There are no restrictions if the EMC specifications as well as the specifications for installing the frequency converter and the magnetically-operated switches have been carefully observed.
If the sensor (magnetically-operated switch) is influenced by the effect of EMC (which is not to be expected) and outputs inconsistent signals, then this is detected by the converter electronics and is brought into the fail-safe state (the switch manufacturer should be contacted for technical data and MTBF values).
Using the fail-safe inputs of the SINAMICS G120 and the safety functions integrated in the inverter, how can fail-safe JOG-Mode be implemented where the maximum travel velocity is safe limited?
After SLS has been activated in the SINAMICS G120, a minimum frequency of 1Hz must be reached within 5 s, otherwise, the SINAMICS G120 inverter goes into the safe operation (STO). This means that SLS may only be activated immediately before moving in the JOG-Mode.
In order to guarantee that the SINAMICS G120 in the JOG-Mode is always in a safe operating state, when the “JOG” button is not actuated, the STO or SS1 (depending on the parameterization) safety functions are activated and when the “JOG” button is actuated, the SLS safety function is activated.
This document only applies to SINAMICS G120 with Firmware (FW) V3.x
Content of Downloads
( 656 KB )
IEC 62061 Safety Evaluation Tool Project
( 6 KB )
ISO 13849-1 Safety Evaluation Tool Project
( 6 KB )
Note The Safety Evaluation Tool Projects can after dearchivation only be opened by using the Safety Evaluation Tool
Caution The functions and solutions described in this article confine themselves to the realization of the automation task predominantly. Please take into account furthermore that corresponding protective measures have to be taken up in the context of Industrial Security when connecting your equipment to other parts of the plant, the enterprise network or the Internet. Further information can be found under the Entry-ID 50203404.
Where can I find information on the ATEX-PTC-STO shutdown application?
This document describes the use of a thermistor motor protection device to sense the motor overtemperature (temperature rise) of an explosion-protected motor with integrated PTC thermistor in conjunction with a connected inverter with integrated safety-oriented shutdown.
The shutdown for a motor overtemperature (excessive increase in the motor temperature) is achieved by safely shutting down (cancelling) the motor control pulses of the inverter – and not by disconnecting the main line supply using a motor contactor. According to the ATEX Directive 94/9/EC, the following Ex classification is achieved for this application:
Ex II (2) GD
The same restrictions when using third-party motors apply as when using SIEMENS motors:
The motor must be able to use in combination with inverters
The EMC regulations must be adhered
SS1 and SLS are not permissible for continuous regenerative operation or loads that pull the drive, STO is always permissible
The pre-condition for using fail-safe functions is that the closed-loop control always functions perfectly. The drive (system comprising inverter + motor + driven load) must be designed so that all of the operating situations that can possibly occur for the particular application can be handled with absolute safety.
For more information please look at the documentation of the corresponding inverter.
STO = Safe Torque Off
SS1 = Safe Stop 1
SLS = Safely limited Speed
SBC = Safe Brake Control
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Can I deactivate the alarm A1699 (forced checking procedure required) alarm?
Although the safety functions in SINAMICS G120 / G120D and SIMATIC ET200S FC / ET200pro FC inverters with safety functionality are not activated, after 8 hours in operation alarm A1699 (forced checking procedure required) is displayed.
This alarm, which does not result in the inverter being shut down, cannot be deactivated. The reason for this is that even though the safety functions are not being used, a safety-relevant drive unit is still being used. However, the time period until the alarm is activated can be extended up to a maximum of one year.
The alarm can be “acknowledged” by switching-off the power supply voltage and switching-on again. The reason for this is that the inverter shutdown channels are then subject to a forced checking procedure.
- After entering the safety password (standard = 12345) call the Safe Torque Off (STO) screen form
- For test periods for shutdown paths, enter the value 8760.0 (this corresponds to 1 year)
- Accept the settings by pressing the Accept settings button.
- Acknowledge the checksums of the two processors.
SINAMICS G120 with Safety-CU
SINAMICS G120D with Safety-CU
SIMATIC ET200S FC with Safety-CU
SIMATIC ET200pro FC with Safety-CU
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Where do I find documents for acceptance- test and certificate for my safety G120D application?
Can I also use the Safety functions (STO, SS1 and SLS) of the SINAMICS G120 (CU240S DP-F and CU240S PN-F), SINAMICS G120D (CU240D DP-F and CU240D PN-F), SIMATIC ET200S FC, SIMATIC ET200pro FC for group drives?
A group drive is involved when several motors are connected to a common frequency inverter.
Extensive tests conducted for the safety functions implemented without using an encoder (sensorless) in the SINAMICS G120 (CU240S DP-F and CU240S PN-F), SINAMICS G120D (CU240D DP-F and CU240D PN-F), ET200S FC and ET200pro FC frequency inverters (STO, SS1 and SLS) have indicated that these are also suitable for group drives and can be used for such applications.
- The frequency inverter must be dimensioned according to the sum (total) of the rated motor currents – and not according to the sum (total) of the motor powers.
- The individual motors are parameterized in the frequency inverter as one motor; this is done by adding the rated motor powers and the rated motor currents (refer to the motor rating plate).
- The individual motors should be appropriately protected against overload. This can be realized by applying one of the following measures; as a consequence, this trips (shuts down) the frequency inverter:
The simplest method is to use motors with Thermoklick thermo switches (bimetallic switches). The switches, connected in series can be directly connected to the thermo sensor input of the frequency inverter (only SINAMICS G120 / G120D) or read-in via a digital input and then evaluated.
Using motors with PTC thermo sensors provides a more extensive protection against thermal overload. However, external evaluation units are required to evaluate several thermo sensors. The reason for this is that the monitoring, integrated in the frequency inverter, is only normalized for one sensor.
Instead of using the thermo sensors integrated in the motor, it is also possible to install a motor protection circuit breaker in front of each motor and then appropriately evaluate the signals from this motor protection circuit breaker.
- The Safety functions can be controlled as usual.
- - The Safety functions should be parameterized in the frequency inverter as usual. To determine the corresponding SS1 and SLS values, a calculation tool is available in the Internet under the following link: 24488874
- All motors that are operated from one frequency inverter must have the same technical data (the same Order No.).
- Only V/f control is permissible as control type.
- The maximum cable length between the frequency and the motors must be carefully observed (refer to the technical data of the frequency inverter).
- When activating motor holding brakes from the frequency inverter, then the maximum current of the brake control (refer to the technical data of the brake control) must be carefully observed).
This FAQ explains how, using the STARTER commissioning software, a list of parameters that has been changed can be created. An explanation is also given how this list of parameters that has been changed can be saved in a project or printed-out.
The SINAMICS G120 and G120D with their STO, SS1 and SLS safety functions are certified according to Cat. 3 (EN954-1:1996).
In order to implement STO according to Cat. 4, it is necessary to install an additional line contactor in the 400V feeder cable to SINAMICS G120/G120D.
STO is activated in the SINAMICS G120/G120D frequency converter from the F-CPU via PROFIsafe (using PROFIBUS or PROFINET). In addition, the 400V power supply voltage of the SINAMICS G120/G120D is disconnected via the line contactor. This shutdown is monitored in the safety program using the safety-relevant feedback signals of the SINAMICS G120/G120D frequency inverter (PROFIsafe) and the signalling contact of the line contactor (digital input).
How should the fail-safe digital inputs of the SINAMICS G120 be connected-up?
When using the CU240S DP-F or CU240S PN-F, the SINAMICS G120 has the following safety functions integrated in the frequency inverter:
- STO: Safe Torque Off (acc. to EN60204)
- SS1: Safe Stop 1 (acc. to EN60204)
- SLS: Safely Limited Speed (acc. to EN60204)
- SBC: Safe Brake Control
The STO, SS1 and SLS safety functions can be controlled via PROFIsafe (3 from 3 safety functions) and also via the fail-safe digital inputs FDI0 and FDI1 (2 from 3 safety functions).
These fail-safe digital inputs can be used to directly connect safety sensors (Emergency Stop pushbutton, light curtains etc.) and also to connect pre-evaluating safety relays and devices (e.g. fail-safe controls).
Using circuit examples, this FAQ is intended to help you in understanding how to ensure that the fail-safe digital inputs are connected-up acc. to the relevant standards.
Connecting the modular 3RK3 safety system, safety relay and SINAMICS G120 in the same control cabinet