SINUMERIK Safety Integrated - Siemens · PDF fileThe instructions and information on commissioning in Chapter 9 of the SINUMERIK Safety ... SI functions Page 5 of 58 Abnahmetest_SIN840D

Company name

SINUMERIK

Safety Integrated ®

Acceptance Certificate, SI Functions

Machine XYZ 1200

Type Handling machine

Serial No. V 01

SINUMERIK

Safety Integrated ®

Safe to say, more than just a control

Acceptance Certificate, SI functions Page 1 of 58 Abnahmetest_SIN840D sl_en.doc 08.03.2012

Company name

Note

The requirements for an acceptance test arise from the EU Machinery Directive. According to this, the machine manufacturer (OEM) is obliged

• to carry out an acceptance test for safety-related functions and machine parts and

• to issue an “Acceptance Certificate” specifying the test results.

When the Safety Integrated function is used, the acceptance test serves to verify that the configuration of the SI monitoring functions used in the NCK, PLC and drive is correct. For this purpose, the right imple-mentation of the defined safety functions is examined, the implemented test mechanisms (forced dormant error detection measures) are checked, and tripping of the individual monitoring functions is provoked through systematic violation of the tolerance limit. This has to be carried out for all safety functions, that means for the axial monitoring functions, the SPL, the safe communication relations, the safe I/O, etc.

The goal of the acceptance test is to check the correct parameter assignment for the safety functions. The acceptance test shall be used to detect potential configuration errors and to document the correct configuring. The values measured (e.g. travel, time) and the system behavior observed (e.g. triggering of a correct stop) during the execution of the acceptance test are used as plausibility check of the config-ured safety functions. The measured values determined are typical and not worst-case values. They rep-resent the behavior of the machine at the time of the measurement. The measurements cannot be used to derive maximum travel paths for over-travel.

Testing of each SI function has to be carried out by an authorized person and has to be documented in the Acceptance Certificate. The Certificate must be signed by the person, who carried out the acceptance test. The Acceptance Certificate must be kept with the machine logbook.

Authorized in the sense above means that the person has been entitled by the machine manufacturer and is able to carry out the acceptance test in an appropriate way due to his/her professional training and knowledge of the safety functions.

The instructions and information on commissioning in Chapter 9 of the SINUMERIK Safety Integrated ® Functions Manual must be observed.


Company name

Contents 1 SYSTEM DESCRIPTION - DOCUMENTATION, SECTION 1 ............................................................. 4

1.1 MACHINE ......................................................................................................................................... 4 1.1.1 Machine Overview .................................................................................................................. 5

1.2 CONTROL......................................................................................................................................... 6 1.3 CONFIGURATION PLAN...................................................................................................................... 6

2 DESCRIPTION OF THE SAFETY FUNCTIONS - DOCUMENTATION, SECTION 2 ......................... 8 2.1 FUNCTION TABLE.............................................................................................................................. 8 2.2 SI FUNCTIONS PER AXIS ................................................................................................................... 9 2.3 SAFETY EQUIPMENT / DEVICES ....................................................................................................... 13

2.3.1 Protection door...................................................................................................................... 13 2.3.2 Protection door switch .......................................................................................................... 13 2.3.3 Operation mode switch ......................................................................................................... 13 2.3.4 Enable button........................................................................................................................ 13 2.3.5 Monitoring about max. axis velocity or spindle rotation........................................................ 13 2.3.6 Emergency stop button......................................................................................................... 13 2.3.7 Power on button.................................................................................................................... 13 2.3.8 Safe software limit switch ..................................................................................................... 13 2.3.9 Holding brake of hanging axis (Z1)....................................................................................... 13 2.3.10 Teststop ................................................................................................................................ 14

3 TESTING THE SAFETY FUNCTIONS ............................................................................................... 15 3.1 FUNCTION TEST, SECTION 1 ........................................................................................................... 15

3.1.1 Test of Pulse Disable Paths.................................................................................................. 15 3.1.2 Test of Forced Checking Procedure (External Stops).......................................................... 16 3.1.3 Test of Forced Checking Procedure (SPL Inputs/Outputs) .................................................. 19 3.1.4 Test of Emergency Stop Reaction ........................................................................................ 20 3.1.5 Test of Functional Relationships........................................................................................... 24

3.2 FUNCTION TEST, SECTION 2 ........................................................................................................... 25 3.2.1 Test of SBH (Safe Operating Stop) Reaction ....................................................................... 25 3.2.2 Brake Test (Safe Brake Test) ............................................................................................... 34 3.2.3 Test of SG (Safely Reduced Speed) .................................................................................... 37 3.2.4 Test of SE (Safe Software Limit Switch)............................................................................... 44

4 COMPLETING THE CERTIFICATE ................................................................................................... 56 4.1 SI MACHINE DATA .......................................................................................................................... 56 4.2 CHECK SUMS ................................................................................................................................. 56

4.2.1 Global.................................................................................................................................... 56 4.2.2 Axis-specific .......................................................................................................................... 56 4.2.3 NCK-SPL (only when using SPL) ......................................................................................... 57

4.3 COMPLETING COMMISSIONING, NCK............................................................................................... 57 4.4 COMPLETING COMMISSIONING, PLC ............................................................................................... 57 4.5 DATA ARCHIVING............................................................................................................................ 58 4.6 COUNTER-SIGNATURES .................................................................................................................. 58

4.6.1 Acceptance Test - Execution ................................................................................................ 58 4.6.2 Acknowledgement - Machine Manufacturer ......................................................................... 58


Company name

1 System Description - Documentation, Section 1

1.1 Machine

Designation XYZ 1200

Type Milling machine

Serial No. Version 01 SINUMERIK 840Dsl

Manufacturer Customer

PLC Manufacturer Customer

Ultimate Customer Endcustomer

Electronic Axes 3

Other Axes 0

Spindles 1

Use Safe Programmable Logic Yes

Comments:


Company name

1.1.1 Machine Overview

(vertical axis)

(horizontal axis)

(horizontal axis)

Protection doorMachine cover

Comments: Axis X1,Y1,Z1: Handling-axis Axis SP1 Spindle Axis Z1 with holding brake


Company name

1.2 Control

Type Sinumerik 7XX

SW Release V02.06 + SP 01 + HF 07

NC TypeST-W92032528 - B - 6FC5 373-0AA01-0AA1 - 6FC5 373-0AA01-0AA1

PLC Type PLC 319 3PN/DP

NCK Release78.06.05

SI78.06.00

Drive Release 02.60.52.00

PLC Release

27.90.14

-3PN/DP

-FB15 SI02.06.19

SW Versions

GP Release 02.06.06 10/03/19

System Clock Cycle 0.0020 sec.

IPO Clock Cycle 0.0080 sec.

Monitoring Clock Cycle 0.0060 sec.

Comments:

1.3 Configuration Plan

Channel 1

Axis / Spindle X1

Name X1

Control Not Applicable Closed-Loop Drive

Module Type MM_1AXIS_DCAC

Logical Drive Number SERVO_3.3:4

Measuring System IMS(abs.)/IMS(inc.)

Channel 1

Axis / Spindle Y1

Name Y1




Measuring System IMS(inc.)


Company name

Channel 1

Axis / Spindle Z1

Name Z1




Measuring System IMS(inc.)

Channel 1

Axis / Spindle SP1

Name SP1




Measuring System IMS(inc.)/IMS(inc.)


Company name

2 Description of the Safety Functions - Documentation, Section 2

2.1 Function Table

Active monitoring functions as a function of the operating mode and the protective doors or other sensors.

Operating Mode Protective Doors Axis / Spindle Monitoring

Closed and locked X1, Y1, Z1, SP1 SG4 active Production

unlocked X1, Y1, Z1, SP1 SBH active

Closed and locked X1, Y1, Z1, SP1 SG4 active

Setting-up Unlocked

Unlocked and enable button is pressed

X1, Y1, Z1, SP1

X1, Y1, Z1, SP1

SBH active

SG1 active

Independent mode

Emergency stop X1, Y1, Z1, SP1 Stop C – Stop A

Switch off external Hardware

Comments:


Company name

2.2 SI Functions per Axis

Axis / Spindle X1

Limit Value 1.0 mm SBH

Active If

Limit Value 2000.0 mm/min SG1

Active If


Active If


Active If


Active If

Limit Value 1000.0 mm SE1+

Active If

Limit Value -900.0 mm SE1-

Active If


Active If


Active If

Position Tolerance

1 mm

Limit Force Not Applicable SBC

Torque 5 %

Safe Cam Direction Enabled Limit Value

Plus No 1

Minus No

Plus No 2

Minus No

Plus No 3

Minus No

Plus No 4

Minus No


Company name

Axis / Spindle Y1


Active If


Active If


Active If


Active If


Active If


Active If


Active If


Active If


Active If

Position Tolerance

1 mm


Torque 5 %


Plus No 1

Minus No

Plus No 2

Minus No

Plus No 3

Minus No

Plus No 4

Minus No


Company name

Axis / Spindle Z1


Active If


Active If


Active If


Active If


Active If


Active If


Active If


Active If


Active If

Position Tolerance

1 mm


Torque 20 %


Plus No 1

Minus No

Plus No 2

Minus No

Plus No 3

Minus No

Plus No 4

Minus No


Company name

Axis / Spindle SP1

Limit Value 1.0 deg. SBH

Active If

Limit Value 50.0 rpm SG1

Active If


Active If


Active If


Active If

Limit Value Not Used SE1+

Active If

Limit Value Not Used SE1-

Active If

Limit Value Not Used SE2+

Active If

Limit Value Not Used SE2-

Active If

Position Tolerance

1 deg.

Limit Force 5 % SBC

Torque Not Applicable


Plus No 1

Minus No

Plus No 2

Minus No

Plus No 3

Minus No

Plus No 4

Minus No

Comments:


Company name

2.3 Safety Equipment / Devices

2.3.1 Protection door

The protection door is unlocked through a single-channel request key if safety-relevant requirements have been met (n < nact of the drives X1, Y1, Z1, SP1).

2.3.2 Protection door switch

The protection door is fitted with a protection door switch. The protection door switch supplies the two-channel signal “Door closed and locked”. Information on switchover and selection of the safety functions according to the functions table can be found in Section 2.1.

2.3.3 Operation mode switch

The operation modes “Production” and “Install” are selected via the operation mode selector switch. The key switch has two contact levels. Information on switchover and selection of the safety func-tions according to the functions table can be found in Section 2.1.

2.3.4 Enable button

The safe operating stop is deselected via a two-channel acknowledgement button with the protection door open and in the operation mode “Install”.

2.3.5 Monitoring maximum axis velocity or spindle rotation

For the protection of the machine, the maximum permitted feed rate of the axes and/or the maximum permitted spindle speed is monitored with the protection installation closed. For this reason, SG4 is active with the protection installation closed (no trace necessary / possible for the documentation since the limit value for the SG4 is higher than the maximum axis velocity).

2.3.6 Emergency stop button

Using the two-channel EMERGENCY STOP signal, an external Stop C is triggered for X1, Y1, Z1, SP1 via the SPL logic. After one second an external Stop A is triggered for the axes X1, Y1, Z1 and spindle SP1. The hydraulics system, the coolant pump and the chip conveyor are safely disabled with an EMERGENCY STOP stop via SGAs (OUSE/P) of the SPL logic.

2.3.7 Power-on button

The button serves for the EMERGENCY STOP acknowledgement and the power connection.

2.3.8 Safe software limit switch

The linear axes X1, Z1, Y1 are fitted with a safe software limit switch (SE1) for the working area limi-tation. The function SE1 is always active and safe with the user agreement set.

2.3.9 Holding brake of hanging axis (Z1)

The holding brake is connected via a Sinamics motor module and activated via safe stop (SH). The safety function SBT is used to monitor the correct function of the holding brake for the vertical axis Z1. The safety function SBT is executed with the request signal “Unlock protection door”. The protection door is unlocked only after the first successful brake test. If SBT reveals an error, the axis must be traversed into a set down position before the protection door can be unlocked.


Company name

2.3.10 Test stop

The test stop can be started after the ramp-up of the control with the machine on.


Company name

3 Testing the Safety Functions

Series Commissioning No

3.1 Function Test, Section 1

3.1.1 Test of Pulse Disable Paths

Test Name Test of Disable Path Success Yes Test Condition Activate the teststop

Alarms

27002 : Axis X1 test stop is running, 27002 : Axis Y1 test stop is running, 27002 : Axis Z1 test stop is running, 27002 : Axis SP1 test stop is running, 201798 : Axis Y1 SERVO_3.14:2 (2):%nSI Motion CU: Test stop running., 201798 : Axis X1 SERVO_3.3:4 (4):%nSI Motion CU: Test stop running., 201798 : Axis Z1 SERVO_3.15:2 (2):%nSI Motion CU: Test stop running., 201798 : Axis SP1 SERVO_3.3:3 (3):%nSI Motion CU: Test stop running.,

Fatal Alarms Missing Alarms


Company name

3.1.2 Test of Forced Checking Procedure (External Stops)

Test Name X1-Axis test of external stops Success Yes Axis / Spindle AX1:X1

Test Initiated By Activate the teststop Results

(seconds)7,3 7,4 7,5 7,6 7,7 7,8 7,9

SGE Drive Stop E

SGA Drive Stop E

SGE NCK Stop E

SGA NCK Stop E

SGE Drive Stop D

SGA Drive Stop D

SGE NCK Stop D

SGA NCK Stop D

SGE Drive Stop C

SGA Drive Stop C

SGE NCK Stop C

SGA NCK Stop C

SGE Drive Stop A

SGA Drive Stop A

SGE NCK Stop A

SGA NCK Stop A


Company name

Test Name Y1-Axis test of external stops Success Yes Axis / Spindle AX2:Y1


(seconds)3,6 3,7 3,8 3,9 4 4,1 4,2 4,3

SGE Drive Stop E

SGA Drive Stop E

SGE NCK Stop E

SGA NCK Stop E

SGE Drive Stop D

SGA Drive Stop D

SGE NCK Stop D

SGA NCK Stop D

SGE Drive Stop C

SGA Drive Stop C

SGE NCK Stop C

SGA NCK Stop C

SGE Drive Stop A

SGA Drive Stop A

SGE NCK Stop A

SGA NCK Stop A

Test Name Z1-Axis test of external stops Success Yes Axis / Spindle AX3:Z1


(seconds)2 2,1 2,2 2,3 2,4 2,5 2,6

SGE Drive Stop E

SGA Drive Stop E

SGE NCK Stop E

SGA NCK Stop E

SGE Drive Stop D

SGA Drive Stop D

SGE NCK Stop D

SGA NCK Stop D

SGE Drive Stop C

SGA Drive Stop C

SGE NCK Stop C

SGA NCK Stop C

SGE Drive Stop A

SGA Drive Stop A

SGE NCK Stop A

SGA NCK Stop A


Company name

Test Name SP1-Axis test of external stops Success Yes Axis / Spindle AX4:SP1


(seconds)3,1 3,2 3,3 3,4 3,5 3,6 3,7

SGE Drive Stop E

SGA Drive Stop E

SGE NCK Stop E

SGA NCK Stop E

SGE Drive Stop D

SGA Drive Stop D

SGE NCK Stop D

SGA NCK Stop D

SGE Drive Stop C

SGA Drive Stop C

SGE NCK Stop C

SGA NCK Stop C

SGE Drive Stop A

SGA Drive Stop A

SGE NCK Stop A

SGA NCK Stop A


Company name

3.1.3 Test of Forced Checking Procedure (SPL Inputs/Outputs)

Test Name Test of chip conveyor Success Yes

Test Initiated By

The chip conveyor is switched off in safety-oriented manner at EMERGENCY STOP or protection door open with the help of an SGA (OUTSE/P[10]). For the test, the PLC feedback input E30.0 is disconnected with the protection door closed and the EMERGENCY STOP acknowledged, and the SGA switched off. In order to provoke an error and to document the reaction, the protection door is opened.

Results

The SGA OUTSE/P [10] switches off (status from 1-> 0), and within a defined time, the PLC input must report the status “Chip conveyor switched off (E30.0 =1)”. By evaluating the PLC, the missing feedback is detected and the error message 700007 is output

Alarms

700007 : Feedback input “Chip conveyor switched off E30.0” missing. , , ,



Company name


3.1.4 Test of Emergency Stop Reaction

Test Name X1-Axis test of Emergency stop SH Success Yes Axis / Spindle AX1:X1 SH Selected Yes Protective Circuit ID

Emergency stop on MSST INSE(P)[1] pressed Group 1

Checkback Input

MARKERSI(P)[1] Emergency stop is active I30.0 Emercency stop Checkback

Status

Signalstate: Emergency stop switch: INSE(P)[1] from 1 to 0 Emergency stop aktive: MARKERSI(P)[1] from 1 to 0 Checkback input: I30.0 from 0 to 1 If the emergency stop switch pressed, is directly a stop C active. After a decelera-tion tim of 1sec. is stop A active.

(seconds)2,5 2,6 2,7 2,8 2,9 3 3,1 3,2 3,3 3,4 3,5 3,6

SGE Drive Stop E

SGA Drive Stop E

SGE NCK Stop E

SGA NCK Stop E

SGE Drive Stop D

SGA Drive Stop D

SGE NCK Stop D

SGA NCK Stop D

SGE Drive Stop C

SGA Drive Stop C

SGE NCK Stop C

SGA NCK Stop C

SGE Drive Stop A

SGA Drive Stop A

SGE NCK Stop A

SGA NCK Stop A

Company name


Test Name Y1-Axis test of emergency stop SH Success Yes

Axis / Spindle AX2:Y1 SH Selected Yes Protective Circuit ID


Checkback Input


Status

Signalstate: Emergency stop switch: INSE(P)[1] from 1 to 0 Emergency stop aktive: MARKERSI(P)[1] from 1 to 0 Checkback input: I30.0 from 0 to 1 If the emergency stop switch pressed, is directly a stop C active. After a decelera-tion time of 1 sec. is stop A active.

(seconds)12,4 12,6 12,8 13 13,2 13,4

SGE Drive Stop E

SGA Drive Stop E

SGE NCK Stop E

SGA NCK Stop E

SGE Drive Stop D

SGA Drive Stop D

SGE NCK Stop D

SGA NCK Stop D

SGE Drive Stop C

SGA Drive Stop C

SGE NCK Stop C

SGA NCK Stop C

SGE Drive Stop A

SGA Drive Stop A

SGE NCK Stop A

SGA NCK Stop A

Company name


Test Name Z1-Axis test of emergency stop SH Success Yes

Axis / Spindle AX3:Z1 SH Selected Yes Protective Circuit ID


Checkback Input


Status


(seconds)1,7 1,8 1,9 2 2,1 2,2 2,3 2,4 2,5 2,6 2,7 2,8

SGE Drive Stop E

SGA Drive Stop E

SGE NCK Stop E

SGA NCK Stop E

SGE Drive Stop D

SGA Drive Stop D

SGE NCK Stop D

SGA NCK Stop D

SGE Drive Stop C

SGA Drive Stop C

SGE NCK Stop C

SGA NCK Stop C

SGE Drive Stop A

SGA Drive Stop A

SGE NCK Stop A

SGA NCK Stop A

Company name


Test Name SP1-Axis test of emergency stop SH Success Yes

Axis / Spindle AX4:SP1 SH Selected Yes Protective Circuit ID


Checkback Input


Status


(seconds)1,7 1,8 1,9 2 2,1 2,2 2,3 2,4 2,5 2,6 2,7 2,8 2,9

SGE Drive Stop E

SGA Drive Stop E

SGE NCK Stop E

SGA NCK Stop E

SGE Drive Stop D

SGA Drive Stop D

SGE NCK Stop D

SGA NCK Stop D

SGE Drive Stop C

SGA Drive Stop C

SGE NCK Stop C

SGA NCK Stop C

SGE Drive Stop A

SGA Drive Stop A

SGE NCK Stop A

SGA NCK Stop A

Company name

3.1.5 Test of Functional Relationships

Test Name Check of the functional relationship Success Yes Test Initiated By look at function table

Results OK

Test Name Control S7 HW config Success Yes Test Initiated By The parameter of PROFIsafe peripherie in the S7 HW config is checked

Results OK

Test Name Check the combination of the software version Success Yes Test Initiated By Verification of permission firmware- / software- version combination.

Results OK


Company name

3.2 Function Test, Section 2

3.2.1 Test of SBH (Safe Operating Stop) Reaction

Test Name X1-Axis test of SBH Success Yes SBH

Axis / Spindle AX1:X1 Direction Positive

Test Initiated By

Protection door open. X1-Axis SBH active. Operation mode- manual. X1-Axis is active. Drive with + / - button the axis.

Alarms

27007 : Axis X1 acceptance test mode is active, 201799 : Axis X1 SERVO_3.3:4 (4):%nSI Motion CU: Acceptance test mode ac-tive., 27010 : Axis X1 tolerance for safe standstill exceeded, 27023 : Axis X1 stop B triggered, 27024 : Axis X1 stop A triggered, 201707 : Axis X1 SERVO_3.3:4 (4):%nSI Motion CU: Tolerance for safe operating stop exceeded., 201701 : Axis X1 SERVO_3.3:4 (4):%nSI Motion CU: STOP B initiated., 201700 : Axis X1 SERVO_3.3:4 (4):%nSI Motion CU: STOP A initiated., ,


Speed Ex-ceeded

6415.8 mm/min

Response Time 0.0020 sec Overtravel from

start 3.1368 mm

Overtravel from limit

2.1368 mm


Company name


Actual Position during testing of SBH for X1-Axis test of SBH

(seconds)2,7 2,71 2,72 2,73 2,74 2,75 2,76 2,77 2,78 2,79

6938,500

6939,000

6939,500

6940,000

6940,500

6941,000

6941,500A - Motion StartB - Fault OccurrenceC - System ReactionD - Standstill

A B C D

SBH Limit

Actual Speed during testing of SBH for X1-Axis test of SBH

(seconds)2,7 2,71 2,72 2,73 2,74 2,75 2,76 2,77 2,78 2,79

0,000

500,000

1000,000

1500,000

2000,000

2500,000

3000,000

3500,000

4000,000

4500,000

5000,000

5500,000

6000,000

6500,000 A - Motion StartB - Fault OccurrenceC - System ReactionD - Standstill

A B C D

Company name

Set Speed during testing of SBH for X1-Axis test of SBH

(seconds)2,7 2,71 2,72 2,73 2,74 2,75 2,76 2,77 2,78 2,79

0,000

500,000

1000,000

1500,000

2000,000

2500,000

3000,000

3500,000

4000,000

4500,000

5000,000


A B C D

Test Name Y1-Axis test of SBH Success Yes SBH

Axis / Spindle AX2:Y1 Direction Positive

Test Initiated By

Protection door open. Y1-Axis SBH active. Operation mode- manual. Y1-Axis is active. Drive with + / - button the axis.

Alarms

27007 : Axis Y1 acceptance test mode is active, 201799 : Axis Y1 SERVO_3.14:2 (2):%nSI Motion CU: Acceptance test mode ac-tive., 27010 : Axis Y1 tolerance for safe standstill exceeded, 27023 : Axis Y1 stop B triggered, 27024 : Axis Y1 stop A triggered, 201707 : Axis Y1 SERVO_3.14:2 (2):%nSI Motion CU: Tolerance for safe operating stop exceeded., 201701 : Axis Y1 SERVO_3.14:2 (2):%nSI Motion CU: STOP B initiated., 201700 : Axis Y1 SERVO_3.14:2 (2):%nSI Motion CU: STOP A initiated., ,


Speed Ex-ceeded

2636.7 mm/min


start 1.8552 mm


0.8552 mm


Company name


Actual Position during testing of SBH for Y1-Axis test of SBH

(seconds)4,22 4,24 4,26 4,28 4,3 4,32 4,34 4,36

0,000

0,200

0,400

0,600

0,800

1,000

1,200

1,400

1,600


A B C D

SBH Limit

Actual Speed during testing of SBH for Y1-Axis test of SBH

(seconds)4,22 4,24 4,26 4,28 4,3 4,32 4,34 4,36

-500,000

0,000

500,000

1000,000

1500,000

2000,000


A B C D

Company name

Set Speed during testing of SBH for Y1-Axis test of SBH

(seconds)4,22 4,24 4,26 4,28 4,3 4,32 4,34 4,36

0,000

200,000

400,000

600,000

800,000

1000,000

1200,000

1400,000

1600,000

1800,000

2000,000

2200,000

2400,000


A B C D

Test Name Z1-Axis test of SBH Success Yes SBH

Axis / Spindle AX3:Z1 Direction Positive

Test Initiated By

Protection door open. Z1-Axis SBH active. Operation mode- manual. Z1-Axis is active. Drive with + / - button the axis.

Alarms

27007 : Axis Z1 acceptance test mode is active, 201799 : Axis Z1 SERVO_3.15:2 (2):%nSI Motion CU: Acceptance test mode ac-tive., 27010 : Axis Z1 tolerance for safe standstill exceeded, 27023 : Axis Z1 stop B triggered, 27024 : Axis Z1 stop A triggered, 201707 : Axis Z1 SERVO_3.15:2 (2):%nSI Motion CU: Tolerance for safe operating stop exceeded., 201701 : Axis Z1 SERVO_3.15:2 (2):%nSI Motion CU: STOP B initiated., 201700 : Axis Z1 SERVO_3.15:2 (2):%nSI Motion CU: STOP A initiated., ,


Speed Ex-ceeded

2820.7 mm/min


start 2.0915 mm


1.0915 mm


Company name


Actual Position during testing of SBH for Z1-Axis test of SBH

(seconds)2,96 2,98 3 3,02 3,04 3,06 3,08

0,000

0,200

0,400

0,600

0,800

1,000

1,200

1,400

1,600

1,800


A B C D

SBH Limit

Actual Speed during testing of SBH for Z1-Axis test of SBH

(seconds)2,96 2,98 3 3,02 3,04 3,06 3,08

0,000

200,000

400,000

600,000

800,000

1000,000

1200,000

1400,000

1600,000

1800,000

2000,000

2200,000

2400,000

2600,000


A B C D

Company name

Set Speed during testing of SBH for Z1-Axis test of SBH

(seconds)2,96 2,98 3 3,02 3,04 3,06 3,08

0,000

200,000

400,000

600,000

800,000

1000,000

1200,000

1400,000

1600,000

1800,000

2000,000

2200,000

2400,000

2600,000


A B C D

Test Name SP1-Axis test of SBH Success Yes SBH

Axis / Spindle AX4:SP1 Direction Positive

Test Initiated By

Protection door open. SP1-Axis SBH active. Operation mode- manual. SP1-Axis is active. Drive with + / - button the axis.

Alarms

120407 : SINAMICS: Read job for parameter 10, area DC: 2.5 s timeout!, 27007 : Axis SP1 acceptance test mode is active, 201799 : Axis SP1 SERVO_3.3:3 (3):%nSI Motion CU: Acceptance test mode ac-tive., 27010 : Axis SP1 tolerance for safe standstill exceeded, 27023 : Axis SP1 stop B triggered, 201707 : Axis SP1 SERVO_3.3:3 (3):%nSI Motion CU: Tolerance for safe operat-ing stop exceeded., 201701 : Axis SP1 SERVO_3.3:3 (3):%nSI Motion CU: STOP B initiated., 27024 : Axis SP1 stop A triggered, 201700 : Axis SP1 SERVO_3.3:3 (3):%nSI Motion CU: STOP A initiated., ,


Speed Ex-ceeded

67.8 rpm


start 146.2146 deg.


145.2146 deg.


Company name


Actual Position during testing of SBH for SP1-Axis test of SBH

(seconds)1,2 1,3 1,4 1,5 1,6 1,7 1,8 1,9

280,000

300,000

320,000

340,000

360,000

380,000

400,000


LimitAB C DSBH

Actual Speed during testing of SBH for SP1-Axis test of SBH

(seconds)1,2 1,3 1,4 1,5 1,6 1,7 1,8 1,9

-10,000

0,000

10,000

20,000

30,000

40,000

50,000

60,000


AB C D

Company name

Set Speed during testing of SBH for SP1-Axis test of SBH

(seconds)1,2 1,3 1,4 1,5 1,6 1,7 1,8 1,9

0,000

10,000

20,000

30,000

40,000

50,000

60,000


AB C D


Company name

3.2.2 Brake Test (Safe Brake Test)

Test Name Z1-Axis Brake test Success Yes SBC

Library Export

Date/Time

Machine Machine Serial

Number

NC Checksums 2E9FBB90, 61AE41A, F80BABAB Drive

Checksums 89B5DD67, A5149D3C, 0

Axis / Spindle AX3:Z1 Direction Negative

Test initiated by Activate the braketest Alarms


Reference Torque

3.6800 Nm

Torque Limit for brake test

10.0037 %

Torque at the beginning of the

test 0.0076 Nm

Additional torque during

the test -0.3603 Nm

Test Time 2.330 Sec.


Company name

Torque Limitation value during testing of SBC for Z1-Axis Brake test

(seconds)2,5 3 3,5 4 4,5 5 5,5 6 6,5

0

10

20

30

40

50

60

70

80

90

100

Desired Torque during testing of SBC for Z1-Axis Brake test

(seconds)2,5 3 3,5 4 4,5 5 5,5 6 6,5

-0,350

-0,300

-0,250

-0,200

-0,150

-0,100

-0,050

0,000


Company name

Actual Position during testing of SBC for Z1-Axis Brake test

(seconds)2,5 3 3,5 4 4,5 5 5,5 6 6,5

-0,000

-0,000

-0,000

-0,000

-0,000

-0,000

-0,000

Setpoint of Axis Specific Feedrate Z1-Axis Brake test

(seconds)2,5 3 3,5 4 4,5 5 5,5 6 6,5

-3000,000

-2500,000

-2000,000

-1500,000

-1000,000

-500,000

0,000


Company name

3.2.3 Test of SG (Safely Reduced Speed)

Test Name X1-Axis test SG 1 Success Yes SG SG1


Test Initiated By

Operation mode- manual is active. Protection door is open. Enable button is pressed (X1-Axis SG1 is active) X1-Axis is active Drive with + / - Button

Alarms

27007 : Axis X1 acceptance test mode is active, 201799 : Axis X1 SERVO_3.3:4 (4):%nSI Motion CU: Acceptance test mode ac-tive., 27011 : Axis X1 safe velocity exceeded, 27022 : Axis X1 stop C triggered, 201714 : Axis X1 SERVO_3.3:4 (4):%nSI Motion CU: Safely-Limited Speed ex-ceeded. 100., 201708 : Axis X1 SERVO_3.3:4 (4):%nSI Motion CU: STOP C initiated., , , ,


Speed Ex-ceeded

2715.1 mm/min


start 2.2887 mm


2.0075 mm


Company name


Actual Position during testing of SG for X1-Axis test SG 1

(seconds)2,2 2,25 2,3 2,35 2,4 2,45 2,5

-92,800

-92,600

-92,400

-92,200

-92,000

-91,800

-91,600

-91,400

-91,200

-91,000

-90,800

-90,600

-90,400A - Motion StartB - Fault OccurrenceC - System ReactionD - Standstill

A B C D

Actual Speed during testing of SG for X1-Axis test SG 1

(seconds)2,2 2,25 2,3 2,35 2,4 2,45 2,5

-1000,000

-500,000

0,000

500,000

1000,000

1500,000

2000,000

2500,000

3000,000

3500,000

4000,000

4500,000


A B C D

SG Limit

Company name

Set Speed during testing of SG for X1-Axis test SG 1

(seconds)2,2 2,25 2,3 2,35 2,4 2,45 2,5

0,000

500,000

1000,000

1500,000

2000,000

2500,000

3000,000

3500,000

4000,000

4500,000


A B C D

Test Name Y1-Axis test SG 1 Success Yes SG SG1


Test Initiated By

Operation mode- manual is active. Protection door is open. Enable button is pressed (Y1-Axis SG1 is active) Y1-Axis is active Drive with + / - Button

Alarms

27007 : Axis Y1 acceptance test mode is active, 201799 : Axis Y1 SERVO_3.14:2 (2):%nSI Motion CU: Acceptance test mode ac-tive., 27011 : Axis Y1 safe velocity exceeded, 27022 : Axis Y1 stop C triggered, 201714 : Axis Y1 SERVO_3.14:2 (2):%nSI Motion CU: Safely-Limited Speed ex-ceeded. 100., 201708 : Axis Y1 SERVO_3.14:2 (2):%nSI Motion CU: STOP C initiated.,


Speed Ex-ceeded

552.6 mm/min


start 1.6390 mm


0.8764 mm


Company name


Actual Position during testing of SG for Y1-Axis test SG 1

(seconds)7,02 7,04 7,06 7,08 7,1 7,12 7,14 7,16 7,18 7,2 7,22 7,24

0,000

0,200

0,400

0,600

0,800

1,000

1,200

1,400


A B C D

Actual Speed during testing of SG for Y1-Axis test SG 1

(seconds)7,02 7,04 7,06 7,08 7,1 7,12 7,14 7,16 7,18 7,2 7,22 7,24

-500,000

0,000

500,000

1000,000

1500,000

2000,000


A B C D

SG Limit

Company name

Set Speed during testing of SG for Y1-Axis test SG 1

(seconds)7,02 7,04 7,06 7,08 7,1 7,12 7,14 7,16 7,18 7,2 7,22 7,24

0,000

200,000

400,000

600,000

800,000

1000,000

1200,000

1400,000

1600,000

1800,000

2000,000

2200,000


A B C D

Test Name Z1-Axis test SG 1 Success Yes SG SG1


Test Initiated By

Operation mode- manual is active. Protection door is open. Enable button is pressed (Z1-Axis SG1 is active) Z1-Axis is active Drive with + / - Button

Alarms

27007 : Axis Z1 acceptance test mode is active, 201799 : Axis Z1 SERVO_3.15:2 (2):%nSI Motion CU: Acceptance test mode active., 27011 : Axis Z1 safe velocity exceeded, 27022 : Axis Z1 stop C triggered, 201714 : Axis Z1 SERVO_3.15:2 (2):%nSI Motion CU: Safely-Limited Speed ex-ceeded. 100., 201708 : Axis Z1 SERVO_3.15:2 (2):%nSI Motion CU: STOP C initiated., , , ,


Speed Ex-ceeded

512.3 mm/min


start 1.6559 mm


Company name



0.8740 mm

Actual Position during testing of SG for Z1-Axis test SG 1

(seconds)1,9 1,95 2 2,05 2,1

1,200

1,400

1,600

1,800

2,000

2,200

2,400

2,600

2,800


A B C D

Actual Speed during testing of SG for Z1-Axis test SG 1

(seconds)1,9 1,95 2 2,05 2,1

-500,000

0,000

500,000

1000,000

1500,000

2000,000


A B C D

SG Limit

Company name

Set Speed during testing of SG for Z1-Axis test SG 1

(seconds)1,9 1,95 2 2,05 2,1

0,000

200,000

400,000

600,000

800,000

1000,000

1200,000

1400,000

1600,000

1800,000

2000,000

2200,000


A B C D


Company name


3.2.4 Test of SE (Safe Software Limit Switch)

Test Name X1-Axis test SE1 positive Success Yes SE SE1


Test Initiated By

X1-Axis SE 1 active (User enable is set) Operation mode -JOG is active X1-Axis is active Drive with + button across the safe software switch

Alarms

27008 : Axis X1 SW limit switch deactivated, 27022 : Axis X1 stop C triggered, 201715 : Axis X1 SERVO_3.3:4 (4):%nSI Motion CU: Safely-Limited Position exceeded. 10., 201708 : Axis X1 SERVO_3.3:4 (4):%nSI Motion CU: STOP C initiated., 27012 : Axis X1 safe end position exceeded, , , ,

Fatal Alarms Missing Alarms Position Limit 1000.0000 mm

Response Time 0.0017 sec Overtravel 0.0030 mm

Actual Position during testing of SE for X1-Axis test SE1 positive

(seconds)5,3 5,35 5,4 5,45 5,5

999,870

999,880

999,890

999,900

999,910

999,920

999,930

999,940

999,950

999,960

999,970

999,980

999,990

1000,000A - Motion StartB - Fault Occurrence

em ReactionD - Standstill

t

B C D

C - SystSE Limi

Company name

Actual Speed during testing of SE for X1-Axis test SE1 positive

(seconds)5,3 5,35 5,4 5,45 5,5

0,000

10,000

20,000

30,000

40,000

50,000

60,000

70,000


B C D

Set Speed during testing of SE for X1-Axis test SE1 positive

(seconds)5,3 5,35 5,4 5,45 5,5

0,000

10,000

20,000

30,000

40,000

50,000

60,000

70,000


B C D

Test Name Y1-Axis test SE1 positive Success Yes SE SE1



Company name


Test Initiated By

Y1-Axis SE 1 active (User enable is set) Operation mode-JOG is active Y1-Axis is active Drive with + button across the safe software switch

Alarms

27008 : Axis Y1 SW limit switch deactivated, 27012 : Axis Y1 safe end position exceeded, 27022 : Axis Y1 stop C triggered, 201715 : Axis Y1 SERVO_3.14:2 (2):%nSI Motion CU: Safely-Limited Position exceeded. 10., 201708 : Axis Y1 SERVO_3.14:2 (2):%nSI Motion CU: STOP C initiated., , ,



Actual Position during testing of SE for Y1-Axis test SE1 positive

(seconds)7,7 7,75 7,8 7,85 7,9

999,880

999,900

999,920

999,940

999,960

999,980

1000,000

1000,020A - Motion StartB - Fault OccurrenceC - System Reaction

dstillt

B C D

D - StanSE Limi

Company name

Actual Speed during testing of SE for Y1-Axis test SE1 positive

(seconds)7,7 7,75 7,8 7,85 7,9

-10,000

0,000

10,000

20,000

30,000

40,000

50,000

60,000

70,000

80,000

A - Motion StartB - Fault OccurrenceC - System ReactionD - Standstill

B C D

Set Speed during testing of SE for Y1-Axis test SE1 positive

(seconds)7,7 7,75 7,8 7,85 7,9

0,000

10,000

20,000

30,000

40,000

50,000

60,000

70,000


B C D

Test Name Z1-Axis test SE1 positive Success Yes SE SE1



Company name


Test Initiated By

Z1-Axis SE 1 active (User enable is set) Operation mode-JOG is active Z1-Axis is active Drive with + button across the safe software switch

Alarms

27008 : Axis Z1 SW limit switch deactivated, 27012 : Axis Z1 safe end position exceeded, 27022 : Axis Z1 stop C triggered, 201715 : Axis Z1 SERVO_3.15:2 (2):%nSI Motion CU: Safely-Limited Position exceeded. 10., 201708 : Axis Z1 SERVO_3.15:2 (2):%nSI Motion CU: STOP C initiated., , ,



Actual Position during testing of SE for Z1-Axis test SE1 positive

(seconds)5,05 5,1 5,15 5,2 5,25

999,880

999,890

999,900

999,910

999,920

999,930

999,940

999,950

999,960

999,970

999,980

999,990

1000,000

1000,010

1000,020


B C D

SE Limit

Company name

Actual Speed during testing of SE for Z1-Axis test SE1 positive

(seconds)5,05 5,1 5,15 5,2 5,25

-10,000

0,000

10,000

20,000

30,000

40,000

50,000

60,000

70,000


B C D

Set Speed during testing of SE for Z1-Axis test SE1 positive

(seconds)5,05 5,1 5,15 5,2 5,25

0,000

10,000

20,000

30,000

40,000

50,000

60,000

70,000


B C D

Test Name X1-Axis test SE1 negative Success Yes SE SE1

Axis / Spindle AX1:X1 Direction Negative


Company name


Test Initiated By

X1-Axis SE 1 active (User enable is set) Operation mode-JOG is active X1-Axis is active Drive with - button across the safe software switch

Alarms

27008 : Axis X1 SW limit switch deactivated, 27012 : Axis X1 safe end position exceeded, 27022 : Axis X1 stop C triggered, 201708 : Axis X1 SERVO_3.3:4 (4):%nSI Motion CU: STOP C initiated., 201715 : Axis X1 SERVO_3.3:4 (4):%nSI Motion CU: Safely-Limited Position exceeded. 10., , , ,

Fatal Alarms Missing Alarms Position Limit -900.0000 mm


Actual Position during testing of SE for X1-Axis test SE1 negative

(seconds)8,45 8,5 8,55 8,6 8,65

-900,020

-900,000

-899,980

-899,960

-899,940

-899,920

-899,900

-899,880


B C D

SE Limit

Company name

Actual Speed during testing of SE for X1-Axis test SE1 negative

(seconds)8,45 8,5 8,55 8,6 8,65

-80,000

-70,000

-60,000

-50,000

-40,000

-30,000

-20,000

-10,000


B C D

Set Speed during testing of SE for X1-Axis test SE1 negative

(seconds)8,45 8,5 8,55 8,6 8,65

-80,000

-70,000

-60,000

-50,000

-40,000

-30,000

-20,000

-10,000


B C D

Test Name Y1-Axis test SE1 negative Success Yes SE SE1

Axis / Spindle AX2:Y1 Direction Negative


Company name


Test Initiated By

Y1-Axis SE 1 active (User enable is set) Operation mode-JOG is active Y1-Axis is active Drive with - button across the safe software switch

Alarms

27008 : Axis Y1 SW limit switch deactivated, 27012 : Axis Y1 safe end position exceeded, 201715 : Axis Y1 SERVO_3.14:2 (2):%nSI Motion CU: Safely-Limited Position exceeded. 10., 201708 : Axis Y1 SERVO_3.14:2 (2):%nSI Motion CU: STOP C initiated., 27022 : Axis Y1 stop C triggered, , ,



Actual Position during testing of SE for Y1-Axis test SE1 negative

(seconds)7,95 8 8,05 8,1 8,15

-900,020

-900,000

-899,980

-899,960

-899,940

-899,920

-899,900

-899,880 A - Motion StartB - Fault OccurrenceC - System ReactionD - Standstill

B C D

SE Limit

Company name

Actual Speed during testing of SE for Y1-Axis test SE1 negative

(seconds)7,95 8 8,05 8,1 8,15

-80,000

-70,000

-60,000

-50,000

-40,000

-30,000

-20,000

-10,000

0,000


B C D

Set Speed during testing of SE for Y1-Axis test SE1 negative

(seconds)7,95 8 8,05 8,1 8,15

-80,000

-70,000

-60,000

-50,000

-40,000

-30,000

-20,000

-10,000


B C D

Test Name Z1-Axis test SE1 negative Success Yes SE SE1

Axis / Spindle AX3:Z1 Direction Negative


Company name


Test Initiated By

Z1-Axis SE 1 active (User enable is set) Operation mode-JOG is active Z1-Axis is active Drive with - button across the safe software switch

Alarms

27008 : Axis Z1 SW limit switch deactivated, 27012 : Axis Z1 safe end position exceeded, 201715 : Axis Z1 SERVO_3.15:2 (2):%nSI Motion CU: Safely-Limited Position exceeded. 10., 201708 : Axis Z1 SERVO_3.15:2 (2):%nSI Motion CU: STOP C initiated., 27022 : Axis Z1 stop C triggered, , ,



Actual Position during testing of SE for Z1-Axis test SE1 negative

(seconds)8,5 8,55 8,6 8,65 8,7

-900,020

-900,000

-899,980

-899,960

-899,940

-899,920

-899,900

-899,880 A - Motion StartB - Fault OccurrenceC - System ReactionD - Standstill

B C D

SE Limit

Company name

Actual Speed during testing of SE for Z1-Axis test SE1 negative

(seconds)8,5 8,55 8,6 8,65 8,7

-80,000

-70,000

-60,000

-50,000

-40,000

-30,000

-20,000

-10,000

0,000


B C D

Set Speed during testing of SE for Z1-Axis test SE1 negative

(seconds)8,5 8,55 8,6 8,65 8,7

-80,000

-70,000

-60,000

-50,000

-40,000

-30,000

-20,000

-10,000


B C D


Company name

4 Completing the Certificate

4.1 SI Machine Data

Specified Limit Value Checked Attachment

yes no yes no

Drive X X

NC X X

4.2 Check Sums

4.2.1 Global

NC, MD13318[0..x] 47F08E50, E6F5AA52, D774C6A, 4DE58

Time 05:13:46 Check Sum (8 HEX)

Date 12/03/1994

4.2.2 Axis-specific

Axis / Spindle X1

Drive Number 2

NC, MD36998[0..x] 7BD7C406, DABD12E4, 49FE9E92

Drive 2A03525D, 7E0335AB, 0

Time 05:20:33

Date 26/07/1994

Control Unit DEB179D1

Check Sum (8 HEX)

Motor Module 689A0D77

Axis / Spindle Y1

Drive Number 13

NC, MD36998[0..x] F6E79BED, 7DA304C2, 1301AE7C

Drive DEBB25C4, A5149D3C, 0

Time 05:20:33

Date 26/07/1994

Control Unit 548F5C22

Check Sum (8 HEX)

Motor Module 9F0FAFAF


Company name

Axis / Spindle Z1

Drive Number 7

NC, MD36998[0..x] 25FA0127, 61AE41A, F80BABAB

Drive DEBB25C4, A5149D3C, 0

Time 05:20:33

Date 26/07/1994

Control Unit 548F5C22

Check Sum (8 HEX)

Motor Module 26DC7F4B

Axis / Spindle SP1

Drive Number 1

NC, MD36998[0..x] 6C0A82CD, 4D45DF2B, 269EA070

Drive B8C14761, D4DA6115, 0

Time 05:20:33

Date 26/07/1994

Control Unit DD023D37

Check Sum (8 HEX)

Motor Module 1A0F110B

4.2.3 NCK-SPL (only when using SPL)

Name SAFE.SPF

Check Sum (8 HEX) 000dd9f1

4.3 Completing Commissioning, NCK

Name 11500 PREVENT_SYNACT_LOCK[0]

IDS No. 1

Name 11500 PREVENT_SYNACT_LOCK[1]

IDS No. 100

4.4 Completing Commissioning, PLC

Action DB18.DBX36.0 = 1

Result Yes


Company name


4.5 Data Archiving

Type

Designation Memory Medium

Date

Machine Data

Archive Location

Type


Date

PLC Program

Archive Location

Type


Date

Circuit

Diagrams

Archive Location

4.6 Counter-Signatures

4.6.1 Acceptance Test - Execution

This confirms that the forenamed tests and checks were correctly performed.

Date 28/02/2012

Name

Company/Dept.

Signature

4.6.2 Acknowledgement - Machine Manufacturer

This confirms that the forenamed limit values and functions are correct.

Date

Name

Company/Dept.

Signature

Documents

SINUMERIK Safety Integrated - Siemens · PDF fileThe instructions and information on commissioning in Chapter 9 of the SINUMERIK Safety ... SI functions Page 5 of 58 Abnahmetest_SIN840D