• Safety-related communication via standard PROFIBUS using the PROFIsafe profile
• Safe brake management (SBM)
• NC – internal pulse cancellation
• Safety-related software – relays

Further, additional expanded functions and supplementary functions have been incorporated in the NCK software release 06 of SINUMERIK 840D/DE.


1) Safe communication via the standard PROFIBUS with the PROFIsafe profile SINUMERIK 840D/DE is available as fail-safe DP master from NCK software release 06.03.30. In conjunction with fail-safe DP modules, this master allows fail-safe communications along PROFIBUS DP as specified in accordance with the PROFIsafe profile. This means that the safety-related input and output signals can be connected to the Safety Integrated function "safe programmable logic" (SPL) and therefore unified for PLC and NCK – SPL via PROFIBUS DP. The following fail-safe modules are presently available for the ET 200S distributed peripheral system: 

• Digital electronics module 4/8 F – DI 24V DC (6ES7138 – 4FA00 – 0AB0)
• Digital electronics module 4 F – DO 24V DC/2A (6ES7138 – 4FB00 – 0AB0)
• Power module PM – E F 24V DC PROFIsafe (6ES7138 – 4CF00 – 0AB0)
• Power module PM – D PROFIsafe (3RK1903 – 3BA00) for safe motor starters

Prerequisites:

• SINUMERIK 840D with NCU 561.4, 571.4, 572.4 or 573.4
• ET 200S PROFIsafe, fail-safe modules
• SINUMERIK software release from 06.03.30
• Software option "Peripheral interface via PROFIBUS – DP"
• Software option "SINUMERIK Safety Integrated"
• S7 configuring package "Distributed Safety"

2) Safe brake management The "safe brake management" comprises safe brake control (through two channels) and the safe brake test. In conjunction with the safety-related drive (SINUMERIK 840D and SIMODRIVE 611D), this means that a redundant holding system is available which extensively fulfills the requirements from the data sheet of the Berufsgenossenschaft [German trade association] (this data sheet involves itself with reducing the risk of hazard for vertical axes). This means, that for the first time, a brake application can be implemented across the board in safe technology in conjunction with our safety-related operation which fulfills the requirements of control Category 3 acc. to EN 954 – 1.

Prerequisites:

• SINUMERIK software release from 06.03.30

3) Safety-related NC – internal pulse cancellation

Using the safety-related NC – internal pulse cancellation, the pulses are enabled and feedback is provided as to whether the pulse cancellation was successfully internally via the drive bus. This means that the module-specific wiring of terminal 663 and AS1 / AS2 at the safety-related inputs and outputs (SGE; SGA) and on the DMP modules is not required. This significantly reduces the number of required NCK peripherals (I/O).

As the result of a worst-case analysis, the Berufsgenossenschaft [German Trade Association] still specifies that there must be a possibility of externally canceling the pulses. In order to fulfill this requirement, one onboard output of the NCU (refer to point 5) is connected to all 663 terminals of the control modules which are used in the control system.

Prerequisites:

• SINUMERIK software release from 06.03.30
• SIMODRIVE control module High Standard with direct and indirect measuring system input (6SN1118 – 0DM33 – 0AA0) or SIMODRIVE control module High Performance with direct and indirect measuring system input
  (6SN1118 – 0DJ23 – 0AA0 or 6SN1118 – 0DK23 – 0AA0)

4) Safety-related software relays

With the "safety-related software - relays" there is a certified standard software module for the safe programmable logic - both in the PLC as well as in the NCK. This standard SPL module is designed, for example, for the requirements when implementing Emergency Stop or controlling a protective door.

Prerequisites:

• SINUMERIK software release from 06.03.30

5) NCU onboard inputs and outputs can be used for Safety Integrated U p until now, the 4 binary input and 4 binary output signals on the NCU were only available for standard applications. Effective immediately, these can be used for safety integrated as SGEs and SGAs (safety-related inputs and safety-related outputs) independent of how the safe programmable logic is used.

Prerequisites:

• SINUMERIK software release from 06.03.30
• Cable distributor (6FX2006 – 1BA02)

6) Increasing the encoder limiting frequency

The encoder limiting frequency was increased from the previous 300 kHz up to 420 kHz.

Prerequisites:

• SINUMERIK software release from 06.03.30
• Cable which should be used: 6FX8002 – 2CA31 – 1CA0
• Maximum cable length is 20 m
• SIMODRIVE control module High Standard with direct and indirect measuring system input (6SN1118 – 0DM33 – 0AA0) or SIMODRIVE control module High Performance with direct and indirect measuring system input
  (6SN1118 – 0DJ23 – 0AA0 or 6SN1118 – 0DK23 – 0AA0)

7) Eight additional timers for the safe programmable logic (SPL)

The number of SPL timers has been increased from 8 to 16.

Prerequisites:

• SINUMERIK software release from 06.03.30

8) Direct communications between NCK and PLC – SPL

In an SPL application, in addition to the two-channel processing of safety-related signals, there is always a specific requirement for single-channel communications between the two SPLs (NCK and PLC). From software release 06.03.xx, there is now a new communications interface which is available. On the PLC side, this interface is represented as an expansion of DB 18 and new system variables were introduced on the NCK side for this particular purpose.

Prerequisites:

• SINUMERIK – a minimum software release of 06.03.30

9) Expansing the diagnostic possibilities

In software release 6, extensive expanded diagnostic functionality was introduced in the form of diagnostic screens/pictures and fault messages for Safety Integrated:

• Diagnostics display with axis-specific plain text displays of all of the relevant monitoring states for NCK and drive
• Diagnostics diagram for safe programmable logic
• Expanded functionality and fault messages for differences in the monitoring channels
  NCK and drive (fault messages 27101 to 27107)
• For a fault in a crosswise data comparison between NCK and PLC, the address of the terminal block, the DMP module and the input involved are displayed. In addition, the user can generate a text file which assigns/allocates a plain text to each SGE. This text is displayed when a fault condition develops (fault message 27090)
• New fault message to diagnose SGE - differences between NCK and the drive during commissioning
  (fault message 27004)
• Fault message to diagnose actual value differences (fault message 27005)
• The selection of the displayed fault messages can be parameterized by the user using machine data. In this case, the user can select between the following possibilities:
• All fault messages are displayed
• Alarms with the same significance/meaning are only displayed once
• Axial fault messages are replaced by a group message (this refers to the SINUMERIK alarm 27000 and to the SIMODRIVE alarm 300950 "Axis is not safely referenced")

Application Manual Safety Integrated 4th Edition (6ZB5000-0AA01-0BA0) in German
Application Manual Safety Integrated 4th Edition (6ZB5000-0AA02-0BA0) in English