SIMOTION with SINAMICS S120 Safety Integrated … Example No. MC-FE-I-011-V10-DE SIMOTION with...

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

SIMOTION with SINAMICS S120

Safety Integrated Extended Functions Failsafe Drives on SIMOTION D435

with PROFIsafe Control via PROFIBUS Data Exchange Broadcast

SIMOTION mit SINAMICS S120 Fehlersichere Antriebe eitragsArticle ID: 38701812

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

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Preliminary remarks

The Functional Examples dealing with “Safety Integrated” are fully functional and tested automation configurations based on I DT & IA standard products for simple, fast and inexpensive implementation of automation tasks in safety engineering. Each of these Functional Examples covers a frequently occurring subtask of a typical customer problem in safety engineering.

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

Important note

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

These Safety Functional Examples do not relieve you of the responsibility in safely and professionally using, installing, operating and servicing equipment. When using these Safety Functional Examples, you recognize that Siemens cannot be made liable for any damage/claims beyond the liability clause described. We reserve the right to make changes to these Safety Functional Examples at any time without prior notice. If there are any deviations between the recommendations provided in these Safety Functional Examples and other Siemens publications - e.g. Catalogs - then the contents of the other documents have priority.



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Contents

1 Warranty, Liability and Support ................................................................... 5

2 Automation Function .................................................................................... 6 2.1 Function Example Description......................................................................... 6 2.2 Advantages / Customer Benefits ..................................................................... 9

3 Components Required................................................................................ 10 3.1 Hardware Components ................................................................................. 10 3.2 Software Components................................................................................... 11 3.2.1 Engineering software .................................................................................... 11 3.2.2 Firmware....................................................................................................... 11

4 Configuration and Wiring ........................................................................... 12 4.1 Overview of the Hardware Configuration....................................................... 12 4.2 Hardware Component Wiring ........................................................................ 13 4.2.1 Control voltage wiring.................................................................................... 13 4.2.2 DRIVE-CLiQ wiring ....................................................................................... 14 4.3 Major Hardware Component Settings............................................................ 15 4.3.1 Bus interfaces ............................................................................................... 15 4.3.2 Bus topology ................................................................................................. 18

5 Overview and Operation ............................................................................. 19 5.1 Operating Description ................................................................................... 19 5.2 List of Input Signals....................................................................................... 21

6 Sample Project ............................................................................................ 22 6.1 Passwords .................................................................................................... 22 6.2 Basic Configurations ..................................................................................... 23 6.2.1 Hardware configuration of the failsafe SIMATIC Controller............................ 23 6.2.2 Inserting SIMOTION in the existing SIMATIC project .................................... 28 6.2.3 Basic commissioning of the SINAMICS drives (without safety)...................... 34 6.2.4 Telegram configuration.................................................................................. 38 6.2.5 Inserting F-CPU in the SIMOTION HW Config and connecting it................... 40 6.3 Programming the Failsafe Controller ............................................................. 45 6.4 Parameterizing the Safety Functions in SINAMICS ....................................... 51 6.4.1 Configuring the safety functions on the drives ............................................... 51 6.4.2 Configuring the safety data block on SINAMICS ........................................... 55 6.5 SIMOTION .................................................................................................... 57 6.5.1 Creating SIMOTION axes ............................................................................. 57 6.5.2 SIMOTION programs .................................................................................... 65 6.5.3 Runtime system configuration ....................................................................... 68 6.5.4 SIMOTION messages ................................................................................... 70 6.6 Downloading the Sample Project .................................................................. 70 6.6.1 Loading the S7-F-CPU configuration............................................................. 70 6.6.2 Loading the SIMOTION and SINAMICS configuration................................... 72



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6.7 Acceptance Test ........................................................................................... 74

7 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 the use of the examples, information, programs, engineering and performance data 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 of intent, gross negligence, or injury of life, body or health, guarantee for the quality of a product, fraudulent concealment of a deficiency or breach of a condition which goes to the root of the contract (“wesentliche Ver-tragspflichten”). However, claims arising from a breach of a condition which goes 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. The above 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 S120 drives according to IEC 61800-5-2:

Name Function Description

STO Safe Torque Off • Failsafe disconnection of the torque-forming power supply from the motor.

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

SBC Safe Brake Control

• SBC is only used with existing motor brake which is connected to the power connector via the outputs.

• SBC always responds in combination with STO or when the internal safety monitors respond with failsafe pulse suppression.

SS1 Safe Stop 1 • Fast and safely monitored drive standstill along the OFF3 ramp.

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

SS2 Safe Stop 2 • Fast and safely monitored drive standstill along the OFF3 ramp.

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

SOS Safe Operating Stop

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

SLS Safely-Limited Speed

• Safe drive speed monitoring.

• Parameterizable cutoff reaction in case of limit value violation.

SSM Safe Speed Monitor

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

These extended safety functions can be activated both via PROFIsafe with PROFIBUS and via a terminal extension module TM54F. In the present example, the safety functions are activated from a SIMATIC F-CPU using the 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-CPU using 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-stated telegram. In this case, the SIMOTION serves as PROFIBUS master and the F-CPU as I slave. The PROFIdrive communication is established be-tween the SIMOTION and the SINAMICS, the PROFIsafe telegrams are exchanged 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) and the SAFETY training case.

The following figure provides a sample overview of the assumed machine configuration.

Further considerations are based on the following safety functions.



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Safety function

Description Reaction

SF1 Actuation of the emergency stop button

Fast controlled stopping of drive 1 -> followed by pulse suppression (SS1)

Stopping of drive 2 with immediate pulse suppression (STO)

SF2

The drive 1 must be quickly stopped when opening the protective door 1. The drive 1 must then be stopped with speed setpoint = 0 and the standstill position safely monitored.

The SIMOTION decelerates the drive 1 with position control. Upon expiry of a waiting time, the standstill position is safely monitored (SOS)

SF3 With open protective door 2, the drive 2 may not exeed a maximum 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 data exchange 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 Double Motor Module. Motion Control is performed via a SIMOTION D435 and the motor control via a SINAMICS S120. The Double Motor Module controls the two mutually independent servo motors. A Smart Line Module is used as infeed unit.

The safety-related signals are acquired via failsafe ET200M inputs and logically processed in the F-CPU. The F-CPU uses the failsafe data to create a PROFIsafe telegram for each drive. This is transferred via the PROFIBUS data exchange broadcast to the SINAMICS drives where it activates 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 time period, the standstill position is safely monitored (activation of the SOS function). When the door is closed, the axis 1 is restarted (deactivation of the SOS function). When the protective door 2 is opened, the speed for drive 2 is monitored for a configurable maximum value (SLS function). The setpoint speed is limited to 80% of the selected SLS step. When closing the simulated door, the speed limitation is canceled without influencing the other 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 diagnostic information

• 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 failsafe input module

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

SIMATIC S7 failsafe output module

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

SINAMICS failsafe Terminal 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 Siemens Protective door simulation switches

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

Mushroom pushbutton, red, 16mm

3SB2000-1AC01 1 Siemens Emergency stop control device

S1 Holder with solder pins 3SB2908-0AB 1 Siemens

Pushbutton, flat pushbutton, 16mm, white

3SB2000-0AG01 1 Siemens Reset button

S4 Holder with lamp socket, lamp and solder pins

3SB2455-1B 1 Siemens

Load resistors

R1 .. R8 1kOhm 1W

Type PO595-0 Style 0207 Power Metaloxide film

resistors 1

Yageo Europe

ST 2,5-QUATTRO-TG 3038451 8 Phoenix Contact Terminals for load resistors

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

Phoenix Contact

Load resistor R9 SMA0207 1K2 1% TK WID_MET_SHT_1K2_+-1%_600mW_+50ppm_02

07 1 Beyschlag

TERMINALS_ACCESS_DUMMYPLUG_TYPE1_GRAY

280-801 1 WAGO Terminals 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 components listed. Alternatively, you can use other, functionally equivalent components. In such cases, you may have to use another component parameterization resp. wiring. Components highlighted in yellow are not relevant 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 Safety Programming

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 all SINAMICS components.

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



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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.

CU320

DRIVE CLiQ

X100

X101

X102

X103

PROFIBUS

SLM

X126

DMM

DRIVE CLiQ

X200

X201

X202

X203

Drive 2

Drive 1

D435

DRIVE CLiQ

X100

X101

X102

X103

PROFIBUS

X126

X127

Ethernet

X120

X130

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 in the drives. For this, control and status signals are exchanged between the drives 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 and SIMOTION.

4.3.1 Bus interfaces

Programming device / PC

• PROFIBUS address = 0

• Since the SIMOTION used is the bus master, the PROFIBUS interface of 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 not be ticked). After increasing the transfer speed in the HW Config to 12Mbit/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 coincide with 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 be set via the DIL switch; see section 6.2.1 Hardware configuration of the failsafe SIMATIC controller.

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

• The DRIVE-CliQ topology of the SINAMICS components is complied with.

• The motors are connected to the Motor Module via power and encoder cable.

• The Motor Module has been properly connected to the infeed unit (dc link 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 the “RUN“ state. In the example, this is done via the SCOUT. For this, mark the object 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 the SIMOTION. 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 Safety training case which is used to activate the different safety functions. The switches -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 acknowledge pending errors. In this example, the switches on the SIMOTION training case 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). -S6 starts and stops the related traversing program. The axis 2 (lower motor) is enabled 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 is activated for drive 1 (upper motor); that means the drive is decelerated along the OFF3 ramp and STO activated. STO is directly triggered with drive 2 (lower motor), that means the drive coasts down. When triggering the 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 means the drive is decelerated by the SIMOTION until it stops. Upon expiry of a configurable time period, the standstill position is safely monitored by the drive. 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 the safety function SLS. Upon expiry of a defined time period, this limit value is monitored by the safety function SLS. When closing -S3, the SLS is deacti-vated and the speed limitation canceled on the SIMOTION. The drive can now 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 1 Start / stop traversing program

DI2 -S7 Drive 2 Set / remove axis enables

DI3 -S8 Drive 2 Start / stop traversing program

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 button Drive 1: SS1

Drive 2: STO

F-DI1 -S2 Protective door 1 (for drive 1)

SOS

F-DI2 -S3 Protective door 2 (for drive 2)

SLS

F-DI3 -S4 Acknowledgement button

Failsafe acknowledgement (drive 1 & 2) and depassivation (all F slaves)



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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 and SINAMICS S120. Distributed safety is required to program the F-CPU.

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

6.1 Passwords

To simplify matters, we have used a common safety password for program and hardware regarding the SIMATIC components used in the project. A password 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 SIMATIC Manager, insert a SIMATIC 300 station in the project.

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

For this, move the mo-dules included in the parts list from Chap. 3.1 Hardware Components via Drag&Drop from the catalog screen to the configuration screen.

Make address settings for the DP interface as described in Chap. 4.3.



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Description Remark

Configuring the F-CPU

In the Properties screen of the F-CPU in the Protection tab, activate the access protection for the F-CPU and protect it by a password.

Activate safety program ("CPU contains safety program.")

Configuring the F-DI module.

Configuring the PROFIsafe address according to the DIL switches.


Configuring F-DI 0 (Channel 0, 12)



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Description Remark






Configuring the F-DO module.

Configuring the PROFIsafe address according to the DIL switches.



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Description Remark

Configuring the F-DO module.

Configuring F-DO 7

Save and compile HW Config

Configuring the DP interface as slave (step 1)



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Description Remark

Configure the DP inter-face as slave (step 2). Press the button “New“ to open a second screen. Press the button “OK“ to accept the default setting. Note: This link is automati-cally inserted here by the system to allow a proper compilation of the HW Config. This link is not required for the example and can be deleted after-wards (after creating the F-link).



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6.2.2 Inserting SIMOTION in the existing SIMATIC project

Description Remark

Insert another SIMATIC 300 station in the existing object.

Then rename (if required) the station; e.g. into “SIMOTION D“



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Description Remark

Select the corresponding SIMOTION component from the catalog and enter it in the working area (Drag&Drop).

Configure and network the DP interface of the SIMOTION.

DP2 is used in the example (see also section 4.3.2 Bus topology)

Save and compile. Then load the HW Config into the SIMOTION. You can now close the HW Config.



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Description Remark

Save and compile the HW Config.

Load the HW Config into the SIMOTION.

Insert the PC in NetPro to generate the routing information required to access the SINAMICS online.

From the folder “Stations“, move the object “PC/PG“ into the working area.

“Double click“ the Properties screen.



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Description Remark

Select the tab “Interfaces“ and press the button “New“.

In the following screen, select “PROFIBUS“and confirm with OK.

Set the PG PROFIBUS address to the value 0 and establish the connection using the already configured PROFIBUS (selection “PROFIBUS(1)“)

Confirm settings with “OK“.



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Description Remark

Assign the interface on the PC/PG.

In the example, the computer is equipped with the CP5512 interface which shall be connected to the “PROFIBUS(1)“.

Press the button “Assign“ to set up the connection.

Check whether the interface has been set to “active“.

Press “OK“ to close the screen.

The PG now comprises the active interface.

Store and compile the project and load it into the CPU (place focus on the SIMATIC CPU).



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Description Remark

The SIMOTION is now integrated in the existing project.



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6.2.3 Basic commissioning of the SINAMICS drives (without safety)

Description Remark

Open the SCOUT / STARTER from the SIMATIC project (-> Double-click “Commissioning“)

Go online.

Start automatic drive configuration.

Select “Servo“ mode for both drives.

Go offline and “Store and compile“



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Description Remark

Reconfiguring Drive 1

In the project navigator, open the configuration screen for drive 1 (SERVO_02).

“Configure DDS“ starts the guided reconfigu-ration.

Note: The following section only describes the screens to be changed.

Reconfiguring both drives

Configure a signal for “Infeed in progress“ (p0864).

The fixed binector 1 is used in the example.

Note: In real applications, you should not use the fixed binector 1 as the signal for “Infeed in progress“ (p0864).



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Description Remark


The second drive has no Drive-CLiQ en-coder; the motor must be selected manually.

The motor used in the example has type 1FK7022 - 5AK71 - 1AG0.


Analogously to the motor, you must manually select the encoder. For this, also use the type number (MLFB).

Save configuration, go online and load the modified project into the SINAMICS.



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Description Remark

Via the Project Naviga-tor, open the “Speed controller“screen with the object SERVO_02.

For both drives, the speed controller has been set as follows in the example: P gain = 0.1 Nms/rad Reset time = 10ms

On both drives, adapt some parameters in the expert list.

Adaptation to the 230V operation.

Configuring the OFF3 ramp.

Interconnect alarm acknowledgement with -S9 (= DI 6).

p2101 = r722.6 in the CU expert list

Copy RAM to ROM (on SINAMICS), load con-figuration onto the PG and save.



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6.2.4 Telegram configuration

Description Remark

In the SCOUT (offline!), open the screen for configuring the PROFIdrive telegram. Select telegram type 105 for both drives.

Create PROFIsafe slot for both drives via the button “Insert line“ and “PROFIsafe“.

Select telegram type 390 for CU.



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Description Remark

Insert telegram extension for the so-called safety data block.

Three words are required to transfer data from the drive to the SIMOTION (input data). The SIMOTION does not transfer data to the drive (output data)

Insert this telegram extension for both drives.

Enter changes in the HW Config.

The telegram configuration should look as displayed here (same address assignment assumed).

Save, go online and load 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 of the SIMOTION and enter the F-CPU.

For this, enter the object “CPU 31X” from the folder “already configured stations“ in the working area.

The screen displayed is automatically opened.

Press the “Connect“ button.

After closing and reopening the Properties screen of the DP slave, it should look as displayed here. The default connection can be deleted.

Another tab “F configuration“ is displayed. Select this tab and press the button “New“.



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Description Remark

Create the F-connection for the first drive.

Settings in the example:

Address (LADDR) = 15

Input address= 76

Exit the screen with “OK“ and create the second F-connection via the button “New“ in the Properties screen.

Note: The drive 1 has the PROFIsafe address 76. The F-program, however, accesses the drive via the address 15. The address 76 is only required for data exchange broadcast.

Create the F-connection for the second drive.

Settings in the example:

Address (LADDR) = 21

Input address= 82

Exit the screen with “OK“ and create the second F-connection via the button “New“ in the Properties screen.

Note: The drive 2 has the PROFIsafe address 82. The F program, however, accesses the drive via the address 21. The address 82 is only required for data exchange broadcast.



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Description Remark

Save and compile the HW Config and load it onto the SIMOTION.

To check the correct configuration of the PROFIsafe setting of the drives, open the screen “DP Slave properties“ of the SINAMICS.

The tab “Data Exchange Broadcast - overview“ shows the data exchange broadcast setting.

In the tab “Configuration“, press the button “Activate“.



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Description Remark

Place focus on object 1 resp. 2 (first resp. second line) and press the button “PROFIsafe“.

The following screens are opened for the F parameters of the two drives.

This screen shows the PROFIsafe settings of the first drive. No changes are required.

“F_Dest_Add“ designates the PROFIsafe address of the first drive. This is later required for the safety configuration of the drives. The value is 3FEhex (= 1022 dez).

Note: The watchdog time (F_WD_Time = 150msec) must match the OB35 cycle. In the example, this is 100msec.



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Description Remark

This screen displays the PROFIsafe settings of the second drive. No changes are required.

“F_Dest_Add“ designates the PROFIsafe address of the second drive. This is later required for the safety configuration of the drives. The value is 3FDhex (= 1021 dez).

Note: The watchdog time (F_WD_Time = 150msec) must match the OB35 cycle. In the example, this is 100msec.

Set the clock synchronization in the tab “clock synchronization“.

For this, checkmark “Synchronize drive to equidistant DP cycle“, set the DP cycle to 3ms and confirm with the button “Align“.



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Description Remark

Then open the HW Config of the F-CPU öffnen. The Properties screen of the MPI/DP interface should also display the connection.

The setting made in the tab “Configuration“ is displayed. No changes are required.

The settings made in the tab “F configuration“ are displayed. No changes are required.

Save, compile and load the HW Config of the F-CPU.

6.3 Programming the Failsafe Controller

We have intentionally selected a very easy safety program. In the present case, it is the main task of the safety program to compose the PROFIsafe control 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 safety program.

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 call up the safety program.

In this example, the safety program is processed in a function block (here FB1); that means the FB 1 must be inserted with the generation language F-KOP (F-LAD) or F-FUP (F-FBD).

Description Remark

Programming OB35

Calling up the safety program



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Description Remark

Programming FB1

Network 1: Activate automatic acknowledgement

Network 2: -S4 is used for acknowledgement (for errors which cannot be acknowledged automatically)

Programming FB1

PROFIsafe control word for drive 1; A15 and A16 (LOW/HIGH byte)

Network 3: A15.0 (STO) is permanently deactivated with VKE1.

Network 4: -S1 is connected to A15.1 (SS1).



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Description Remark

Programming FB1

PROFIsafe control word for drive 1; A15 and A16 (LOW-/HIGH byte)

Network 5: A15.2 (SS2) is permanently deactivated with VKE1.

Network 6: -S2 is connected to A15.3 (SOS). Inversion required because -S2 is wired as NO contact/NC contact.

Network 7: A15.4 (SLS) is permanently deactivated with VKE1.

Network 8: - S4 is connected to A15.7 (failsafe acknowledgement).

Networks 9 and 10: The VKE0 is connected to A16.1 and A16.2 and the SLS step 1 permanently activated.



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Description Remark

Programming FB1

PROFIsafe control word for drive 2; A21 and A22 (LOW-/HIGH byte)

Network 11: -S1 is connected to A21.0 (STO).



Network 14: A21.3 (SOS) is permanently deactivated with VKE1.

Network 15: -S3 is connected to A21.4 (SLS).

Network 16: - S4 is connected to A21.7 (failsafe acknowledgement).

Networks 17 and 18: The VKE0 is connected to A22.1 and A22.2 and the SLS step 1 permanently activated.



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Description Remark

The checkback signal SSM from the safety status word of both drives is AND-ed and connected to the lamp in S4 via DO7.

Creating new F runtime group

Here, the safety program (FB1) is assigned to the FC1 and the related I-DB defined.

Then generate the safety program and load it into the CPU.

In addition, load the standard blocks into the 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 the F-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 parameter changes.

On both drives, the safety functions STO, SS1, SS2, SOS, SLS and SSM are 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, STO and SLS are activated.

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

Description Remark

Open the “Safety integrated“screen of the drive 1/2 (SERVO_02 / SERVO_03) and activate commissioning mode with “Change settings“.

The password for first commissioning is “0“.



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Description Remark

“Safety integrated“ screen

The following must be configured in the example:

Select control with “Motion Monitoring via PROFIsafe“

Set enables to “Enable“.

“Configuration“ screen


PROFIsafe address with 3FEhex (for drive 1) resp. 3FDhex (for drive 2)

Speed limit (SSM) with 100 mm/min

Test stop signal source with DI7 of the SINAMICS



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Description Remark

“Safe Stops“ screen


Delay time SS1 -> Pulse suppression = 500msec

Delay time selection SOS -> SOS active = 500msec

Delay time SS2 -> SOS active = 500msec

Acceleration monitor-ing = 500mm/min

Shutdown speed SS1 = 100mm/min

Standstill tolerance SOS = 2.5mm

“Safely reduced speed“ screen


n_max for step 1 = 625mm/min

Copy parameters and open dialog to change the password.



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Description Remark

Assign new password. The example uses the value “1“.

Activate settings.

Copy RAM to ROM, save.

Axis backup is sufficient (start with “Axis parameters“).

Note: Restart only upon completion of the configuration.

With Version V2.5 (SINAMICS), the two drives need to be adapted to the clock-synchronized PROFIBUS.

1. p10 = 95 2. p9510 = 1 3. p10 = 0

Copy RAM to ROM (on SINAMICS).

Perform Power On reset.

Go online, load configuration onto the PG and save.



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The use of drive-integrated safety functions is selected, these functions can be 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 only state that the safety functions test stop must be performed in the drives (A1697). These are warnings, that means the drives can be activated and traversed 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 supplied by SINAMCS Integrated with the necessary data. Six bytes / three words are required. The data are transferred from the drive to the SIMOTION. No safety 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 be changed. The feed back bits of the drive safety functions are transferred in the first word.



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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 a floating 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 variable D435.Axis_1.drivedata.drivesafetyextendedfunctionsinfodata.state.

The setpoint speed limitation value is displayed in D435.Axis_1.drivedata.drivesafetyextendedfunctionsinfodata.safespeedlimit.

Safety status word r2089[3]

effective setpoint speed limiting r9733 [0] = p9531 [x] * p9533 / p9520 (x: active SLS stage)



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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 an axis (Axis_1). Before loading the project into the SIMOTION, you must con-figure both axes.

Description Remark

Start Commissioning Wizard by double-clicking “Insert axis“ in the Project Navigator.

In the example, the first axis is called “Axis_1“.

“Speed control“ and “Positioning“ are activated.

The preset values are kept. They refer to a linear axis with electrical drive.



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Description Remark

In the example, the values preset in the “Units“ screen are kept.

Modulo correction is not activated in the example.



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Description Remark

The assignment between the SIMOTION object (Axis_1) and the SINAMICS axis (SERVO_02) is made in this screen.

Perform data adjustment with the drive (normalization speed and maximum speed).

Check whether the PROFIdrive telegram 105 is selected.

Press the button “Change PROFIdrive message frame“ to open the following screen.

Since the configuration of the SINAMICS drives has been completed, you must only check whether the values have been correctly transferred. In general, no changes must be made.

Check particularly the message frame extension by three words at the input end, because this is required to transfer the safety data from the drive to the SIMOTION.



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Description Remark

The encoder is assigned here.

Press the button “Data transfer from the drive“ to transfer the encoder data to the Wizard.

Further encoder data are displayed here. No changes are required if the data have been correctly transferred from the drive.



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Description Remark

Terminate Wizard for the creation of the object axis on the SIMOTION.

Upon completion of the Commissioning Wizard, some parameters must still be changed in the example. These are displayed in the following screens.

“Dynamic response“ screen

The speed is set to the value 83.33 mm/s (corresponds to 500rev/min).

The value 333.33mm/s

2 is

entered for acceleration and delay.



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Description Remark

“Limits“ screen

Set the maximum speed to 500mm/s.

“Closed-loop control“ screen

In the example, the servo gain factor is set to 12 1/s.

With the second axis, differences arise in the “Drive assignment“ screen.

The logical hardware addresses according to Servo_03 are entered here.



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Description Remark

With the second axis, differences also arise in the “Encoder assignment“ screen.

The encoder data can be entered in the Wizard by pressing the button “Data transfer from the drive“.

With the second axis, differences also arise in the “Encoder data“ screen.

Further encoder data are displayed here. Changes are not required if the data have been properly transferred from the drive.



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Description Remark

Since the“Safety alarms“ of the SIMOTION do not yet completely correspond to the specification, we recommend that you hidde these alarms for both axes.

Open the screen by selecting the TechFault Task in the runtime system, then press the button “Alarm configuration“.

The axis-specific reactions in this example do not use these alarms either.

Note: As from Version 4.1.4, the alarm func-tion is correct. How-ever, we recommend that you refrain from using the alarms for programming axis-specific reactions.

Upon completion of commissioning both axis on the SIMOTION, save the project and load it onto the SIMOTION (in the Project Navigator, place focus on D435).

If the commissioning was performed as shown here, all settings for the safety data block are correct.

You should only check if the start address was correctly entered (276 for Axis_1 and 302 for Axis_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 the right 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 variable “io_cu320_inword“. The variable “io_cu320_outword“ is used to control the SINAMICS outputs (this variable is not used in this example). The inputs are 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) for the 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 can be 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 signals at 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 BackgroundTask and is responsible for activating/deactivating the axis enable, error ac-knowledgement and for starting and stopping the traversing program “mt_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 BackgroundTask and is responsible for activating/deactivating the axis enable, error ac-knowledgement and for starting and stopping the traversing program “mt_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 are cyclically called by “mmc_bg_task1“ while a HIGH level is pending at -S1. That means, after starting the traversing program once, the axis performs an “endless movement“ until this is aborted by activating a safety function or through a LOW level at -S1. This program is processed in the Motion-Task_3. This task is cyclically started by the program “Axis_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 are cyclically called by “mmc_bg_task2“ while a HIGH level is pending at -S3. That means, after starting the traversing program once, the axis performs an “endless movement“ until this is aborted by activating a safety function or through a LOW level at -S3. This program is processed in the Motion-Task_4. This task is cyclically started by the program “Axis_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 can perform 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 the individual 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.

STO No special reaction is required when activating STO because the pulses are immediately deleted. No reaction is required when deactivating STO because 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 the axis movement.

SS2 When activating SS2, the axis must be switched to follow-up mode and the movement 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.

SOS When 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. When activating SOS, the MotionTask_3 is resumed and the next pending posi-tioning command processed. That means, no command need be entered in order to restart the axis movement.

SLS When activating SLS, the permissible maximum positioning speed (SIMOTION variable: pluslimitsofdynamics.velocity) is reduced to the value transferred by the SINAMICS (via the so-called safety data block) to the SIMOTION. 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 axis movement 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 in this ST program.

6.5.2.9 ST_Main

This program comprises three subprograms: “startup“, “extsafety“ and “techfault“.

Note:

As from Version 4.1.4, the function of the safety messages of SIMOTION 50201 to 50203 is correct. In earlier versions, these did not yet completely correspond to the specification. In general, we recommend that you cycli-cally evaluate the safety status word and refrain from using the alarms for axis-specific reactions.

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



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

“extsafety“ This program evaluates the safety status word to obtain information about the status of safety functions. A differentiation is made between the statuses “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 only necessary when using the functions SS2 or SS1. Without these two func-tions, processing in the BackgroundTask is sufficient. When activating the safety functions SS1 resp. SS2, the drive is immediately separated from the higher-level set point of the SIMOTION upon activation of the function and you must prevent following errors leading to pulse suppression (with stan-dard setting). In such a case, processing must therefore be performed as quickly as possible. The functions SOS and SLS include a configured timer between selection and activation; for this reason, more time is available for the reaction of the SIMOTION.

“techfault“ This is an “empty“ program (dummy) which must be integrated in the Tech-nologicalFaultTask. If this program is missing, the operating status of the SIMOTION 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 the SIMOTION 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 reactions of 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 states that 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 “stop“ of positioning through deactivation of -S6 resp. S8. The reason for this is that the current positioning command was aborted prior to or during proc-essing.

40002: The programmed speed is limited This error occurs when activating SLS if the configured speed is above the limit 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 enables with 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, SIMOTION and 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-click “Hardware“ 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 first connect the F-CPU to the PC/PG to download the hardware configuration thus 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 section 4.3.1.

Note: If a safety program was installed on the CPU before, this is protected by a password. You must know this to perform the download. If you do not know the 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 blocks onto the F-CPU.



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First open the screen for loading the safety function via the “yellow“ button in 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, no online 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 the devices 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 done via “Confirm hardware replacement“. The easiest method is to open the safety screen on both drives and press the button “Confirm hardware re-placement“.

Then start the backup process from RAM to ROM for the SINAMICS and perform 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-related parameters. 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 parameterization and Power On reset.

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

7 History

Version Date Change

V1.0 11/2009 First edition

SIMOTION with SINAMICS S120 Safety Integrated … Example No. MC-FE-I-011-V10-DE SIMOTION with...

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