand SLS are activated.

The safety functions are configured in the same way on both drives. Thereis only one exception regarding the PROFIsafe address (input in the con-figuration screen). For drive 1 (SERVO_02), the value is 3FEhex and fordrive 2 (SERVO_03), the value is 3FDhex.

Description Remark

Open the Safetyintegratedscreen ofthe drive 1/2(SERVO_02 /SERVO_03) andactivate commissioningmode with Changesettings.

The password for firstcommissioning is 0.

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Description Remark

Safety integratedscreen

The following must beconfigured in theexample:

Select control withMotion Monitoring viaPROFIsafe

Set enables toEnable.

Configuration screen


PROFIsafe addresswith 3FEhex (for drive1) resp. 3FDhex (fordrive 2)

Speed limit (SSM) with100 mm/min

Test stop signal sourcewith DI7 of theSINAMICS

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Description Remark

Safe Stops screen


Delay time SS1 ->Pulse suppression =500msec

Delay time selectionSOS -> SOS active =

500msecDelay time SS2 ->SOS active = 500msec

Acceleration monitor-ing = 500mm/min

Shutdown speed SS1= 100mm/min

Standstill toleranceSOS = 2.5mm

Safely reduced speedscreen


n_max for step 1 =625mm/min

Copy parameters andopen dialog to changethe password.

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Description Remark

Assign new password.The example uses thevalue 1.

Activate settings.

Copy RAM to ROM,save.

Axis backup issufficient (start withAxis parameters).

Note:Restart only uponcompletion of theconfiguration.

With Version V2.5(SINAMICS), the twodrives need to beadapted to the clock-synchronizedPROFIBUS.

1. p10 = 952. p9510 = 13. p10 = 0

Copy RAM to ROM (onSINAMICS).

Perform Power Onreset.

Go online, loadconfiguration onto thePG and save.

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The use of drive-integrated safety functions is selected, these functions canbe activated resp. deactivated via the F-CPU operator elements.

Only the following messages shall be visible.

These messages do not affect the functionality described above. They onlystate that the safety functions test stop must be performed in the drives(A1697). These are warnings, that means the drives can be activated andtraversed as soon as the SIMOTION configuration has been completed.

6.4.2 Configuring the safety data block on SINAMICS

The telegram extension for the so-called safety data block was created in

section 6.2.4 Telegram configuration. This data block shall be suppliedby SINAMCS Integrated with the necessary data. Six bytes / three wordsare required. The data are transferred from the drive to the SIMOTION. Nosafety signals are transferred from the SIMOTION to the drive.The operator connects the process data via the SINAMICS BiCo wiring.The sequence of the individual signals in the safety data block may not bechanged.

The feed back bits of the drive safety functions are transferred in the firstword.

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Perform the following BiCo wiring for each drive:

The status word is then provided in parameter r2089[3].

The effective setpoint speed limitation when selecting SLS (r9733) as afloating point number is transferred in the second and third word.

The safety data block wiring at the drive end has the following assignment:

The SINAMICS safety status signals are displayed in the SIMOTION sys-tem variableD435.Axis_1.drivedata.drivesafetyextendedfunctionsinfodata.state .

The setpoint speed limitation value is displayed inD435.Axis_1.drivedata.drivesafetyextendedfunctionsinfodata.safespeedlimit .

Safety statusword r2089[3]

effective setpoint speed limitingr9733 [0] = p9531 [x] * p9533 / p9520(x: active SLS sta e)

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6.5 SIMOTION

6.5.1 Creating SIMOTION axes

On the SIMOTION, the axes must be created as follows using the Commis-sioning Wizard. SERVO_02 is assigned to Axis_1, SERVO_03 is con-nected accordingly to Axis_2. This example shows the procedure for anaxis (Axis_1). Before loading the project into the SIMOTION, you must con-figure both axes.

Description Remark

Start CommissioningWizard by double-clicking Insert axis inthe Project Navigator.

In the example, thefirst axis is calledAxis_1.

Speed control andPositioning areactivated.

The preset values arekept. They refer to alinear axis withelectrical drive.

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Description Remark

In the example, thevalues preset in theUnits screen arekept.

Modulo correction isnot activated in theexample.

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Description Remark

The assignmentbetween the

SIMOTION object(Axis_1) and theSINAMICS axis(SERVO_02) is madein this screen.

Perform dataadjustment with thedrive (normalizationspeed and maximumspeed).

Check whether thePROFIdrive telegram105 is selected.

Press the buttonChange PROFIdrivemessage frame toopen the followingscreen.

Since the configurationof the SINAMICSdrives has beencompleted, you mustonly check whether thevalues have beencorrectly transferred. Ingeneral, no changesmust be made.

Check particularly the

message frameextension by threewords at the input end,because this isrequired to transfer thesafety data from thedrive to theSIMOTION.

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Description Remark

The encoder isassigned here.

Press the button Datatransfer from the driveto transfer the encoderdata to the Wizard.

Further encoder dataare displayed here. Nochanges are required ifthe data have beencorrectly transferredfrom the drive.

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Description Remark

Terminate Wizard forthe creation of theobject axis on theSIMOTION.

Upon completion of theCommissioningWizard, someparameters must stillbe changed in the

example. These aredisplayed in thefollowing screens.

Dynamic responsescreen

The speed is set to thevalue 83.33 mm/s(corresponds to500rev/min).

The value

333.33mm/s

2

isentered foracceleration and delay.

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Description Remark

Limits screen

Set the maximumspeed to 500mm/s.

Closed-loop controlscreen

In the example, theservo gain factor is setto 12 1/s.

With the second axis,differences arise in the

Drive assignmentscreen.

The logical hardwareaddresses according toServo_03 are enteredhere.

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Description Remark

With the second axis,differences also arisein the Encoderassignment screen.

The encoder data canbe entered in theWizard by pressing thebutton Data transferfrom the drive.

With the second axis,differences also arisein the Encoder datascreen.

Further encoder dataare displayed here.Changes are notrequired if the datahave been properlytransferred from thedrive.

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Description Remark

Since theSafetyalarms of the

SIMOTION do not yetcompletely correspondto the specification, werecommend that youhidde these alarms forboth axes.

Open the screen byselecting the TechFaultTask in the runtimesystem, then press thebutton Alarmconfiguration.

The axis-specificreactions in thisexample do not usethese alarms either.

Note: As from Version4.1.4, the alarm func-tion is correct. How-ever, we recommendthat you refrain fromusing the alarms forprogramming axis-specific reactions.

Upon completion ofcommissioning bothaxis on the SIMOTION,save the project andload it onto theSIMOTION (in theProject Navigator,place focus on D435).

If the commissioningwas performed asshown here, allsettings for the safetydata block are correct.

You should only checkif the start address wascorrectly entered (276for Axis_1 and 302 forAxis_2)

Axis_1

Axis_2

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6.5.2 SIMOTION programs

This section briefly presents the programs used in the function example.

We have refrained from providing the program code resp. a detailed de-scription because the programs include comments.

ST programs include comments directly in the code. With MMC programs,commented blocks are marked with a green triangle in the upper right cor-ner. You can open the comment by marking the block and pressing theright mouse button to open a menu. Here, select the entry Enter com-ment....

6.5.2.1 IO_ReadWrite (read in resp. write digital I/Os)

The digital inputs of the SINAMICS are used to control the axis movements.These inputs are read in on the SIMOTION via the I/O variableio_cu320_inword. The variable io_cu320_outword is used to control theSINAMICS outputs (this variable is not used in this example). The inputsare used, for example, to activate the drives, start traversing program, ac-knowledge faults and start test stop resp. forced dynamization.

These two variables are created in the Project Navigator under I/O as de-scribed in the following.

In this example, the DIs are provided by the SINAMICS at the address 310

(corresponding to PZD 2 of the Control Unit send direction). Use the Ad-dress 298 (corresponding to PZD 2 of the Control Unit receive direction) forthe outputs.

The program IO_ReadWrite was transferred from the FAQ with the num-ber 29063656. Program sections which are not required have been re-moved subsequently. A detailed documentation and the program code canbe downloaded at the following link:

http://support.automation.siemens.com/WW/view/de/29063656

The program is processed in the Background Task and provides the signalsat the digital inputs of the SINAMICS using the above-stated variables for

the SIMOTION program sequence.

6.5.2.2 Axis_01.mmc_bg_task1 (runtime controller for Axis_1)

This program is used to actuate the upper training case drive (Axis_1; resp.SERVO_02). The program is cyclically processed in the BackgroundTaskand is responsible for activating/deactivating the axis enable, error ac-knowledgement and for starting and stopping the traversing programmt_axis_1.

Program functions:-S5 (DI 0) Set / remove enables for Axis_1-S6 (DI 1) Start resp. stop traversing program mt_axis_1.-S9 (DI 6) Acknowledge alarms

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6.5.2.3 Axis_02.mmc_bg_task2 (runtime controller for Axis_2)

This program is used to actuate the lower training case drive (Axis_2; resp.

SERVO_03). The program is cyclically processed in the BackgroundTaskand is responsible for activating/deactivating the axis enable, error ac-knowledgement and for starting and stopping the traversing programmt_axis_2.

Program functions:-S7 (DI 2) Set / remove enables for Axis_2-S8 (DI 3) Start resp. stop traversing program mt_axis_2.-S9 (DI 6) Acknowledge alarms

6.5.2.4 Axis_01.mt_axis_1 (traversing program for Axis_1)

The traversing program comprises three traversing commands which arecyclically called by mmc_bg_task1 while a HIGH level is pending at -S1.That means, after starting the traversing program once, the axis performsan endless movement until this is aborted by activating a safety functionor through a LOW level at -S1. This program is processed in the Motion-Task_3. This task is cyclically started by the programAxis_01.mmc_gb_task1.

6.5.2.5 Axis_02.mt_axis_2 (traversing program for Axis_2)

The traversing program comprises three traversing commands which arecyclically called by mmc_bg_task2 while a HIGH level is pending at -S3.

That means, after starting the traversing program once, the axis performsan endless movement until this is aborted by activating a safety functionor through a LOW level at -S3. This program is processed in the Motion-Task_4. This task is cyclically started by the programAxis_02.mmc_bg_task2

6.5.2.6 Axis_01.mt_safety_axis_1

This program is used to perform the axis-specific reactions to the activation/ deactivation of safety functions. Since several safety functions can be ac-tive at the same time, you must first determine the priority before you canperform the axis-specific reaction. For this, determine the value of a vari-

able which is used to select the reaction (via CASE instruction). In the ex-ample, the reactions described below are initiated for the individual func-tions. When they have been performed, the variables for the status of theindividual safety functions (determined in ST_Main.extsafety) and for priori-tization (determined in Axis_01.mt_safety_1) are reset. The program is pro-cessed in MotionTask_6.

STONo special reaction is required when activating STO because the pulsesare immediately deleted. No reaction is required when deactivating STObecause a new ON command must be set after deactivating STO.

SS1

When activating SS1, the axis must be switched to follow-up mode and the

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movement program Axis_01.mt_axis_1 aborted. For this, the Motion-Task_3 and the current traversing command are aborted. When deactivat-ing SS1, the MotionTask_3 is reset in order to restart it again. Since SS1

directly leads to an STO, a new ON command must be entered to start theaxis movement.

SS2When activating SS2, the axis must be switched to follow-up mode and themovement program Axis_01.mt_axis_1 aborted. For this, the Motion-Task_3 and the current traversing command are aborted. When deactivat-ing SS2, the MotionTask_3 is resumed. The movement automatically con-tinues upon deactivation. No further command is required.

SOSWhen activating SOS, the axis movement is decelerated via a STOP com-mand in position control until it stops. Afterwards, the MotionTask_3 is

aborted to prevent traversing by the following positioning command. Whenactivating SOS, the MotionTask_3 is resumed and the next pending posi-tioning command processed. That means, no command need be entered inorder to restart the axis movement.

SLSWhen activating SLS, the permissible maximum positioning speed(SIMOTION variable: pluslimitsofdynamics.velocity) is reduced to the valuetransferred by the SINAMICS (via the so-called safety data block) to theSIMOTION. The movement is performed at the reduced speed. When de-activating SLS, this limit value is reset to the original value.

6.5.2.7 Axis_02.mt_safety_axis_2

See 6.6.2.6 where this program is processed in MotionTask_7 and the axismovement of Axis_2 is controlled via MotionTask_4.

6.5.2.8 ST_VarGlobal

The variables required for evaluating the safety status word are defined inthis ST program.

6.5.2.9 ST_Main

This program comprises three subprograms: startup, extsafety andtechfault.

Note:

As from Version 4.1.4, the function of the safety messages of SIMOTION50201 to 50203 is correct. In earlier versions, these did not yet completelycorrespond to the specification. In general, we recommend that you cycli-cally evaluate the safety status word and refrain from using the alarms foraxis-specific reactions.

startupThis program assigns the axis instances, that means it determines whichaxis corresponds to which variable. Further, the speed limit value of theSIMOTION configuration is stored in a variable. When activating SLS, this

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value is overwritten and must be provided upon deactivation. The programis processed in the StartupTask.

extsafetyThis program evaluates the safety status word to obtain information aboutthe status of safety functions. A differentiation is made between thestatuses activated / selected (incoming event), active, deactivated /deselected (outgoing event) and inactive. Depending on this information,the motion task is started which comprises the program initiating the axis-specific reaction to the safety functions (MotionTask_6 for Axis_1 and Mo-tionTask_7 for Axis_2).

In the example, the program is processed in the IPO task, which is onlynecessary when using the functions SS2 or SS1. Without these two func-tions, processing in the BackgroundTask is sufficient. When activating thesafety functions SS1 resp. SS2, the drive is immediately separated from the

higher-level set point of the SIMOTION upon activation of the function andyou must prevent following errors leading to pulse suppression (with stan-dard setting). In such a case, processing must therefore be performed asquickly as possible. The functions SOS and SLS include a configured timerbetween selection and activation; for this reason, more time is available forthe reaction of the SIMOTION.

techfaultThis is an empty program (dummy) which must be integrated in the Tech-nologicalFaultTask. If this program is missing, the operating status of theSIMOTION changes to the operating status STOP in case of a Tech-nologicalFault alarm.

6.5.2.10 other_MMCs.peripheralfault

This is an empty program (dummy) which must be integrated in the Pe-ripheralFaultTask. If this program is missing, the operating status of theSIMOTION changes to the operating status STOP in case of a Peripher-alFault alarm.

6.5.2.11 other_MMCs.executionfault

This is an empty program (dummy) which must be integrated in the Exe-cutionFaultTask. If this program is missing, the operating status of the

SIMOTION changes to the operating status STOP in case of a Execu-tionFault alarm.

6.5.3 Runtime system configuration

The different SIMOTION programs must be assigned to the different tasks.The function example is based on the following configuration.

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6.5.4 SIMOTION messages

6.5.4.1 Safety messages

The SIMOTION outputs three messages for the extended safety functions.

50201: Safety alarm in the drive

50202: Drive starts Safety Integrated Extended Function

50203: Drive terminates Safety Integrated Extended Function

These messages shall not be used to configure the axis-specific reactionsof the SIMOTION.

6.5.4.2 Other messages

When activating the different safety functions, further messages are dis-played. These are to be expected and do not display an incorrect behavior.

20005: Device type: X, log. address: Y faulty.This error occurs among others when activating STO and SS1 and statesthat the drive has been deactivated.

30002: Command aborted (reason: X, command type: Y)This message is also output upon the activation of STO and SS1 and stopof positioning through deactivation of -S6 resp. S8. The reason for this isthat the current positioning command was aborted prior to or during proc-essing.

40002: The programmed speed is limitedThis error occurs when activating SLS if the configured speed is above thelimit for SLS.

40005: Missing enable(s) (Parameter1: X) and/or incorrect mode (Parame-ter2: Y)This error occurs when activating STO and indicates missing axis enableswith a pending movement command.

6.6 Downloading the Sample Project

So far, we have described step by step the configuration setup of the func-tion example. If you wish to load the sample project directly onto the hard-ware, please note the following steps.

First, perform a general reset of all components (S7-F-CPU, SIMOTIONand SINAMICS) resp. reset them to the factory setting.

6.6.1 Loading the S7-F-CPU configuration

First download the hardware configuration of the S7-F-CPU. Double-clickHardware to open the hardware configuration.

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Depending on the preset values resp. the previous F-CPU configuration,you may have to adapt the baudrate of the PC/PG interface for download-ing the F-CPU hardware configuration. If the SIMOTION and the F-CPU

have the same PROFIBUS address (the default for both is 2), then firstconnect the F-CPU to the PC/PG to download the hardware configurationthus changing the bus address and baud rate to the values stated in sec-tion 4.3.1. Then you can connect the SIMOTION to the PROFIBUS net-work. Before you can go online, change the baud rate according to section4.3.1.

Note:If a safety program was installed on the CPU before, this is protected by apassword. You must know this to perform the download. If you do not knowthe password, you have to destroy the memory card using a suitable device(e.g. SIEMENS PG). Deletion resp. formatting using a card reader will de-

stroy the card.After downloading the hardware configuration, load the program blocksonto the F-CPU.

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First open the screen for loading the safety function via the yellow buttonin the function bar. Then press the button Load to start the download from

this screen. The remaining (unsafe) blocks are loaded as usual.

6.6.2 Loading the SIMOTION and SINAMICS configuration

First, load the hardware configuration of the SIMOTION. In general, noonline connection is set up to the SINAMICS without performing this step.Double-click Hardware to open the hardware configuration.

After performing the download, open the SCOUT from the SIMATIC project(double-click Commissioning).

1

2

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Here you can load the complete SIMOTION and SINAMICS configuration.

Since the series numbers of the encoder modules do not coincide with thedevices used to create the sample project. Various safety faults are pend-ing after the download. Analogously to series commissioning, you have to

transfer the new series numbers to the safety configurations. This is donevia Confirm hardware replacement. The easiest method is to open thesafety screen on both drives and press the button Confirm hardware re-placement.

Then start the backup process from RAM to ROM for the SINAMICS andperform a restart (Power On reset).

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6.7 Acceptance Test

To verify safety-related parameters, you have to perform an acceptance

test when first commissioning the machine and changing the safety-relatedparameters. The acceptance test must be recorded accordingly. The ac-ceptance certificates must be stored and archived appropriately.

The acceptance test must be performed after successful parameterizationand Power On reset.

Information regarding the acceptance test, the acceptance certificate andan example for the corresponding acceptance certificate is provided In the"Function Manual SINAMICS S120 Safety Integrated" (FHS) in the sectionAcceptance Test and Acceptance Certificate.

7 History

Version Date Change

V1.0 11/2009 First edition

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