Safety Integrated Component Replacement

Safety Integrated

Safety Integrated is a 2-channel safety option from Siemens protecting against dangerous machine movements. With this option, the CNC and drive system perform safety functions in addition to their normal operating tasks. Due to short data paths, safety relevant data's are evaluated very quickly when safety issues arise and respond accordingly.

Therefore, every machine fitted with Safety Integrated is provided with an acceptance report, which is compiled for this machine on completion of the commissioning procedure. The checksums (cross-reference sums across all machine data relevant to Safety Integrated and hardware configuration) form part of this document. If machine data's, safety programs are changed, or hardware and/or software is replaced, parts of these checksums are automatically recalculated by the system and must be manually added to the acceptance report. In addition, An appropriate safety acceptance test of the system must also be carried out. In some cases, windows also appear at the HMI interface as a reminder and must be acknowledged. This document explores the replacement of components that generate a new checksum. A complete overview of the required measures can be found in the Siemens Instruction Sinumeric 840D sl / Sinamics S120 Sinumerik Safety Integrated FBSI sl.

Relevant components:

Replacement of absolute Drive Cliq motors

Replacement of sensor module (SMC, SME)

Confirmation:

Once these components have been replaced, the softkey [Confirm SI HW] appears in the [Menu Select] [Diagnostics] [Alarms] menu. When this softkey is pressed, all the newly created checksums are transfered to the reference checksums and a message appears showing which safety functions have to be tested (described below).

Safe function test:

• Drive Cliq motors:
  • Calibrate the measuring system to the correct actual value
  • Traverse the axis in the plus and minus direction and check the counting direction
  • Check the safe speed SG1, SG2 from operating modes 2 and 3

• On SMC's and SME's:
  • Traverse the axis in the plus and minus directions and check the counting direction

Checksums:

Note down the checksums newly ensuing from axis machine datum 36998 $MA_SAFE_CHECKSUM[1]

The actual checksum calculated newly PowerOn during and NC reset is entered here via the current values for the safety-relevant machine data.

Index assignment:

Index 0: axial monitoring functions

Index 1: HW component detection (change when replacing motor and SMx)

Index 2: Drive assignment

Entry in the Acceptance Report:

The noted checksums must be entered into the Machine Acceptance Report, Checksum change, axis-specific.

No Acceptance Report:

If replaced by customer:

It there is no Acceptance Report, the checksums must be recorded on a separate sheet to the machine documentation or at least on the wiring diagram.

If replaced by Heller Engineer:

The absence of the Acceptance Report and the checksums must be noted in the Engineer's Report. The checksums must also be entered onto the template from Document SI-HW Replacement V1.0 and printed out for the customer.

Conclusion:

For the preparation of new series commissioning procedures by all departments.