Applications & Tools: Handling The "Safe Brake Test" (SBT) in Conjunction With The EPOS Function of The Sinamics S120

Cover sheet
Handling the "Safe Brake Test" (SBT) in

conjunction with the EPOS function of the
SINAMICS S120
SINAMICS S120
Application description July 2013
Applications & Tools

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EPOS und SBT

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1
s Task
Solution 2
Function mechanisms of
the application 3
Installation 4
SINAMICS S120 Configuration and project
5
engineering (optional)
Safety Integrated
Commissioning the
Handling the Safety Integrated Extended Function application 6
"Safe Brake Test" (SBT) in conjunction with the
EPOS function of the SINAMICS S120
(CU320-2 PN with firmware V4.6) Operating the application 7
References 8
Contact persons 9
10
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History
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Warranty and liability
Warranty and liability
Note The application examples are non-binding and do not claim to be complete in
terms of configuration and equipment or to take account of any other
contingencies. These application examples do not represent specific customer
solutions – but are only intended to provide support when it comes to typical
applications. You are responsible for the proper operation of the described
products. These application examples do not exempt the user from their due
diligence obligation with regard to application, installation, operation and
maintenance. By using these application examples, you agree that Siemens
cannot be made liable for possible damage beyond the mentioned liability
clause. We reserve the right to make changes to these application examples at
any time and without prior notice. If there are any differences between the
suggestions made in these application examples and other Siemens
publications, such as catalogs, the contents of the other document(s) take
priority.
We give no guarantee that the information contained in this document is complete,

accurate, or up to date.
We accept no liability for any damage or loss caused by the examples, information,
programs, planning data, or performance data described in this application
example, irrespective of the legal basis for claims arising from such damage or
loss, unless liability is mandatory. For example, according to the product liability
law, in cases of malfeasance, gross negligence, due to endangerment of life, body
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be limited to liability for damages to the contract-specific, foreseeable damages,
provided there is no mandatory liability for intent, acts of gross negligence, harm to
the life, body and health of human beings. Any change to the burden of proof to
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your disadvantage is not covered hereby.
Any form of duplication of these application examples or excerpts hereof is not

permitted without the express consent of Siemens Industry Sector.
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Table of contents
Table of contents
Warranty and liability ............................................................................................... 4
1 Task................................................................................................................. 6
1.1 Overview ........................................................................................... 6
1.2 Requirements .................................................................................... 9
2 Solution......................................................................................................... 10
2.1 Overview of the overall solution ....................................................... 10
2.2 Description of the core functionality.................................................. 12
2.3 Hardware and software components used ....................................... 14
3 Function mechanisms of this application ................................................... 16
3.1 "Safe Brake Test" (SBT) function description ................................... 16
3.2 Safety Info Channel (SIC) and Safety Control Channel (SCC) .......... 23
3.3 Data blocks DB100 and DB102........................................................ 26
4 Installation .................................................................................................... 29
4.1 Installing the hardware ..................................................................... 29
5 Configuration and project engineering ....................................................... 32
5.1 Passwords....................................................................................... 32
5.2 Preparation...................................................................................... 33
5.3 Hardware configuration .................................................................... 36

5.4 Configuring the basic drive functions................................................ 44
5.5 Generating the standard program .................................................... 54
5.6 Parameterizing the safety functions integrated in the drive ............... 63
5.7 Generating the fail-safe program of the F-CPU ................................ 69
5.8 Acceptance test ............................................................................... 75
6 Commissioning the application ................................................................... 79
6.1 Preconditions................................................................................... 79
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6.2 Commissioning ................................................................................ 80

7 Operating the application............................................................................. 84
7.1 Overview ......................................................................................... 84
7.2 Description of function ..................................................................... 84
8 References .................................................................................................... 87
8.1 Related documents.......................................................................... 87
8.2 Internet links .................................................................................... 87
9 Contact persons ........................................................................................... 88
10 History .......................................................................................................... 89
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1 Task
1.1 Overview
1 Task
1.1 Overview
Introduction
The following safety functions according to DIN EN 61800-5-2 are currently
integrated in SINAMICS S120 drives:
Table 1-1: SINAMICS S120 safety functions according to DIN EN 61800-5-2
Name Function Description

Safe disconnection of the torque-generating power
supply to the motor.
STO Safe Torque Off The switching on inhibited function prevents the
drive from restarting. (Stop function, Category 0
according to EN 60204-1)
SBC is only used when there is a motor brake; the

motor brake is connected to the power connector
Safe Brake through the outputs.
SBC
Control SBC always responds in conjunction with STO or
when internal safety monitoring functions respond
with safe pulse suppression.
The drive is quickly and safely stopped along the

OFF3 ramp and is safely monitored.
SS1 Safe Stop 1 Transition to STO after a delay time has expired or
the shutdown speed has been reached. (Stop
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function, Category 1 according to EN 60204-1)
The drive is quickly and safely stopped along the

OFF3 ramp and is safely monitored.
Transition to SOS after a delay time has expired; the
SS2 Safe Stop 2
drive remains in closed-loop control. (Stop function,
Category 2 according to EN 60204-1)
Not available for safety functions without encoder.
This function serves to safely monitor the standstill
Safe Operating position of a drive; the drive remains in closed-loop
SOS control.
Stop
The drive speed is safely monitored.

Safely Limited
SLS Parameterizable shutdown response when the limit
Speed
value is violated.
Safe Speed Safely displays when the speed falls below a speed
SSM
Monitor limit (n < nx).
Safety monitors the motion direction (positive and
negative directions).
SDI Safe Direction
Parameterizable shutdown response when
traversing in a direction that has not been enabled.
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1 Task
1.1 Overview

Safe monitoring of the drive positioning range;
corresponds to safe software limit switches.
Safely Limited
SLP Parameterizable shutdown response when position
Position
limits are violated.
In addition to the functions defined in Standard DIN EN 61800-5-2, the following

safety functions are also available in SINAMICS S120.
Table 1-2: SINAMICS S120 safety functions not covered by DIN EN 61800-5-2

Transferring safe position values of SINAMICS S120
using PROFIsafe telegram to a higher-level fail-safe
SP Safe position control system (F-CPU)
Only available with restrictions for safety functions
without encoder.
Using this function, the holding torque of up to 2
(holding) brakes can be checked.

SBT Safe Brake Test In conjunction with the SBC function, a safety-
relevant brake can be implemented.
For CU320-2/CU310-2, these extended safety functions can be controlled (with the
exception of SBT) via PROFIsafe with PROFIBUS or PROFINET – as well as via a
TM54F terminal expansion module. For the CU310-2, safety-relevant onboard
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terminals are also available for control. The SBT function is not controlled using
safety-relevant signals.
In the current example, a SIMATIC F-CPU uses the PROFIsafe telegram with
PROFINET to control the safety functions. The "Safe Brake Test" (SBT) function is
controlled using telegram 701 (Safety Info Channel SIC and Safety Control
Channel SCC).
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1 Task
1.1 Overview
Overview of the automation task

The following diagram provides an overview of the automation task.
Fig. 1-2: Concept of the safety functions
STO + SBC Safe

brake
M
Emergency
Stop button Drive Brake
-S1
SBT
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Description of the automation task

Using the safety function "Safe Brake Control" (SBC), the (holding) brake is safety
controlled each time an Emergency Stop is initiated. However, a safety-relevant
control is not sufficient to implement a safety-relevant brake or a safety-relevant
holding system. It must be guaranteed that the safely controlled brake can also
provide the required holding torque.
The holding torque or the holding force can be checked using the Safety Integrated
Extended Function "Safe Brake Test" (SBT) available from version V4.6. Up to 2
brakes per drive can be tested using this safety function.
Handling this function when using the basic positioner (EPOS) is described within
the scope of this function example. This includes configuring the required function
modules as well as their control using a SINAMICS S120 drive and a higher-level
SIMATIC F-CPU.
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1 Task
1.2 Requirements
1.2 Requirements
Requirements of the automation task
Table 1-3: Requirements when using the "Safe Brake Test" (SBT) safety function
Requirement Explanation
SBT is only available for safety functions
Using a safety-capable encoder concept.
with an encoder.
Enabling Safe Brake Control (SBC) for SBC must be enabled for testing the
testing the (motor holding) brake brake, which is operated using the
controlled from the SINAMICS SINAMICS brake control.
SBT is part of the Extended Safety
Enabling the Safety Integrated Extended
functions. As a consequence, these
Functions
must be enabled.
License for using the Safety Integrated SBT is part of Safety Integrated
Extended Functions of SINAMICS S120 Extended Functions.
"Closed-loop speed control with
It is not possible to use the SBT function

encoder" (p1300=21) must be configured
in other operating modes.
as operating mode.
The SBT safety function is available from
Using firmware V4.6 or higher
Version V4.6.
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2 Solution
2.1 Overview of the overall solution
2 Solution
Schematic
The following schematic diagram shows the most important components of the
solution:
Fig. 2-1: Components relevant when controlling the SBT function

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This function example shows how to control the STO safety function with SBC via
PROFIsafe – and to control SBT using telegram 701 (Safety Info Channel / Safety
Control Channel). The function example also shows how to operate the basic
positioner (EPOS) on a SINAMICS S120 drive.
The drive line-up in the booksize format comprises an infeed and a Double Motor
Module. Position control and motor control is carried out by a Control Unit CU320-2
PN. This involves hardware that is installed in the SINAMICS S120 demonstration
cases. In this particular example, only one motor is controlled from the Double
Motor Module; this motor is equipped with a brake. This motor is not contained in
the demonstration cases. A Smart Line Module is used as infeed.
The safety-relevant signals are sensed using fail-safe inputs of the ET200M series
and logically processed in the F-CPU. The F-CPU sends the fail-safe data to the
drive via the PROFIsafe telegram, where it controls the safety functions.
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2 Solution
Signals from the switchbox belonging to the demonstration case are used to
operate EPOS and the SBT function. These are cyclically communicated to the F-
CPU, where they are evaluated. Telegram 110 to operate EPOS and telegram 701
to control SBT are generated from these signals and transferred to the drive.
Configuration
This function example is based on the SINAMICS S120 training case (6ZB2 480-
0BA00) and the SAFETY training case.
Advantages
The application described here offers you the following advantages:
The "Safe Brake Test" (SBT) safety function integrated in the drive can be
simply controlled
Simple design using standardized technology
Space-saving and low-cost design using integrated safety functions –
additional hardware is not required
A project example that can be used for demonstration purposes
The project example can be used to transfer individual blocks/function modules
to your own project
This description provides basic knowledge for using the SBT safety function;
even if this is used without the EPOS function module.
Demarcation
This application does not contain a description of
the safety functions of the SINAMICS S120
the general drive functions of the SINAMICS S120
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the "basic positioner" function module (EPOS) of the SINAMICS S120

the hardware interfaces of the CU320-2
It is assumed that readers have basic knowledge of these topics.
Information on these topics can be found in the documents in the references.
Knowledge required
It is assumed that readers have basic knowledge of engineering SINAMICS S120
drives with the STARTER and STEP7 engineering software.
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2 Solution
2.2 Description of the core functionality
Overview and description of the hardware used

Fig. 2-2: Hardware components used
Sequence of the core functionality

Switches -S1 to -S4 are located on a switchbox that belongs to the Safety training
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case. For this particular application example, only the Emergency Stop pushbutton
(-S1) and pushbutton (-S4) are used. The STO function (with SBC) is initiated
using –S1. Pushbutton -S4 is used for fail-safe acknowledgement.
Switches -S5 to -S8 are located on a switchbox that belongs to the SINAMICS
training case. Using these switches, the drive is switched on and switched off,
traversing programs started, tracking operation selected – and the test stop for the
safety functions initiated.
The remaining switches -S9 to -S12 are used to select the Safe Brake Test, start
the test direction as well as select the particular test sequence.
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Typical applications
Table 2-1: Typical applications
Machine or sector Task Fig.
Hoisting drives for cranes or

Implementing a safety-
electric suspended
relevant holding system
monorails
Main press drives that have

Implementing a safety-
integrated operator safety
relevant brake
functions
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2 Solution
2.3 Hardware and software components used

The application was created with the following components:
Hardware components
Table 2-2: Safety training case (essential components)
Component Type MLFB/ordering data Qty Manufactu
rer
SITOP SMART
SITOP power supply 6EP1 333-2AA01 1 Siemens
120W
CPU 315F-2 PN/DP 6ES7 315-2FH13-0AB0 1 Siemens
SIMATIC S7-300 CPU SIMATIC MMC,
6ES7 953-8LJ20-0AA0 1 Siemens
512KB
SIMATIC S7 fail-safe
SM 326 F-DI 24 6ES7 326-1BK01-0AB0 1 Siemens
input module
SIMATIC S7 fail-safe
SM 326 F-DO 8 6ES7 326-1BF40-0AB0 1 Siemens
output module
SINAMICS fail-safe
TM54F 6SL3055-0AA00-3BA0 1 Siemens
Terminal Module
Cable, gray, metal

Drive-CLiQ 6FX2002-1DC00-1AC0 1 Siemens
connector
Toggle switch 0-I,
Protective door latching, 16 mm, 3SB2000-2AB01 2 Siemens
simulation switches black
S2 and S3 Holder with solder
3SB2908-0AB 2 Siemens
pins
Mushroom
Emergency Stop pushbutton, red, 16 3SB2000-1AC01 1 Siemens
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command device mm
S1 Holder with solder
3SB2908-0AB 1 Siemens
pins
Pushbutton, flat, 16
3SB2000-0AG01 1 Siemens
Reset button mm, white
S4 Holder with lamp
3SB2455-1B 1 Siemens
socket and lamp
Type PO595-0 Style
Load resistors 0207 Yageo
1kOhm 1W 1
R1 .. R8 Power metal oxide film Europe
resistors
ST 2.5-QUATTRO- Phoenix
3038451 8
Terminals for load TG Contact
resistors (R1..R8) P-CO component Phoenix
3036796 8
connector Contact
WID_MET_SHT_1K2_+-
SMA0207 1K2 1%
Load resistor R9 1%_600mW_+50ppm_0 1 Beyschlag
TK
207
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TERMINALS_ACC
ESSORY_EMPTY_
280-801 1 WAGO
CONNECTOR_TYP
Terminals for load E1_GRAY
resistor (R9)
TERMINAL_4-
CONDUCTOR_GR 280-686 1 WAGO
AY
Table 2-1: SINAMICS training case

rer
SINAMICS training
S120 CU320 6ZB2 480-0BA00 1 SIEMENS
case
Table 2-2: Additional Components

rer
Control Unit CU320-2 PN 6SL3040-1MA01-0AA0 1 SIEMENS
Motor with brake 1FT6 1FT6062-1AF71-3AH1 1 SIEMENS
Note The application example was tested with the hardware components listed here.
Alternatively, other components with the same function may be used. In such a
case, a different parameter assignment and different wiring of the components may
be required. Components marked yellow are not relevant for this function example.
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Standard software components

Table 2-5: Engineering software
rer
STEP 7 V5.5 SP2 HF1 6ES7810-4CC10-0YA7 1 SIEMENS
S7 Distributed Safety
V5.4 SP5 6ES7833-1FC02-0YA5 1 SIEMENS
Programming
S7 F Configuration
V5.5 SP10 1 SIEMENS
Pack
STARTER V4.3.2.0 6SL3072-0AA00-0AG0 1 SIEMENS
Sample files and projects

The list below contains all the files and projects used in this example.
Table 2-6: State of the function example when supplied
Component Note
MC_FE_I_016_V10.zip Project
76457011_MC_FE_I_016_V10_en.pdf This document
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3 Function mechanisms of this application
3.1 "Safe Brake Test" (SBT) function description

General information
Using the "Safe Brake Test" (SBT) safety function, the holding torque (rotary
drives) or the holding force (linear drives) can be tested for up to two brakes for
each drive. Brakes can be tested, that are directly controlled by SINAMICS S120
as well as externally controlled brakes (e.g. from a PLC).
The SBT function complies with SIL 1 (acc. IEC 61508) and PL d / Cat. 2 acc. to
EN ISO13849-1.
The parameters of this function can only be modified in the safety commissioning
mode, and are protected against undesirable or unauthorized changes using a
safety password. Contrary to all other safety function parameters, the SBT function,
parameter management for the SBT function is only controlled through one
channel.
During the test, the drive establishes a configurable test torque against the closed
brake and checks whether axis motion exceeds a parameterizable tolerance
window – or not. In parallel, the system monitors that the speed lies below 1% of
the configured maximum drive speed. The brake is operating correctly if motion
remains within the tolerance and the speed below the specified limit.
You can select two test sequences for each brake. Within these test sequences,
different holding torques can be parameterized, for example. Further, the test
torque sign can be switched over using a signal.
Input and output signals are available for the interaction with externally controlled
brakes. These are used to request that the brake is closed, and a feedback signal
can be given to SBT as to whether the external brake is open or closed.
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The actual states and test progress can be monitored using a status word (r10234)
and a diagnostics parameter (r10240).
When selected, the SBT function determines the actual load torque available, and
takes this into account when entering a test torque.
Preconditions
The following preconditions must be fulfilled to be able to use the SBT function:
Enabling the Safety Integrated Extended Functions; SBT is also available for
the safety functions without selection
Using a safety-capable encoder concept and configuring Extensive Functions
with encoder
Closed-loop speed control with encoder (p1300=21) must be configured as
control mode
When testing the (motor holding) brake, that is controlled by SINAMICS, SBC
must also be configured and the brake configuration parameterized just like the
sequence control (p1215=1).
When selecting the SBT function the pulses must be enabled and the brakes
open.
When SBT is selected, the actual speed value must not exceed 1% of the
maximum speed (p1082).
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Control
You can operate the SBT function in the following ways:
BiCo signals (p10203 = 1)
Interconnection of the individual signals (e.g. DIs) with the SBT control word
p10230[0..5]
Safety Info Channel / Safety Control Channel (SIC/SCC) (p10203 = 0)
The control and status word of the SBT function are included in telegram 701
(see Section 3.2)
Automatic start when selecting a test stop (p10203 = 2)
However, using this control type, only one brake can be tested, which is
controlled by SINAMICS. Further, it is not possible to switch over the sign of
the test direction and select the test sequences using signals.
For this particular case, the sign of the test torque is only specified using
parameter p10218.
Configuring
Some information about the individual parameters of the STARTER screen form
belonging to the SBT function is provided in the following. For reasons of
transparency, only individual sections of the screen form are shown.
Fig. 3-1: Overview of the STARTER screen form for SBT

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Fig. 3-2: Configuring Part 1 - basic SBT settings
To use the SBT function, it must be enabled using parameter p10201, bit 0.
The SBT function is available for linear and rotating drives. The drive type is
configured in p10204. Generally, adaptation is not required, as when safety is first
commissioned, the parameter is taken from r108 bit 12.
The control type is selected using parameter p10203.
= 0: Control via SCC/SIC (telegram 701)
= 1: Control via BiCo

= 2: Control when selecting a test stop
Fig. 3-3: SBT function diagram

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The principle of operation of the brake test is graphically described in the diagram
above. The test torque is established within a configurable time, and is kept
constant for a parameterizable test time. The torque is then decreased. Axis motion
is monitored during this time. The position tolerance can also be configured.
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Fig. 3-4: Configuration Part 2 – basic settings for the test
In the next step, p10202 is used to select which brake is to be considered in SBT
as brake 1 or brake 2. Index 0 indicates the setting for brake 1, index 1 stands for
brake 2. P10202 can assume the following values:
= 0: block (if the corresponding brake is either not available or is not to be
tested)
= 1: Motor holding brake
= 2: External brake
The time, in which the test torque to be established and later also decreased to
zero, is specified in p10208.
The basic value of the test torque to test the brakes is parameterized using
p10209.
Note Please note that the torque that can be achieved depends on factors such as
current limits, torque limits, power limits etc. It is possible that these quantities
must be changed in order to achieve the configured test torque.
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CAUTION When entering the test torque, observe the maximum permissible torque of
the brake. If this is exceeded, the test can damage or even destroy the
holding brake.
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Fig. 3-5: Configuration Part 3 – parameterizing the test sequences
Using parameters p10210 and p10220, a factor is set for the individual test
sequences; it is multiplied by the value in p10209, to obtain the test torque for the
particular sequence. The permissible range of values extends from 0.3 up to 1.0.
The permissible position tolerance for each test sequence is defined using
parameters p10212 and p10222.
The duration of the particular test sequence is parameterized in p10211 or p10221
.
Fig. 3-6: Configuration Part 4 – additional settings for control via BiCo
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If control using BiCo signal is selected in p10203, then the links to control
parameter P10230 of function SBT are visible in the SBT screen form. The
individual bits are linked with the following functions:
Index 0: Selects the SBT function
Index 1: Starts the selected test sequence
Index 2: Selects the brake for the test
Index 3: Selects the test torque sign
Index 4: Selects the test sequence
Index 5: Feedback signal of an externally controlled brake; a signal is not
required here if only a motor brake is considered
To test an externally controlled brake, information is available in bits 6 of the SBT

status word (r10234) as to when the brake should be opened or closed. This bit
must then be transferred to the control system, which is responsible for
opening/closing the external brake. The particular feedback signal must then be
connected to index 5 of p10230. After SBT requests that the external brake is
opened or closed, the particular feedback signal must be available after a
maximum of 11 seconds. Message A01783 is output and the SBT function is
canceled if the feedback signal is received later.
Execution
Fig. 3-7: Executing SBT
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A successful brake test sequence comprises the following steps:

The currently effective load torque is determined after selecting the SBT function
(positive edge). The pulses must be enabled and the brakes open to select the
function.
The brake test is started (positive edge) after the particular brake, the sign of the
test torque and the test sequence have been selected
The brake to be tested is now closed, or the signal to close the brake is output.
After the brake has been closed, the test torque (taking into account the actual
load) is established in the configured time, kept constant for the parameterized time
(and this value is monitored) and is then decreased back to zero. The (standstill)
position and the speed are monitored at the same time.
At the end of the brake test, the particular brake is opened again or the signal to
open the brake is output.
Additional information on the "Safe Brake Test" (SBT) function is provided in the
Function Manual Safety Integrated Edition 01/2013 see /1/ in the references).
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3.2 Safety Info Channel (SIC) and Safety Control Channel (SCC)
3.2 Safety Info Channel (SIC) and Safety Control Channel

(SCC)
General information
Using the Safety Info Channel (SIC), status information about the Safety Integrated
functions of the drive can be transferred to a higher-level control system (e.g. F-
PLC, SIMOTION).
Using the Safety Control Channel (SCC), a higher-level control system can transfer
standard signals to the Safety Integrated functions of the drive. Currently, initiating
the test stop function and the operating signals for the "Safe Brake Test" are
contained here.
Note Fail safe communication does not take place using SIC and SCC. Only non-
safety relevant data are exchanged here.
Content of Safety Info Channel (SIC)

The Safety Info Channel comprises up to 5 words, and depending on the selected
telegram, contains the following data:
S_ZSW1B: Status word 1 of safety functions (r9734); 16 bit

Status information of the STO, SS1, SS2, SOS, SLS, SDI functions, as well as
safety messages
S_ZSW2B: Status word 2 of the safety functions (r9743); 16 bit
Status information of the SDI and SLP functions as well as the test stop
S_V_LIMIT_B: Actual limit for the setpoint velocity r9733[2]; 32 bit
S_ZSW3B: Status word 3 of the safety functions (r10234); 16 bit, the status
word of the SBT function is also contained here
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Table 3-1: Structure of S_ZSW3B

Bit Meaning Remark Parameter
1 Brake test selected
0 Brake test r10234.0
0 Brake test deselected
1 Setpoint input defined by the brake test
Setpoint input
1 Setpoint input according to the setpoint r10234.1
drive/external (*) 0
channel
1 Test brake 2 active
2 Active brake r10234.2
0 Test brake 1 active
1 Test active
3 Brake test active r10234.3
0 Test inactive
1 Test successful
4 Brake test result r10234.4
0 Test error
1 Test run
5 Brake test completed r10234.5
0 Test incomplete
External brake 1 Close brake
6 r10234.6
request 0 Open brake
1 Negative sign
7 Sign of the actual load r10234.7

0 Positive sign
8..13 Reserved -- -- --
Acceptance test SLP 1 Acceptance test SLP selected
14 (SE) r10234.8
selected 0 Acceptance test SLP deselected
Acceptance test mode 1 Acceptance test mode selected

15 r10234.9
selected 0 Acceptance test mode deselected
(*): setpoint input drive stands for the setpoint specified by the SBT function; setpoint input external, stands
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for the standard setpoint input via the setpoint channel.
Note The information in status word of SBT (S_ZSW3B) is reset if SBT is deselected
with a negative edge at bit 0.
Bits 2, 4 and 5 of S_ZSW3B are already reset for a negative edge at bit 1 (start
test sequence). In this case, it is expected that an additional sequence will be
started or the other brake tested.
You can find the structure of the other status words in Chapter 7.20.20 of the
Function Manual Safety Edition 01/2013 /1/.
Content of the Safety Control Channel (SCC)

The Safety Control Channel comprises 2 words and contains the following data:
S_STW1B: Control word 1 of the safety functions p10250; 16 bit;
Currently, only bit 9 is used to select the test stop of the Extended Functions.
S:STW3B: Control word 3 of the safety functions (r10235); 16 bit;
The bits to control the SBT function are contained here.
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Table 3-2: Structure of S_STW3B

Bit Meaning Remark Parameter
1 Pos. starts the SBT function
0 Select brake test r10231.0 (*)
0 Deselects the SBT function
Pos. edge starts the selected test
1
1 Start brake test sequence r10231.1 (*)
0 Test sequence is exited
1 Test brake 2 is selected
2 Brake is selected r10231.2 (*)
0 Test brake 1 is selected
Direction of rotation is 1 Negative direction of rotation is selected
3 pr0231.3 (*)
selected 0 Positive direction of rotation is selected
Test sequence is 1 Test sequence 2 is selected
4 r10231.4 (*)
selected 0 Test sequence 1 is selected
1 External brake closed
5 Status of external brake r10231.5 (*)
0 External brake open
6..15 Reserved -- -- --
(*): S_STW3B is linked with p10235 on the drive side. The bits listed above are the diagnostic bits
belonging to this parameter, which are used for monitoring.
The feedback signals are reset when deselecting or before starting a new test
sequence. This means that the feedback signals of the SBT function should be
transferred to a higher-level (safety-relevant) control and suitably evaluated. For
instance, the feedback signals of the particular test sequences should be saved in
the program there, and it should be determined as to whether the brake(s) function
correctly and whether access to the dangerous zone can be permitted – or not. If
the brake test is to be cyclically executed, then appropriate timers must be
configured there. The SBT function does not include functions such as these.
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Telegram 700
If only the status information (S_ZSW1B) and the actual limit value of the
velocity/speed (S_V_LIMIT_B) of the safety functions is required, then this
information can be transferred to the higher-level control using telegram 700.
Slots for this data must be manually created as telegram expansion and/or
supplementary data in the drive telegram configuration. STARTER/SCOUT do not
support this functionality at the present time. Parameter p60122 (= 700) can be
used to internally interconnect these PZDs with the corresponding feedback signal
parameters of the drive.
Table 3-3: Telegram 700 structure

Receive data Parameter Transmit data Parameter
PZD1 -- -- S_ZSW1B r9734
PZD2 -- --
S_V_LIMIT_B r9733[2]
PZD3 -- --
Note The SBT function cannot be controlled using telegram 700.
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1.0, Entry ID: 76457011 25
3.3 Data blocks DB100 and DB102
Telegram 701
Telegram 701 must be configured in order to be able to use the Safety Control
Channel and to be able to transfer all feedback signals of the drive safety functions
to the control. The test stop and the SBT function can be controlled with the receive
data of this telegram.
Just the same as for telegram 700, also here, the slots for the data transfer must
be manually created in the telegram configuration of STARTER/SCOUT.
Parameter p60122 (=701) can again be used to establish the interconnections with
the parameters listed in the following table.
Table 3-4: Telegram 701 structure

Receive data Parameter Transmit data Parameter
PZD1 S_STW1B p10250 S_ZSW1B r9734
PZD2 S_STW3B p10235 S_ZSW2B r9743
PZD3 -- --
S_V_LIMIT_B r9733[2]
PZD4 -- --
PZD5 -- -- S_ZSW3B r10234
Summary
Telegrams 700 and 701 help to exchange data between the drive safety functions
and the higher-level control system. However, it is also possible to exchange this
data without using these telegrams. However, in this case, all of the links with the
PZD slots that have had been created, must be manually established.
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NOTICE If you access the input and/or output data of the drive using the SFC14/15
functions, when creating the slots it should be noted as to whether you are
reading out all PROFIdrive data together – or you are specifically accessing the
data of telegrams 700/701.
Overall access: PZDs must be created as telegram extension
Separate access to telegram 700/701: PZDs must be created as supplementary
data.

The signals to switch on/switch off the drive and to start traversing motion using
EPOS are created in the standard F-CPU program.
In the example, the preconfigured DB100 and DB102 data blocks are used to
control telegram 110 of SERVO_03 and telegram 390 of the Control Unit.
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26 1.0, Entry ID: 76457011
The data of a DP slave or a PROFINET device are consistently read or written

using system functions SFC14 (DPRD_DAT) and SFC15 (DPWR_DAT). The
specified data blocks are used here as buffer memory. To start, the status date of
the drive and the CU are read out using SFC 14 and written to DB100 or DB102
(receive data). This data can then be used, and control data are subsequently
saved in DB100 or DB102. At the end, these transmit data are transferred to the
drive and/or the Control Unit consistently using SFC15.
"Drive1" is the symbolic name for DB100.
Table 3-5: Content of DB100 (drive 1)

Address in Associated
Symbol Address in DB
the drive parameters
Receive data (from the drive perspective)
WR_PZD_POSBETR.STW1 DB100.DBW0 AW256 --
WR_PZD_POSBETR.SATZ_ANW DB100.DBW2 AW258 --
WR_PZD_POSBETR.PosStw DB100.DBW4 AW260 --
WR_PZD_POSBETR.STW2 DB100.DBW6 AW262 p2045
WR_PZD_POSBETR.OVER DB100.DBW8 AW264 p2646

WR_PZD_POSBETR.MDIPos DB100.DBD10 AD266 p2642
WR_PZD_POSBETR.MDIVel DB100.DBD14 AD270 p2643
WR_PZD_POSBETR.MDIAcc DB100.DBW18 AW274 p2644
WR_PZD_POSBETR.MDIDec DB100.DBW20 AW276 p2645
WR_PZD_POSBETR.MDIMode DB100.DBW22 AW278 p2654

Transmit data (from the drive perspective)
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RD_PZD_POSBETR.ZSW1 DB100.DBW24 EW256 r2089[0]
RD_PZD_POSBETR.Akt_Satz DB100.DBW26 EW258 r2670
RD_PZD_POSBETR.PosZsw DB100.DBW28 EW260 r2683
RD_PZD_POSBETR.ZSW2 DB100.DBW30 EW262 r2098[1]
RD_PZD_POSBETR.MeldW DB100.DBW32 EW264 r2089[2]
RD_PZD_POSBETR.XistP DB100.DBW34 ED266 r2521[0]

Diagnostic parameters for data transfer
RetVal1 DB100.DBW38 -- --
Data block DB100 (drive1) therefore includes all of the transmit and receive data of
the SERVO_03 drive required to operate and use the EPOS function.
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1.0, Entry ID: 76457011 27
"Digital Inputs" is the symbolic name of the DB102.
Table 3-6: Content of DB102 (digital inputs)

Address in Associated
Symbol Address in DB
the CU parameters
Receive data (from the CU perspective)
WR_PZD_DIDO.STW DB102.DBW0 AW284 p2045
WR_PZD_DIDO.Digital_Output DB102.DBW2 AW286 --

Transmit data (from the CU perspective)
RD_PZD_DIDO.ZSW DB102.DBW4 EW284 r2089[1]
RD_PZD_DIDO.Digital_input DB102.DBW6 EW286 r2089[2]

Diagnostic parameters for data transfer
Within the scope of this function block, from the DB102 (digital inputs), only the
status values of the digital inputs of the DIs of the Control Units are required. These
are used in the standard program to switch off/switch on the drive, to control EPOS
and to operate the SBT function.
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28 1.0, Entry ID: 76457011
4 Installation
4.1 Installing the hardware
4 Installation

The hardware configuration used for this function example is shown in the following
diagrams. Standard demonstration cases were predominantly used.
Fig. 4-1: Overview of the test setup (schematic)

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EPOS und SBT

1.0, Entry ID: 76457011 29
4 Installation
Fig. 4-2: SINAMICS demonstration case cabling

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EPOS und SBT

30 1.0, Entry ID: 76457011
4 Installation
Fig. 4-3: Wiring the F-DIs/F-DOs in the safety demonstration case

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EPOS und SBT

1.0, Entry ID: 76457011 31
5 Configuration and project engineering
5.1 Passwords

In this chapter, you get to know how the individual components must be
parameterized. The STARTER tool is used as engineering software for SINAMICS
S120. STEP7 and Distributed Safety are required when programming the F-CPU.
How the project belonging to this function example was created is described step-
by-step below.
Note These screenshots were set with the language set to English. The graphics
might differ for other language settings.
5.1 Passwords
For reasons of simplicity, a common safety password is used for the program and
hardware on the SIMATIC components in the project.
Safety password for the F-CPU: "0"
Safety password for SINAMICS: "1"
NOTICE In a real application it is not permissible that basic passwords such as

these are used. This is because the configuration is not adequately
protected against unauthorized access.
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32 1.0, Entry ID: 76457011
5.2 Preparation
5.2 Preparation
All of the relevant data is transferred via the PROFINET interfaces of the F-CPU
and the CU320-2 PN (SINAMICS S120). These include:
Configuring and programming the components using STEP7 and STARTER
Control signals of the drive (telegram 110)
Control signals for operating the safe brake test (supplementary data)
PROFIsafe data (control of the safety functions in the drive and associated
feedback signals)
Before configuring can be started, the PROFINET interface of the computer being
used must be suitably set.
Table 5-1: Setting the PG/PC interface

No. Action Remark
Please open the SIMATIC

Manager to change the

PC/PG interface settings.
1. Then click on "Options"
and in the menu tree,
select the "Set PG/PC
Interface" entry.
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Select the hardware via

which you wish to establish
an online connection.
In this particular example, it
involves the USB Ethernet
2.
adapter "ASIX AX88178
USB2.0".
Open the properties
window using the
"Properties" button.
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1.0, Entry ID: 76457011 33
5.2 Preparation
No. Action Remark
In the subsequent window,

please click on the
3.
"Network properties"
button.
Select the network

connection being used,
4. and open the status
window by double-clicking
on the appropriate network.
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Now press the "Properties"

5.
button.
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34 1.0, Entry ID: 76457011
0
No. Action Remark
Now select the menu item

"Internet Protocol
6.
(TCP/IP)" and click the
"Properties" button.
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Now set a fixed IP address.

The following setting is
used in this particular
example:
IP address:
192.168.0.100
7. Subnet mask:
255.255.255.0
Confirm the entry with

"OK", and close all of the
screen forms that are still
open.
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1.0, Entry ID: 76457011 35
5.3 Hardware configuration

Table 5-2: Hardware configuration
No. Action Remark
Please create a new

SIMATIC project.
In this particular example,
"MC_FE_I_016_V10" was
selected as project name.
As a first step, now enter a
SIMATIC 300 station into
1. the project.
To do this, click on the

"Insert" menu item.
In the following submenu,
select the "Station" entry
and then "2 SIMATIC 300
station".
Now open the window to

configure the hardware

being used.
2.
This is done, for example,
by double-clicking on the
"Hardware" entry.
In the "HW Config"
window, first insert a rack.
Then select the F-CPU
being used and insert this.
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To do this, you can drag

the F-CPU and drop it into
the rack (profile rail).
In this particular example,
the following F-CPU is
used:
"CPU 315F-2 PN/DP".
The adjacent window is
3. displayed once this has
been done.
Here, please check that the
IP address of the CPU is
located in the address area
of the PC/PG interface,
and press the "New" button
to create a new subnet
(PROFINET).
In the example, the IP
address "192.168.0.1" and
the name "PN-IO" are used
for the F-CPU.
EPOS und SBT

36 1.0, Entry ID: 76457011
No. Action Remark
Please confirm that you

have created the new
4.
subnet by pressing the
"OK" button.
Now please make the

basic settings with which
safety operation of the F-
CPU being used is
activated. To do this, open
the properties window (by
double-clicking on the F-
CPU) and go to the
"Protection" tab.
Activate safety operation

by setting a checkmark for
"CPU contains safety
5. program".
Select level 1 as protection
level, and activate access
by entering the appropriate
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password.
Assign a password for the
safety program. The
number 0 is used as
password in this particular
example.
Click "OK" to confirm the

data that you have entered.
EPOS und SBT

1.0, Entry ID: 76457011 37
No. Action Remark
Now insert the F-DI module

of the safety demonstration
case by dragging &
dropping.
A "FDI24xDC24V" module
is used in this particular
example.
6.
Check the address settings
for the input and output
area of the data.
In this example, the
following applies:
Input address: 0..9
Output address: 0..3
Make the following

changes in the properties
window of the F-DI module
under the "Parameters"
tab.
Configure the
7.
PROFIsafe address
according to the DIL
switches
(in the example: 199).
Select the "Safety
mode".
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Set "Passivate the

channel" as response to
faults and errors. Set a
checkmark for "Sensor
supply via module" and
then remove the
8. checkmark for "Short-
circuit test".
Please make the settings

shown here for F-DI0
(channel 0, 12).
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38 1.0, Entry ID: 76457011
No. Action Remark
Configuring F-DI 1
(channel 1, 13) *
Configuring F-DI 2
(channel 2, 14) *
9.
Configuring F-DI 3
(Channel 3, 15)
Configuring F-DI 5
(channel 5, 17) *
(*): Is not used in this

particular example.
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Now insert the F-DO

module of the safety
demonstration case by
dragging & dropping.
A "FDO8xDC24V/2A"
module is used in this
particular example.
10. Check the address settings
for the input and output
area of the data.
following applies:
Input address: 10..14
Output address: 10..14
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1.0, Entry ID: 76457011 39
No. Action Remark
In the properties window of

the F-DO module, under
the "Parameters" tab, set
the PROFIsafe address
11. according to the DIL
switches
(in the example: 200).
As response to channel
errors, select "Passivate
the channel".
Only DO 7 is used in the
12. example. For this reason,
remove the checkmark for
"Activated" at all other F-
DOs.
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Now insert the SINAMICS

S120 into the hardware
configuration.
In the catalog, select a
13. SINAMICS S120 with
CU320-2 PN and drag the
component with version
V4.6 and drop at the
PROFINET that has been
created (Ethernet 1).
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40 1.0, Entry ID: 76457011
No. Action Remark

The following window is
opened after insertion.
Here, select the subnet in
which the SINAMICS S120
is to be operated.
This is network "Ethernet
1" in the example.
Also check the

14. automatically created
address. The CU320-2 PN
is assigned address
192.168.0.2 in the
example. The standard
value
"S120xCU320x2xPN" is
used as name.
Close the window by

clicking "OK."
In the following window,

check the setting of the
firmware version.
15.
Firmware version V4.6
must be selected for this
example.
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At this point, save and

16. compile the hardware
configuration.
Now open "NetPro" to
17. insert the PC/PG into the
configuration.
From the catalog, select

the PG/PC object and drag
it to the work area.
18.
Open the properties
window by double clicking
on the symbol.
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1.0, Entry ID: 76457011 41
No. Action Remark
Select the "Interfaces" tab,

and press the "New" button
to configure a new network
interface.
19. An "Industrial Ethernet"
interface is required for the
example.
Confirm your selection with
"OK".
Select the newly created

interface, and press the
"Properties" button to open
the window that is
displayed.
Remove the checkmark for
"Set MAC address / use
ISO protocol", and set the
same network address and
20. subnet mask that you
assigned when setting the
PC/PG interface in Section
5.2.
The following IP address is
used in the example:
192.168.0.100
Confirm your entries with
"OK".
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Now select the

"Assignment" tab to assign
the interface to the
hardware being used.
21. To do this, select the
appropriate interface (in
the example: TCP/IP ->
ASIX AX88178…) and
press "Assign".
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42 1.0, Entry ID: 76457011
No. Action Remark
The assigned interface is

displayed in the "Assigned"
window. Please check that
the checkmark is set for
22. "S7ONLINE Access".

"OK".
The computer is now

inserted with an active
connection shown in
yellow.
23. Please save and compile

the changes that you have
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made.
Then close "NetPro" to

return to HW Config.
Now please save and

24.
compile HW Config again.
Now load the configuration
25.
to the F-CPU.
Note It may be necessary that you assign the IP addresses and names used in this
example to the CU320-2 PN and the F-CPU (initialization).
You can find information on how to proceed in the SINAMICS S120
Commissioning Manual /6/ in Sections 2.2.4 and 2.2.5 (from page 68 onwards).
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1.0, Entry ID: 76457011 43
5.4 Configuring the basic drive functions

All of the necessary settings of the SINAMICS S120 drive lineup are explained in
this section, which are necessary to traverse the axes. This includes the basic
setting (e.g. selecting the components), but also configuring the basic positioner
(EPOS). Configuring the interfaces and the "Safe Brake Test" (SBT) function are
described in a dedicated section.
Note Only those screen forms are described in the following where values that deviate
from the default settings must be set.
Table 5-3: Configuring the basic drive functions

No. Action Remark
Please open the existing

S7 project from STARTER.
1. You can do this by double-
clicking on
"Commissioning".
Now go online and start the

automatic drive
configuration.
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2. To do this, in the project

navigator select the
"Automatic Configuration"
entry and then press the
"Configure" button.
Select "Servo" as the

control mode.
3.
Then press the "Create"
button.
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44 1.0, Entry ID: 76457011
No. Action Remark
You are requested to go

offline once the automatic
configuration has been run.
4.
To do this, press "Go
OFFLINE".
Only the "SERVO_03"

drive is used for this
particular function
example.
5. Please delete the

"SERVO_02" drive that
was automatically created.
Select the drive, press the
right mouse key and select
the "Delete" menu item.
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In the next step the

"SERVO_03" drive must be
post configured.
6. To do this, in the project

navigator select the
"Configuration" entry, and
then press the "Configure
DDS..." button in the
associated window.
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1.0, Entry ID: 76457011 45
No. Action Remark
In this example, the basic

positioner is used to
traverse the drive.
7. Please activate this

function module by setting
a checkmark for "Basic
positioner". Then press
"Next".
A HIGH signal at "Infeed in

operation“ (p0864) is
required to operate the
drive.
Fixed binector 1 is used
here in the example.
Note:
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8.
It is not permissible that
fixed binector 1 is used in a
real application. The
feedback signal of the
infeed must be used here.
Exit the entries in this

window with "Next".
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46 1.0, Entry ID: 76457011
No. Action Remark

The 1FT6 motor used in
the example is not
equipped with a Drive-
CLiQ encoder. This is the
reason that the motor must
now be selected.
Please select "Select

standard motor from list“,
and select the motor type
that you are using (in the
9. example: [206] 1FT6). The
list of saved motors is then
displayed, from which you
can select the motor being
used.
In the example, the
1FT6062-1AF71-3AH1
motor is used.
Close your entries with

"Next".
The basic settings of the

motor brake are configured
in the subsequent screen
form.
Select the entry "Use a

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10.
motor holding brake", and
for the brake configuration,
select "Motor holding brake
acc. to sequence control".
Then press "Next".
The encoder type that is

used is selected in the next
step.
For the
11. 1FT6062-1AF71-3AH1
motor used in this
example, please select
entry "1FT6xxx-xxxxx-
xAxx".
Now confirm your selection
with "OK".
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1.0, Entry ID: 76457011 47
No. Action Remark
The PROFIdrive telegram

is now selected.
For this example, select

telegram 110. This
telegram is generally
employed when using the
12. basic positioner.
Close the selection with

"Next".
This completes post

configuring the drive using
the wizard.
Save the configuration, go

13. online and load it to the
target device.
When using a Single Line

Module for 230V 1AC
(included in the training
cases), now adapt to the
DC link parameters. To do
this, open the expert list p0210: 345V
and make the adjacent
parameter settings. The p1248[0]: 240V
14. specified values can only p1244[0]: 401V
be changed online.
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See also FAQ ID: 27038754

Note
Since the 5 kW SLM has
no DRIVE-CLiQ interfaces,
it is not necessary to
configure the infeed.
Start copying from RAM to
ROM. Then load the
15.
configuration to the PC and
save it.
To continue the
16.
configuration, go offline.
EPOS und SBT

48 1.0, Entry ID: 76457011
No. Action Remark
In the example, telegram

701 (SIC/SCC) is used to
operate SBT. The safety
functions are controlled via
PROFIsafe.
17. To create the slots

required, please open the
configuration screen form
for communication.
To do this, in the project
navigator, select the
"Telegram configuration"
entry
In the first step, the

PROFIsafe telegram is
created. PROFIsafe
telegram 30 is used in this
example.
18.
To do this, press the
"Adapt telegram
configuration" button, and
in the menu, select "Add
PROFIsafe“.
The slots for telegram 701

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are then created. In the

example, these PZDs are
created as supplementary
data so that they can be
19. separately accessed.
Press "Adapt telegram

configuration" again and
now select the entry "Add
supplementary data“.
5 words of input and 2

words of output data are
required for telegram 701
(from the perspective of the
20. CPU!).
For "Length" enter the

values 5 (input data) and 2
(output data).
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1.0, Entry ID: 76457011 49
No. Action Remark

Telegram 390 is still
required to transfer the
digital input signals of the
CU320-2 PN to the CPU.
To do this, click on
telegram type for "Control
21. Unit", and select telegram
390.
Transfer the adapted

telegram configuration to
HW Config. To do this,
press the "Set up
addresses" button.
The overview of the

telegram configuration
should now match what is
shown in the adjacent
screenshot.
22.
Note:
Different addresses must
be subsequently taken into
account when generating PROFIsafe: Input data 15 - 20; output data 15 - 20
the program code. Telegram 110: Input data 256 – 269; output data 256 – 279
Supplementary data: Input data 270 – 279; output data 280 – 283
Telegram 390: Input data 284 – 287; output data 284 – 287
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The PROFIsafe drive

address still has to be
adapted.
To do this, please open

HW Config and select the
SINAMICS S120 object.
23.
The window shown is
opened by double clicking
on "PROFIsafe telegram
30".
Select the "PROFIsafe" tab
and click on "F_Dest_Add".
Now press "Change value".
Now enter the PROFIsafe

address of the drive.
24.
In the example, PROFIsafe
address 198
(= C6hex) is used.
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50 1.0, Entry ID: 76457011
No. Action Remark
After these changes have

been made it is necessary
to save and compile HW
Config and then
subsequently download the
25. modified configuration.
To do this, press the

buttons that have been
marked.
The receive data with the

variables shown are linked
in STARTER.
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This involves default

settings when selecting
telegram 110.
26.
At the present time, on the

drive side, telegram 701
has still not been linked,
and is therefore not
displayed.
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1.0, Entry ID: 76457011 51
No. Action Remark
The transmit data with the

variables shown are linked
in STARTER.
This involves default
settings when selecting
telegram 110.
27.
At the present time, on the

drive side, telegram 701
has still not been linked,
and is therefore not
displayed.
The basic positioner is

adapted in the next step.
28.
To do this, open the "Basic
positioner" menu item in
the project navigator
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The maximum values for

traversing velocity,
acceleration rates and jerk
are now set.
To do this, select menu

item "Limits" and then the
"Traversing profile
29. limitation" tab. For the
example, please enter the
following values.
p2571 = 30000 [1000Lrpm]

p2572 = 2000 [1000LU/s2]
p2573 = 2000 [1000LU/s2]
p2574 = 10000 [1000LU/s3]
p1575 = 1
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No. Action Remark
The traversing program

should be generated in the
next step.
To open the editor, please

30. select menu item
"Traversing blocks" and
then the "Traversing blocks
/ configuration" tab.
Now press the large button
at the center of the
window.
You can now generate the

traversing program in the
window shown.
The traversing program of

the function example is
shown in the adjacent
31. diagram.
The block change is

automatic and at the end, a
jump is made back to the
first command. An endless
loop is obtained in this
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way.
Now please save the
32.
project and then go online.
Please load the modified
configuration to the target
33.
device and initiate a RAM
to ROM copy operation.
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5.5 Generating the standard program

The signals to switch on/switch off the drive and to start traversing motion using
EPOS are created in the standard F-CPU program. The steps required to do this
are described in this section.
Importing data blocks DB100 and DB102

For data exchange of the standard program with the Control Unit and the
SERVO_03 drive, the predefined DB100 and DB102 data blocks are used in this
example. All of the steps that are required to transfer these blocks from the project
example to your project are listed in the following table.
Note You can also generate these data blocks yourself. You can obtain information
about the content of these data blocks from this section 3.3.
Table 5-4: Importing data blocks DB100 and DB102

No. Action Remark
To import the data blocks

into your project, first
dearchive the project
example.
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1.
To do this, click on "File"
and select the menu item
"Retrieve"
Now select the directory in

which you copied the
zipped project (zip file).
2.
Now select the file and
press the "Open" button.
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54 1.0, Entry ID: 76457011
No. Action Remark
In the next step, please

select the directory into
which the project should be
3. unzipped.
Unzip the project with

"OK".
Please open the unzipped

project to copy the data
4. blocks.
To do this press "YES".

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In the project navigator,

select the block folder and
then select the two data
blocks DB100 and DB102.
5.
Confirm using the right-
hand mouse key and select
menu item "Copy".
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No. Action Remark
Now return to your own

project. There, also open
the block folder.
Right-click at any location

6. in this folder and select the
menu item "Paste".
The data blocks have now

been inserted in your
project.
Additional steps to generate the standard program

As a result of importing the two data blocks, a structure is now available for
exchanging data with the SERVO_03 drive and the Control Unit.
The additional steps for generating the standard program are subsequently
described. This involves transferring the switch-on command to the drive, the
operating signals for EPOS, the signals used to control the "Safe Brake Test"
(SBT) function and the signal which is used to control the test stop of the extended
safety functions.
Digital inputs DI0 to DI7 of the Control Unit are used for operation; these can be set
using the switch box of the SINAMICS training case.
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56 1.0, Entry ID: 76457011
Table 5-5: Generating the standard program

No. Action Remark

standard program is
executed in a function
(FC).
To start, insert a "Function"

type object into the block
1. folder.
To do this, in the block

folder, right-click at any
location and select the
"Insert New Object" entry.
Now select the "Function"
object.
Please assign a name for

this function and select the
programming language.
The "FC2" name is used in

the example. The block is
2.
generated in the "Function
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block diagram" language

(FBD).
Confirm your settings with

OK.
This function is cyclically

called in OB1.
To do this, insert a network

in OB1 using the "CALL
3. FC 2" command.
Select STL as
Please save the block.
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No. Action Remark
Open FC2 and insert 2

networks.
In network 1, using system

function SFC14
(DPRD_DAT), the data of
drive SERVO_03 are now
read out.
The start address (LADDR)
is 256 (= 100hex).
4. In network 2, using system

function SFC14
(DPRD_DAT), the data of
the Control Unit are now
read out.
The start address (LADDR)
is 284 (= 11Chex).
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You can find the blocks

under "Libraries ->
Standard Library -> System
Function Blocks"
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No. Action Remark
Now insert 2 additional

networks.
In network 3, the command

for switch on (ON/OFF1) is
set using DI0.

5.
The reference point is set
in network 4 as soon as the
drive is in the "ready to
start" state and if it should
not yet be referenced
(homed).
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No. Action Remark

networks.
In network 5 positioning
motion of EPOS is started

6.
or stopped using DI1.
In network 6 the tracking

mode of EPOS is selected
using DI2.
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No. Action Remark

networks.
In network 7, the test stop

of the extended safety
functions is controlled
using DI3.
7.
In network 8, the SBT
function is selected using
DI4.
In network 9, the selected

test sequence of SBT is
started with DI5.
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No. Action Remark

networks.
In network 10, the sign of

the test torque can be
selected using DI6.
In network 11 you can

8. toggle between the two
SBT test sequences using
DI7.
In network 12, the control

signals for the SERVO_03
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drive are transferred to the

drive using system function
SFC15 (DPWR_DAT).
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5.6 Parameterizing the safety functions integrated in the drive
5.6 Parameterizing the safety functions integrated in the

drive
All of the steps necessary to commission the safety functions being used are
explained in this section. For this function example, the focus is on the "Safe Brake
Test" function. For this reason, in addition to this function, only the STO with SBC
functions are configured.
Configuring the other safety functions is described in other function examples.
Note The following describes how the safety functions are commissioned online. They
can be commissioned offline; however, this involves slight deviations when
configuring. Additional information can be found in the Safety Function Manual
(FHS) Edition 01/1013 /1/.
Only the screen forms are shown here where changes have to be made.
Table 5-6: Parameterizing SINAMICS Safety Integrated functions

No. Action Remark
Please change to
STARTER, and establish
an online connection to
SINAMICS S120.
1. In the project navigator,

select "Safety Integrated",
and activate the safety
commissioning mode by
pressing "Change
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Settings".
Now select the menu item

"Extended functions via
2. PROFIsafe" to control the
extended safety functions
via PROFIsafe
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No. Action Remark
Please ensure that the

safety functions with
encoder are selected "[0]
Safety with encoder …".
Activate Extended
3.
Functions by setting
"Enable" for "Safety
functions".
Then press the

"Configuration" button.
Please press "PROFIsafe

4. configuration" in the
"Configuration" window.
Enter the PROFIsafe

address in the "PROFIsafe
configuration“ window.
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5.
following applies: p9610 =
C6hex.
Close the window with

"Close".
In the safety overview

window (see line 3), please
press "Safe basic
functions".
6. In this window please

enable the SBC function.
p9602 = 1

"Close".
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No. Action Remark
In the safety overview

window, now press the
"Safe Brake Test (SBT)"
button to open the adjacent
window.
Now enable the SBT

7. function, select the motor
type and the type of
control.
p10201.0 = 1 (enable)
p10204 = [0] rotating
p10203 = [0] SBT via SCC
Now configure the

following settings to test
the motor holding brake.
p10202[0] = [1] Test motor

holding brake
p10209[0] = 8.00Nm
p10208[0] = 1000ms
8. p10210[0] = 1.0
p10212[0] = 0.1mm
p10211[0] = 1000ms
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p10220[0] = 0.5
p10222[0] = 0.1mm
p10221[0] = 1000ms

"Close".
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No. Action Remark
Now copy the parameter to

the second channel using
"Copy parameters".
9.
Activate the parameter
changes by confirming
"Activate Settings"
A password was not

previously set to protect
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the safety parameters; as a

consequence you will now
be prompted to enter a
password.
For "current password“

10.
enter a value of 0
(= default value) and for
"new password", enter the
new value twice (in the
example this is 1).
Confirm the change using

"OK".
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No. Action Remark
In the following window you

will be prompted to save
the changes made from
11. RAM to ROM.
Confirm this by pressing

"YES".
A warm restart is required

after the safety functions
have been commissioned
1)
for the first time.
To do this, first go offline 2) Power on reset
and then switch off the
12. SINAMICS training case
and switch it on again. 3)

After powering up, go back
online and load the 4)
configuration into the PG.
Please save the loaded 5)
configuration.
After powering up, safety
alarms 1697 (test stop) and
1796 (wait for
communication) are
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displayed in the alarm

window.
13.
This behavior is normal as
the F program for the F-
PLC has still not been
generated, and a test stop
has still not been executed.
The manually created
supplementary data (see
Table 5-3; line 17ff) must
now be interconnected with
the relevant parameters for
telegram 701.
14.
To do this, please set
parameter p60122 to a
value of 701.
Please observe the note

after this table.
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No. Action Remark
You can check the correct

interconnection in the
communication view of the
drive.
The drive receive data

15.
should look just the same
as in the adjacent diagram.
The two control words of

telegram 701 were
inserted.
You can check the correct

interconnection in the
communication view of the
drive.
The drive transmit data

16.
should look just the same
as in the adjacent diagram.
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The four status words of

telegram 701 were now
inserted.
After completion, copy from

RAM to ROM, load the
17.
actual configuration into
the PG and save this.
Note The offset values of the SCC/SIC telegram are saved in parameters p2070
(receive data) and p2071 (transmit data).
If, as in this function example, a standard telegram (e.g. 110) is used, and if the
data of the SCC/SIC are transferred directly after this telegram, then the
specified values are correctly pre-assigned.
If this is not the case, then please check the setting of p2070/p2071, and if
required, correct.
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5.7 Generating the fail-safe program of the F-CPU

To complete the configuration, the fail-safe program of the F-CPU is now
generated. In this program, the input signals of the switch box of the safety
demonstration case are read out, and based on these, a PROFIsafe telegram is
generated for the SERVO_03 drive. The steps required are described in the
following.
NOTICE The safety program of this function example was consciously kept as
simple as possible and coordinated with the safety demonstration case.
It is not permissible that the program is used in this form for a real
application.
You start with the F-Call block. This is required to call the safety program. To do
this, in the block folder, a function (in this case FC1) must be inserted using the F-
Call programming language. Cyclic interrupt OB35 is required to cyclically call the
safety program.
In this example, the actual safety program is executed in a function block (here,
FB1), this means that FB 1 must now be inserted using the F-LAD or F-FBD
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Table 5-7: Generating the F program

No. Action Remark
An OB cyclic interrupt is
required to cyclically call
the safety program.
1.
Insert such an OB into the
block folder.
Assign a name (e.g.

OB35), select the
2. programming language
(e.g. STL) and confirm the
settings with "OK".
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Please insert an additional

block into the block folder.
This time, select a function.
This is the F-Call block that

is used to call the safety
program. This is simply
3. created. No changes can
be made in this block.
Please assign a name (e.g.

FC1) and select F-CALL as
"OK".
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No. Action Remark
In this example, the actual

safety program is
generated in a function
block FB.
Insert such a block into the

block folder. Then assign a
4. name (e.g. FB1) and select
F-LAD or F-FBD as
The example was
generated using the
F-FBD language.
"OK".
Now open the OB35 block

and insert a network in
which the safety program is
5. called using the "CALL FC

1" command.
Then save the block.

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Now open the FB1 block to

generate the safety
program.
6. After double clicking this

block, you will be prompted
to set a password. "0" is
again used in the example
as password.
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No. Action Remark
Now you can generate the

safety program.
Please insert 2 networks.
Network 1:
In this network, using
switch S4 (=I0.3), global
depassivation of all
PROFIsafe devices is
initiated.
You can find block FB219
under "Libraries
7. -> Distributed Safety (V1) -
> F-Application Blocks.
For example, specify

DB219 as associated data
block. This is then
automatically created.
Network 2:
In this network, all of the
safety functions not
required in the drive are
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permanently deselected.
This is applicable for SS1,
SS2, SOS, SLS, SDI+/-
and SLP.
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No. Action Remark

networks.
Network 3:
In this network, the
acknowledgment bit of the
PROFIsafe telegram is
controlled using button S4
(=I0.3).
Network 4:
The STO with SBC safety
8. function is controlled using
the mushroom pushbutton
S1 (=I0.0).
Network 5:
The signal lamp (=Q10.7)
integrated in pushbutton
S4 is controlled if the SSM
function signals a HIGH
signal.
Close the block and close

the block editor.
The F-runtime group must

be generated in the next
step.
To do this, double-click on
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block FC1. The windows

shown are opened.
9.
Now enter a name for the

data block belonging to the
F-program (e.g. DB1). This
is then automatically
created. Confirm your entry
with "OK".
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Finally, the safety program

must be generated and
loaded.
To do this, please press

the "Compile“ button
followed by "Download".
10.
With the appropriate

setting, the standard blocks
are also loaded. If this is
not the case, then please
manually load the standard
blocks.
Note We recommend that blocks OB82 and OB86 are also integrated in order to
tolerate the failure of the I/O (e.g. the drives for a power on reset) without the F-
CPU going into the STOP operating state.
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5.8 Acceptance test
5.8 Acceptance test

General information
To verify safety-oriented parameterization/configuring, an acceptance test must be
performed when the machine is commissioned for the first time and also after
changes are made to safety-related parameters. The acceptance test must be
appropriately documented. The acceptance reports must be adequately stored and
archived. These involve stipulations laid down in the Machinery Directive.
The acceptance test must be carried out after parameterization has been
completed and a power on reset.
Information about the acceptance test, the acceptance report and an example of
an appropriate acceptance report is provided in the "Function Manual SINAMICS
S120 Safety Integrated" (FHS) /1/ in the Chapter "Acceptance test and acceptance
report".
A script has been generated to make it easier to handle the acceptance test; this is
available at no charge with PRODIS entry 52256131 (link only available in the
SIEMENS intranet), where it can be downloaded by authorized personnel. This
script guides the user step-by-step and easily through the acceptance test.
Note Version V2.1 of the acceptance test only includes the safety functions that were
available up to Version V4.4 of the SINAMICS firmware.
The "Safe Brake Test" (SBT) function is not included there.
Acceptance test of the SBT function

The steps listed in the following table must be executed to test the function. The
table has been taken from Chapter 9 of the Safety Function Manual /1/.
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Table 5-8: SBT acceptance test

No. Description Status
Note:
The test must be performed separately for each configured brake and all the required test scenarios.
1. Initial state
Drive in the "Ready" state (p0010 = 0)
Safety Integrated Extended Functions enabled (p9601.2 = 1)
Safety functions enabled (p9501.0 = 1)
Safety configured with encoder (p9506 = 0)
SBT enabled (p10201.0 = 1)
All brakes open.
SBC enabled (p9602 = 1) if an internal brake is to be tested
No safety faults and alarms (r0945[0...7], r2122[0...7], r9747[0...7])
present at the drive and TM54F (if one is being used);
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5.8 Acceptance test
No. Description Status

2. Configuring and activating the trace recording
Trigger: Trigger on variable – bit pattern (r10231.1 = 1)
Record the following values: r9713[0], r10231, r10234, r10240, r0080, r0063
Select the time interval so that the complete brake test (2 × p10208 + p10211 or
2 × p10208 + p10221) of the particular brake from the trigger instant
can be recorded. Set the pretrigger corresponding to the time from selecting the
brake test up to the start of the first test sequence (e.g. 1 s)
For better analysis, display the following bit values:
r10231.0 (brake test selection)
r10231.1 (brake test start of the test sequence)
r10231.2 (brake selection)
r10231.5 (external brake status) when testing an external brake
r10234.0 (brake test selected)
r10234.3 (brake test active)
r10234.4 (brake test result)
r10234.5 (brake test completed)
Trigger brake test
Read out r10241 after completing the brake test

3. Analyze trace
r0080 must show the required torque characteristic (trapezoidal characteristic); refer to
the curve in the FHS /1/.
r0800 must correspond approximately to –r10241 before the start of the test sequence
p10208 must elapse to build up the torque and to clear the torque
The constant test torque must be present over the time from p10211 or p10221
r10240 contains the maximum value from r0080 + p10241, i.e. the maximum torque
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with which the brake was tested

4. Save/print the trace and attach to the acceptance report
5. Repeat points 1 to 4 for all the brakes to be tested and all test sequences
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5.8 Acceptance test
Fig. 5-1: Trace of the brake test

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5.8 Acceptance test
Trace evaluation:
The test sequence is started at instant T1 (0msec) (the bits "Start brake test"
and "Brake test active" have the value 1). At this point in time, the brake test
has already been selected (bits "Select brake test" and "Brake test selected"
have the value of 1). The "Select Brake" bit indicates that brake 1 (in this case,
the motor holding brake) is tested.
A start is made to establish the test torque at instant T2 (approx. 150msec).
The configured test torque is reached at instant T3 (approx. 1150msec). Here,
check that the configured time interval was maintained (in this case,
1000msec) and the configured torque (in this case, 8Nm) was established. To
do this, check the values of r10240 and r0080.
The test torque is established at instant T4 (approx. 2150msec) after the
configured time (in this case, 1000msec). Also here, check that the configured
time for the constant test torque is maintained.
The test torque has been decreased to zero at instant T5 (approx. 3150msec).
At instant T6 (approx. 3300msec) the feedback signals that the brake test was
successfully performed are set; the "Brake test result" and "Brake test
completed" bits assume a value of 1, and the "Brake test active" bit is reset to
a value of 0.
During the complete tests, it is not permissible that the value of r0063 exceeds
1% of p1082. In the example this means that a value of 33 rpm must not be
exceeded. In this trace, the maximum peaks in r63 are ±3rpm.
During the complete test, the value of r9713 must not change by more than the
configured tolerance.
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6 Commissioning the application
6.1 Preconditions

Until now, the configuration of the application example has been described step-
by-step. The following steps should now be followed if the sample project is to be
directly downloaded to the hardware.
First, all components (S7-F-CPU and SINAMICS S120) should be generally reset
or reset to factory settings.
6.1 Preconditions
Preconditions for operation
The SIMATIC components have been mounted and connected with one
another. The PROFIsafe addresses of the fail-safe input and output modules
must be set using the DIL switch; refer to Table 5-2 (lines 7 and 11) from
Section 5.3.
All components have been connected as specified in Chapter 4.
The motor has been connected to the Motor Module using a power cable.
The Motor Module is correctly connected with the infeed (DC link and 24 V DC
control voltage).
The infeed is connected to the line supply.
The components are supplied with 24 V DC.
Note Contrary to many other function examples, for this example none of the two
drives in the SINAMICS training case can be used. The reason for this is that
they are not equipped with a motor holding brake.
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For this function example, an additional motor equipped with holding brake is
required. If this is not identical with the motor used in the example, then the
configuration must be adapted before being downloaded.
Information on setting the PC/PG interface can be taken from Section 5.2.
Note It may be necessary that you assign the IP addresses and names used in this
example to the CU320-2 PN and the F-CPU (initialization).
You can find information on how to proceed in the SINAMICS S120
Commissioning Manual /6/ in Sections 2.2.4 and 2.2.5 (from page 68 onwards).
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6.2 Commissioning
6.2 Commissioning
Table 6-1: Commissioning the sample project
No. Action Remark
Please unzip the project

supplied into any
directory.
1.
Open the SIMATIC
manager, click on "File"
and then select the menu
item "Retrieve".
Now select the directory

in which the zipped
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project is located
2. "MC_FE_I_016_V10.zip".
Select this and then click
on "Open".
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80 1.0, Entry ID: 76457011
6.2 Commissioning
No. Action Remark
Now select the directory

into which the project
3. should be unzipped.
Then confirm with "OK".

4. Now open the project.

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6.2 Commissioning
No. Action Remark
Then open HW Config

5.
and download the project.
Note If a safety program existed on the CPU beforehand, then this is

password-protected. This must be known for the download. If it is not
6. known, then the memory card must be cleared using a suitable device
(e.g. SIEMENS PG). If the card is cleared or formatted using a card
reader, the card will be destroyed.
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The next step is to load

the safety program.
Depending on the
7. particular setting,
standard blocks are also
loaded. If this is not the
case, then please
manually load these
blocks to the F-CPU.
Now open the integrated

STARTER project.
8.
To do this, double-click on
"Commissioning".
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6.2 Commissioning
No. Action Remark

Then establish an online
9. connection and download
the project.
When using the extended

safety functions, after the
download, you must
confirm that the hardware
has been replaced (see
Chapter 11.1 of the FHS
10. /1/)
To do this, please press

the "Acknowledge
hardware replacement"
button.
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Then start copying from

RAM to ROM.
1)
Then go offline and switch
off the SINAMICS training 2) Power on reset
case and switch it on
11. again.
3)
To complete the
installation, go back 4)
online, load the
configuration to the PG
and save it. 5)
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7 Operating the application
7.1 Overview

7.1 Overview
Fig. 7-1: Overview diagram showing how to operate the application

Switches -S1 to -S4 are located on a switchbox that belongs to the Safety training
case.
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Switches -S5 to -S12 are located on a switchbox that belongs to the SINAMICS
training case.
7.2 Description of function

Switching on/switching off
The -S1 emergency stop button must be released to traverse the drives. The drive
is switched on with the -S5 switch (OFF1).
Starting the traversing program

Using switch -S6, the traversing program for drive 1 is started (HIGH signal) and
stopped (LOW signal).
Referencing (homing)
As a result of the low number of switches and the transparency of the function
example, the reference point is automatically set to the actual value as soon as the
drive is in the "Ready" state and has still not been referenced (not been homed).
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84 1.0, Entry ID: 76457011
Follow-up mode
The follow-up mode of EPOS is activated using switch -S7. The brake test should
only be performed when the follow-up mode is active. If this is not the case, then
EPOS error messages can be output when carrying out the SBT. Further, after
exiting the SBT function, step-like (jumps) equalization operations can occur.
Acknowledging general alarms

Alarms active on the SINAMICS can only be acknowledged using the
acknowledgment function of STARTER or a power-on reset.
Reintegrating/acknowledging safety faults

The drives must be reintegrated after power OFF/ON. All alarm messages are
acknowledged and the signal lamp in -S4 is lit up when pressing button -S4.
Emergency Stop
If the Emergency Stop button -S1 is pressed, then STO in conjunction with SBC is
initiated on the drive. This means that the pulses are safely canceled and the
holding brake safely controlled (closed).
Test stop of the safety functions

The test stop function is activated using switch -S8.
Selecting the brake test

The SBT function is selected using switch -S9. The actual load torque is
determined after it has been selected. This may take approx. 500 msec. Only then
can the test sequence be started.
Starting the SBT test sequence

The selected test sequence is started with the selected sign of the test torque using
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switch - S10. The brake is closed, the torque established and the torque kept
constant for the configured time. At the same time it is monitored as to whether the
drive moves by more than the configured tolerance. The torque is then decreased
to zero. The test sequence has been successfully performed if no error occurred.
Test torque sign

The direction of the brake test can be selected by entering the test torque sign
using switch -S11. The test torque is positive for a LOW signal and negative for a
HIGH signal.
Selecting the test sequences

You can toggle between the two test sequences using switch -S12. For a LOW
level, sequence 1 is selected, and for a HIGH level, sequence 2.
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Table 7-1: Overview of the switch functions on the safety training case
Switch Function
Selects Emergency Stop -> Activates STO with
-S1
SBC
-S2 Not used in the example
-S3 Not used in the example
-S4 Depassivation and fail-safe acknowledgment
Table 7-2: Overview of the switch functions on the SINAMICS training case
Switch Digital input Description
-S5 DI 0 Switches the drive off/on (ON/OFF1)

-S6 DI 1 Start / stop the traversing program
-S7 DI 2 Activates the tracking mode
-S8 DI 3 Starts the test stop of the safety functions
-S9 DI 4 Selects SBT
-S10 DI 5 Starts the test sequence
-S11 DI 6 Selects the test torque sign

-S12 DI 7 Test sequence is selected
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86 1.0, Entry ID: 76457011
8 References
8 References
8.1 Related documents
This list does not claim to be complete and only provides a selection of suitable
references.
Table 8-1: Related documents
Topic Title
/1/ SINAMICS S120 SINAMICS S120
Safety Integrated Safety Integrated Function Manual
01/2013 Edition
MLFB: 6SL3097-4AR00-0BP4
/2/ SINAMICS S120 SINAMICS S120/S150
Parameter Manual Parameter Manual
01/2013 Edition
MLFB: 6SL3097-4AP00-0BP4
Manual 1 Control Units and Additional System Components
Manual
01/2013 Edition
MLFB: 6SL3097-4AH00-0BP3
Manual 2 Manual for Booksize Power Units
01/2013 Edition
MLFB: 6SL3097-4AC00-0BP5
Function Manual Function Manual
01/2013 Edition
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MLFB: 6SF3097-4AB00-0BP3
Commissioning Manual Commissioning Manual
01/2013 Edition
MLFB: 6SF3097-4AF00-0BP3
8.2 Internet links

This list does not claim to be complete and only provides a selection of suitable
information.
Table 8-2:
Topic Title
\1\ Reference to the http://support.automation.siemens.com/WW/view/en/76457011
article
\2\ Siemens Industry http://support.automation.siemens.com
Online Support
\3\
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9 Contact persons
9 Contact persons
Siemens AG
Industry Sector
I DT MC PMA APC
Frauenauracher Strasse 80
D - 91056 Erlangen, Germany
E-mail: safety.team.motioncontrol.i-dt@siemens.com
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10 History
10 History
Table 10-1:
Version Date Revision
V1.0 07/2013 First Edition
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Applications & Tools: Handling The "Safe Brake Test" (SBT) in Conjunction With The EPOS Function of The Sinamics S120

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Handling the "Safe Brake Test" (SBT) in

Application description July 2013

Applications & Tools

EPOS und SBT

EPOS und SBT

Warranty and liability

We give no guarantee that the information contained in this document is complete,

your disadvantage is not covered hereby.

Any form of duplication of these application examples or excerpts hereof is not

EPOS und SBT

5.3 Hardware configuration .................................................................... 36

6.2 Commissioning ................................................................................ 80

EPOS und SBT

Table 1-1: SINAMICS S120 safety functions according to DIN EN 61800-5-2

Name Function Description

SBC is only used when there is a motor brake; the

The drive is quickly and safely stopped along the

function, Category 1 according to EN 60204-1)

The drive is quickly and safely stopped along the

The drive speed is safely monitored.

EPOS und SBT

Name Function Description

In addition to the functions defined in Standard DIN EN 61800-5-2, the following

Name Function Description

(holding) brakes can be checked.

EPOS und SBT

Overview of the automation task

Fig. 1-2: Concept of the safety functions

STO + SBC Safe

Description of the automation task

EPOS und SBT

Requirements of the automation task

It is not possible to use the SBT function

EPOS und SBT

Fig. 2-1: Components relevant when controlling the SBT function

EPOS und SBT

the "basic positioner" function module (EPOS) of the SINAMICS S120

EPOS und SBT

2.2 Description of the core functionality

Overview and description of the hardware used

Sequence of the core functionality

EPOS und SBT

Hoisting drives for cranes or

Main press drives that have

EPOS und SBT

2.3 Hardware and software components used

Cable, gray, metal

EPOS und SBT

Table 2-1: SINAMICS training case

Table 2-2: Additional Components

Standard software components

Sample files and projects

EPOS und SBT

3 Function mechanisms of this application

3.1 "Safe Brake Test" (SBT) function description

EPOS und SBT

Fig. 3-1: Overview of the STARTER screen form for SBT

EPOS und SBT

Fig. 3-2: Configuring Part 1 - basic SBT settings

= 1: Control via BiCo

Fig. 3-3: SBT function diagram

EPOS und SBT