Safety Integrated for SINAMICS G120

SINAMICS G120 standard inverters are available in different versions for safety-related applications. The PM240‑2, PM240 ¹⁾ and PM250 Power Modules are prepared for Safety Integrated. In conjunction with a fail-safe Control Unit, the drive can be turned into a Safety Integrated Drive with comprehensive safety functions.

In conjunction with a standard Control Unit, the drive provides the safety function STO.
The PM240‑2 Power Modules, frame sizes FSD to FSF additionally offer STO acc. to IEC 61508 SIL 3 and EN ISO 13489‑1 PL e and Category 3.

The Safety Integrated functions are fully integrated in the drive system. They can be activated via fail-safe digital inputs or via PROFINET or PROFIBUS with PROFIsafe.

The Safety Integrated functions are implemented electronically and therefore offer short response times compared to solutions with externally implemented monitoring functions.

¹⁾PM240 Power Modules, frame size FSGX (i.e. 160 kW/215 hp and higher) are approved only for the Basic Functions (STO, SS1, and SBC).

Safety Integrated encoderless

The safety functions do not require a motor encoder; the implementation effort is minimal. Existing machines in particular can be updated with integrated safety technology without the need to change the motor or mechanical system.

The STO function can be used without any restrictions for all applications.

The SS1, SLS, SSM and SDI functions are permissible for applications in conjunction with asynchronous and SIEMOSYN motors where the load can never cause acceleration. An encoder that is used for the purposes of motor control has no significance for the safety functions here.

Safety Integrated overview

The availability of Safety Integrated functions depends on the type of Control Unit. Standard Control Units and fail-safe Control Units are available.

All CU240E‑2 and CU250S‑2 standard Control Units have STO.

The fail-safe Control Units offer Extended Functions (SLS, SDI, SSM) in addition to the Basic Functions (STO, SS1). The SBC function is currently supported by the CU250S‑2.

A license is required for operation of the Extended Functions on the CU250S‑2 Control Unit. It is of no consequence here which safety functions are used and how many.

The license can be ordered as an option with the memory card. Alternatively, a single-user license can also be purchased.

Safe Brake Relay

The Safe Brake Control (SBC) function requires a Safe Brake Relay. The Safe Brake Relay allows safe control of electro-mechanical motor brakes.

The 24 V DC solenoid of the motor brake is directly connected to the Safe Brake Relay. External surge suppressors are not required. The cable harnesses for connection to the Power Module are included in the scope of supply.

With the Safe Brake Relay function, the brake is controlled in accordance with IEC 61508 SIL 2 and EN ISO 13849‑1 PL d and Category 3.

Функции

Function	Control	Underlying function	Reaction to limit overshoot	External setpoint input effective	Encoder required	License required	Available in
Basic Functions
STO	F-DI PROFIsafe	SBC (if activated)	–	No	No	No	CU240E-2 CU240E-2 DP CU240E-2 PN CU240E-2 F CU240E-2 DP-F CU240E-2 PN-F CU250S-2 CU250S-2 CAN CU250S-2 DP CU250S-2 PN
SS1 with SBR	F-DI PROFIsafe	Safe Brake Ramp (SBR) during braking. STO and SBC (if activated) following expiry of the parameterized delay time or if the speed falls below the minimum speed limit	STO	No	No	No	CU240E-2 F CU240E-2 DP-F CU240E-2 PN-F CU250S-2 CU250S-2 CAN CU250S-2 DP CU250S-2 PN
SBC	With STO (directly or following expiry of the delay time)	–	–	No	No	No	CU250S-2 CU250S-2 CAN CU250S-2 DP CU250S-2 PN
Extended Functions
SLS	F-DI PROFIsafe	–	STO, SS1 (can be parameterized)	Yes	No	No	CU240E-2 F CU240E-2 DP-F CU240E-2 PN-F
SLS	F-DI PROFIsafe	–	STO, SS1 (can be parameterized)	Yes	No	Yes	CU250S-2 CU250S-2 CAN CU250S-2 DP CU250S-2 PN
SDI	F-DI PROFIsafe	–	STO, SS1 (can be parameterized)	Yes	No	No	CU240E-2 F CU240E-2 DP-F CU240E-2 PN-F
SDI	F-DI PROFIsafe	–	STO, SS1 (can be parameterized)	Yes	No	Yes	CU250S-2 CU250S-2 CAN CU250S-2 DP CU250S-2 PN
SSM	Always active, if configured	–	Signals that the speed has fallen below a specified value	Yes	No	No	CU240E-2 DP-F ¹⁾ CU240E-2 PN-F ¹⁾
SSM	Always active, if configured	–	Signals that the speed has fallen below a specified value	Yes	No	Yes	CU250S-2 CU250S-2 CAN CU250S-2 DP CU250S-2 PN

¹⁾ SSM is possible only with PROFIsafe.

Особенности

Comparison between conventional and integrated safety systems

The safety functions integrated into the drive can greatly reduce the effort required to implement safety concepts.

The integrated safety functions provide support when setting up tailored safety concepts. Configurations of safety concepts are given below based on the example of the SINAMICS G120.

Safe Torque Off (STO)