Siemens Simotion TM 121c Manual

Device Manual Edition 06/2003
simotion
SIMOTION Safety Integrated
Safety Unit TM 121C
Preface, Table of Contents
Area of Application 1
SIMOTION
Safety Integrated 2
Safety Unit TM 121C
Description 3
Device Manual
Mounting and Cabling 4
Parameterization and Diagnosis 5
Technical Data 6
Appendices
Accessories, Order Numbers A
Glossary B
Index I
6AU1900-0CM20-0XA0
Edition 06/2003
Safety instructions
This manual contains instructions that should be observed to ensure your personal safety and to protect the
equipment from damage. The instructions are highlighted in the manual by a warning triangle and are marked
as follows according to the level of danger:
! Danger
This warning indicates an imminently hazardous situation which, if appropriate precautions are not
taken, will result in death, serious injury or considerable property damage.
! Warning
This warning indicates an imminently hazardous situation which, if appropriate precautions are not
taken, may result in death, serious injury or considerable property damage.
! Caution
indicates an imminently hazardous situation which, if appropriate precautions are not taken, may
result in minor injury or property damage.
Caution
indicates an imminently hazardous situation which, if appropriate precautions are not taken, may
result in property damage.
Attention
highlights an important item of information about the product or its use, or indicates a section of the
instructions that deserves careful attention.
Qualified personnel
The equipment may be commissioned and operated by qualified personnel only. For the purposes of the
safety instructions in this instruction manual, a Qualified Person is one who is authorized to commission, ground
and label devices, systems and circuits in accordance with accepted safety standards.
Intended use
Please observe the following information:
! Warning
The device may only be used in applications as provided for in the catalog and in the technical
description, and only in connection with power supply units that have either been recommended or
approved by Siemens.
Successful and safe operation of this equipment is dependent on proper transport, storage, erection
and installation, as well as careful operation and maintenance.
Trademarks
SIMATIC®, SIMOTION®, SINUMERIK® and SITOP® are registered trademarks of Siemens AG.
Other designations in this document may be trademarks whose use by third parties for their own purposes may
infringe on the rights of the trademark holder.
Copyright Siemens AG 2003All Rights Reserved Liability exclusion
Passing this document on to third parties, reproducing this document or We have checked the contents of this Manual to ensure that they match the
using or relating its contents is not permitted without express authority. hardware and software described herein. However, because deviations
Offenders will be liable for damages. All rights, including rights created cannot be completely ruled out, we cannot guarantee complete conformance.
by patent grant or registration of a utility model or design, are reserved. The information contained in this document is checked regularly and any
necessary corrections are included in subsequent editions. We are thankful
Siemens AG for any recommendations or suggestions.
Automation & Drives
Motion Control Systems
P.O. Box 3180, D-91050 Erlangen
Germany © Siemens AG 2003
We reserve the right to make technical changes.
Siemens AG Safety Unit TM 121C

Preface
General information
In the interest of clarity, the information in this Manual does not purport to cover all
details or variations in equipment, nor to provide for every possible contingency to
be met in connection with installation, operation or maintenance.
The contents of this Manual shall neither become a part of nor modify any prior or
existing agreement, commitment or legal relationship. The sales contract contains
the entire obligation of Siemens. The warranty contained in the contract between
the parties is the sole warranty of Siemens. Any statements contained herein do
not create new warranties nor modify the existing warranty.
Purpose of this manual

This manual both supports you in mounting and parameterizing the Safety Unit and
also provides assistance in the implementation of a safety concept for your press
control system.
For whom is this manual intended?

Project planners
Electricians and fitters
Service and operating personnel
Contact persons
If you should encounter problems or questions when working with the manual,
please consult the service center listed on the feedback form at the end of the
manual.
Search assistance
To help you orient yourself, please turn to:
the table of contents,
the glossary
the index.
© Siemens AG 2003 All Rights Reserved

SIMOTION Safety Unit (SU) - Edition 06/2003 v
Preface
Notes

vi SIMOTION Safety Unit (SU) - Edition 06/2003
Table of Contents
1 Area of Application ......................................................................... 1-9
1.1 Introduction.................................................................................... 1-9
1.2 Features ........................................................................................ 1-10
1.3 Compatibility of firmware to software ............................................ 1-10
2 Safety Integrated ............................................................................. 2-11
2.1 Safety requirements ...................................................................... 2-11
2.2 Acceptance of parameterization.................................................... 2-13
2.3 Safety functions............................................................................. 2-15

2.3.1 Fail-safe digital inputs ................................................................ 2-15
2.3.2 Fail-safe digital outputs .............................................................. 2-16
2.4 Responses to errors...................................................................... 2-16
2.5 Requirements regarding encoders and actuators......................... 2-17
2.6 Requirements regarding the power supply ................................... 2-18
2.7 Power supply requirements........................................................... 2-18
3 Description....................................................................................... 3-21
3.1 General information....................................................................... 3-21
3.2 Features ........................................................................................ 3-22

3.2.1 Hardware.................................................................................... 3-22
3.2.2 Operating states......................................................................... 3-23
3.3 Interfaces....................................................................................... 3-23

3.3.1 Connecting terminals ................................................................. 3-24
3.3.2 RS 232 interface ........................................................................ 3-25
4 Mounting and Cabling .................................................................... 4-27
4.1 Mounting........................................................................................ 4-27
4.2 Cabling .......................................................................................... 4-28
5 Parameterization and Diagnosis.................................................... 5-31
5.1 Parameterization ........................................................................... 5-31

5.1.1 General information ................................................................... 5-31

SIMOTION Safety Unit (SU) - Edition 06/2003 vii
Table of Contents
5.1.2 Setting parameters with the "Parameterization tool" ................. 5-31
5.2 Diagnosis....................................................................................... 5-34

5.2.1 Diagnosis using display ............................................................. 5-34
5.2.2 Diagnosis using pilot lamp ........................................................ 5-34
5.2.3 Reading out diagnosis messages.............................................. 5-34
6 Technical Data ................................................................................. 6-39
6.1 Standards and certifications.......................................................... 6-39
6.2 Safety extra low voltage ................................................................ 6-40
6.3 Electromagnetic compatibility........................................................ 6-40
6.4 Mechanical and climatic ambient conditions................................. 6-42

6.4.1 Transport and storage................................................................ 6-42
6.4.2 Operation ................................................................................... 6-42
6.5 Technical data ............................................................................... 6-44
A Accessories, Order Numbers ........................................................ A-49
A.1 Spare parts ................................................................................... A-49
A.2 Accessories................................................................................... A-49
B Glossary .......................................................................................... B-51
I Index .................................................................................................. I-55

viii SIMOTION Safety Unit (SU) - Edition 06/2003
1 Area of Application
1
1.1 Introduction
Safety measures must be implemented on all product machines, especially on

presses, to eliminate any risk of danger to operating personnel during the
machining process. This can be accomplished by securing the machines with
safety gates or light curtains. However, if frequent operator intervention in the
production process is required, the machine responses must be monitored, e.g.
through speed monitoring (motion monitor), in order to prevent dangerous
movements of the machine in the event of malfunctions of the control system and
mechanics.
Such control systems must be constructed in accordance with the specified

regulations and design specifications and have up to now been implemented using
relay and contractor technology. Because of the high switching frequency in press
cycles, the safety contacts are subject to a high rate of wear and require periodic
replacement or reconditioning.
The Safety Unit fills the gap between the conventional contactor and the user-
programmable safety control system (S5-95F/P, S7-300F) with the following
features:
• Simple handling (like contactor)

• Flexibility (parameterizable)
• No service whatsoever

SIMOTION Safety Unit (SU) - Edition 06/2003 1-9
Area of Application
1.2 Features
• Smaller switching cabinet

- an electronic control system supplants approx. 25 contactors of the safety
circuitry
- less wiring
- smaller space requirements
• Improved convenience
- during setup
- during commissioning/diagnosis (incorporated mini-display)
- with standardized design for all machines
• Parameterizable
- can be parameterized using PC-based parameterization tool included
• System integration
- stand-alone machine without system integration
• Short response times
1.3 Compatibility of firmware to software

The following versions are compatible:
FW status SW version
Safety Unit Parameterization
tool
S03 V1.0
S04 V2.0
Note
Further information is given on the CD included in the software package
(readme.doc).

1-10 SIMOTION Safety Unit (SU) - Edition 06/2003
2 Safety Integrated
2
2.1 Safety requirements
Standardized safety requirements
The Safety Unit meets the following safety requirements:
• Safety integrity level SIL3 as per IEC 61508
• Category 4 as per EN 954-1
Risk chart as per IEC 61508

The IEC 61508 defines a risk chart (Fig. 2-1) similar to that for DIN V 19250. The
risk parameters (Table 2-1) are used to determine the requirements of the process.
The risk chart is used to determine the safety integrity level (SIL) with which the
Safety Unit and its sensors and actuators must comply. This procedure yields an
SIL for applications that have no product standard. For applications with a product
standard, the safety measures are specified in that standard.
W3 W2 W1
-
C1
a -
Starting point F1
P1
P2
b a -
for risk reduction C2 c b a a, b, c, d, e, f, g, h represent the
estimation P1 necessary minimum risk
F2 d c b
P2 reduction. The link between the
e d c necessary minimum risk
F1 reduction and the safety integrity
C3 f e d
F2
level is shown in the table.
g f e
C4
h g f
Necessary
minimum risk Safety integrity level
C = Consequence risk parameter
reduction
F = Frequency and exposure time risk
parameter - No safety requirements
a No special safety
P = Possibility of avoiding hazard risk requirements
parameter b, c 1
W = Probability of the unwanted d 2
occurrence e, f 3
g 4
a, b, c ... h = Estimates of the required risk h An E/E/PE SRS is not
reduction for the SRSs sufficient
Fig. 2-1 Risk chart; example (excerpt from IEC 61508-5, similar to DIN V 19250)

Safety Integrated
Risk parameters
Table 2-1 Risk parameters in the risk chart shown in Fig. 2-1 (excerpt from IEC 61508-5)
Risk parameter Classification Comments
Consequence (C) C1 Minor injury 1 The classification system has been
developed to deal with injury and death
C2 Serious permanent injury to one to people. Other classification schemes
or more persons; death to one would need to be developed for
person environmental or material damage.
2 For the interpretation of C1, C2, C3 and
C3 Death to several people C4, the consequences of the accident
and normal healing shall be taken into
C4 Very many people killed account.
Frequency of, and F1 Rare to more often exposure in 3 See comment 1 above.
exposure time in, the the hazardous zone
hazardous zone (F)
F2 Frequent to permanent exposure
in the hazardous zone
Possibility of avoiding P1 Possible under certain 4 This parameter takes into account:
the hazardous event conditions - operation of a process (supervised
(P) (i.e. operated by skilled or unskilled
P2 Almost impossible persons) or unsupervised);
- rate of development of the hazardous
event (for example, suddenly, quickly
or slowly);
- ease of recognition of danger (for
example, seen immediately, detected
by technical measures or detected
without technical measures);
- avoidance of hazardous event (for
example, escape routes possible, not
possible or possible under certain
conditions);
- actual safety experience (such
experience may exist with an identical
EUC or a similar EUC or may not
exist).
Probability of the W1 A very slight probability that the 5 The purpose of the W factor is to
unwanted occurrence unwanted occurrences will come estimate the frequency of the unwanted
(W) to pass and only a few unwanted occurrence taking place without the
occurrences are likely addition of any safety-related systems
(E/E/PE or other technology) but
W2 A slight probability that the including any external risk reduction
unwanted occurrences will come facilities.
to pass and few unwanted
occurrences are likely 6 If little or no experience exists of the
EUC, or the EUC control system, or of a
W3 A relatively high probability that similar EUC and EUC control system,
the unwanted occurrences will the estimation of the W factor may be
come to pass and frequent made by calculation. In such an event a
unwanted occurrences are likely worst case prediction shall be made.

Safety Integrated
Safety integrity level as per IEC 61508

For each "Safety Integrity Level" (SIL), the IEC 61508 defines a target value for the
malfunction probability of a safety function that is assigned to a fail-safe system.
Safety Low demand mode of High demand or continuous

integrity level operation mode of operation
(Average probability of failure to (Probability of a dangerous failure
perform its design function on per hour)
demand)
4 ≥ 10-5 to < 10-4 ≥ 10-9 to < 10-8
3 ≥ 10-4 to < 10-3 ≥ 10-8 to < 10-7
2 ≥ 10-3 to < 10-2 ≥ 10-7 to < 10-6
1 ≥ 10-2 to < 10-1 ≥ 10-6 to < 10-5
• In general, the actuators and sensor are the largest factor in this malfunction
probability (> 80 %).
• Each safety function always encompasses the entire chain of events – from
information collection and processing to the intended action.
• The devices involved, e.g. the Safety Unit, sensors and actuators, must as a
whole comply with the SIL determined in the risk evaluation.
• If a Safety Unit is used to implement both the control functions and the
associated safety functions, operation is in the high demand or continuous
mode.
2.2 Acceptance of parameterization
! Important
• The machine manufacturer must document and archive the parameterization.
The conditions that are subject to approval which are included in the report
accompanying the certificate must be observed in the acceptance procedure.
• A faulty Safety Unit may only be replaced if it has been ensured by
organizational measures that the correct parameter set (memory card) has
been used for the machine and that a function test has been performed.
Machine manufacturer
• The manufacturer defines the control functions and the Safety Unit wiring in
the parameterization. Any new parameterization and all changes made in it
must be checked by means of a function test and being documented.
• The Safety Unit parameterization must be clearly identifiable. The Safety Unit
and memory card must be labeled with a corresponding sticker containing the
relevant description.

Safety Integrated
Parameterization
1. Set keyswitch to PARA
2. Establish the RS 232 interface with the PC (laptop)
3. Activate the parameterization tool of the PC:
a) Select the connected interface (COM1 or COM2)
b) Set the parameters
c) Store the parameters
(the CRC checksum is calculated and also stored)
d) Transfer the parameters into the Safety Unit
(the CRC checksum is also transferred, recalculated by the Safety Unit, sent
back and compared to the original CRC checksum; in the event of an error: a
message is output to the PC; the device cannot be switched to RUN)
e) Read the parameters back into the PC and print out in landscape format for
reporting purposes (back documentation)
4. Carry out a complete function test of the system (press)
5. Sign the report
6. Record the CRC checksum on the back of the memory card and on the label
next to the memory card (housing).
Responsibilities and qualifications

Responsibility for compliance with the safety requirements regarding use of the
Safety Unit in a specific system is assigned as follows:
• The planner is responsible for the implementation of the safety concept of the
system in the form of function, configuration and wiring plans, and for the
observance and implementation of the conditions specified in the report
accompanying the certificate.
• The person installing and starting up the Safety Unit is responsible for the
observance of and adherence to the requirements regarding the area
surrounding the installation site, the faultless implementation of the wiring
plans and the loading of the parameterization into the Safety Unit.
• The person starting up the Safety Unit is responsible for a complete function
text of the system (press) and measuring the required safety intervals
(including the reaction times) and distances.

Safety Integrated
2.3 Safety functions
! Caution
You will require the information provided in this chapter to correctly wire and
parameterize the Safety Unit in adherence with a particular safety integrity level.
2.3.1 Fail-safe digital inputs
Encoder evaluation
For fail-safe digital inputs, the required safety integrity level is attained by means
of the type of encoder evaluation.
Safety integrity level ... ... is attained by the encoder

as per IEC 61508 as per EN 954-1 evaluation
SIL 2 Category 1 1v1 evaluation
SIL 3 Category 4 2v2 evaluation
1v1 evaluation
In 1v1 evaluation, there is one encoder and it is connected to the device via one
channel.
2v2 evaluation
In 2v2 evaluation, the inputs are internally compared with regard to equivalence
and non-equivalence of the signal states.
If two equivalent encoders are used for the same process parameter, e.g.
"EMERGENCY STOP", a two-channel connection of the encoders to two inputs of
the Safety Unit is established.
Discrepancy analysis
The discrepancy analysis is started when different levels are determined for two
associated input signals. The test establishes whether or not the difference has
disappeared after a parameterizable time period, the so-called discrepancy time. If
not, a discrepancy error has occurred.
Parameters for the discrepancy analysis

The parameterization tool is used to define the function-related discrepancy times
for the discrepancy analysis.

Safety Integrated
2.3.2 Fail-safe digital outputs
Switching test signals

For fail-safe digital outputs, the required safety integrity level is attained by means
of switching test signals.
Safety integrity level ... ... is attained by switching

as per IEC 61508 as per EN 954-1 test signals
SIL 3 Category 4 • Illumination time (≤ 1 ms)
and
• Obscuration time (≤ 1 ms)
Obscuration time
Obscuration times occur during switch-off tests and complete bit pattern tests.
Test-dependent 0 signals are switched onto the output of the Safety Unit while the
output is active. The output is then briefly switched off (= "obscuration time"). Any
actuator that is sufficiently slow will not react and remain on.
Illumination time
The illumination times occur during complete bit pattern tests. Test-dependent 1
signals are switched onto the output of the Safety Unit while the output is switched
off (output signal "0"). The output is then briefly switched on (= "illumination time").
Any actuator that is sufficiently slow will not react and remain off.
2.4 Responses to errors

Safe state (safety concept)
The safety concept is based on there being a safe home position for all process
parameters. For digital signals, this is always the value "0".
Responses to system error (see Tab. 5.2)

If the Safety Unit recognizes a system error F0xx, it switches to the safe state
(operating state STOP) and indicates the recognized error on the display and in the
diagnosis buffer.
Responses to error requiring acknowledgement (see Tab. 5.3)

Errors F1xx can be cleared in the "Setup" operating mode via the
acknowledgement facility after the error has been eliminated (e.g. cam error,
motion monitor, valve feedback).
Responses to errors with self-acknowledgement (see Tab. 5.4)

The errors F2xx are automatically cleared after the error state has been eliminated
(e.g. connection errors, contact errors).

Safety Integrated
Error display
Additional information on diagnosis options, error displays and error messages is
provided in Chapter 5.
2.5 Requirements regarding encoders and actuators

General requirements regarding encoders and actuators
! Warning
The use of encoders and actuators lies beyond our sphere of influence.
Therefore, please note that a high degree of responsibility for safety rests with
the instrumentation using encoders and actuators.
Additional requirements regarding encoders
! Warning
• Make sure that the encoders are implemented in such a way that the user
program responds reliably when the encoders are in a "0" state.
Example: Within its application, an EMERGENCY STOP encoder must act to

switch off the respective actuator in a "0" state (EMERGENCY STOP button
pressed).
• Ensure that the encoder signals have a duration of at least 15 ms to

guarantee that the encoder signals can be correctly registered.
Additional requirements regarding actuators

The Safety Unit tests the fail-safe outputs at regular intervals. To do so, the Safety
Unit briefly switches activated outputs off and switches deactivated outputs on.
These test pulses have the following durations:
• Obscuration time ≤ 1 ms
• Illumination time ≤ 1 ms
During the test, rapid action actuators may briefly drop or be activated. If your
process does not tolerate this, use actuators of a sufficiently low speed (> 1ms).

Safety Integrated
! Caution
If the actuators are operated at voltages exceeding 24 V DC (e.g. at 230 V AC),
or if the actuators switch voltages larger than this, the outputs of the Safety Unit
and the parts carrying the high voltage must be reliably isolated from one
another.
This stipulation is generally met by relays and contactors but must be carefully
observed in semiconductor circuitry. The relays and contactors in use must have
positive-action contacts.
Technical data for encoders and actuators
Please consult Chapter 6 for technical data concerning the selection of encoders
and actuators.
2.6 Requirements regarding the power supply
! Caution
The Safety Unit was tested with the following power supplies of the SITOP family
and accepted by the government safety organization:
• 6EP1334-2AA00, 10 A
• 6EP1333-2AA00, 5 A
The safety association certificate only applies for the use of the Safety Unit with
these SITOP power supplies or technically equivalent power supplies. The Safety
Unit must be supplied with power supplies having the following specifications:
• Protection class I in accordance with IEC 60536
• Electrical isolation as per EN 60950-1 (SELV)
• Degree of protection IP20 or higher
• CE, UL certification
• Power loss ride-through ≥ 20 ms
• No dangerous failure with increased EMC requirements in accordance with
E DIN EN 61496-1: Burst load with ± 4 kV (Level 4 according to EN 61000-4-
4) and surge load with ± 4 kV (asymmetric) or ± 2 kV (symmetric) (Level 4
according to EN 61000-4-5)
2.7 Power supply requirements
! Caution
The installation of the system is connected to the grounding system of the
120 V/230 V AC supply network, which can be considerably influenced by
disturbance voltages that arise from switching within the installation itself or from
lightning. Protected electronic equipment and less sensitive electrical equipment
is connected to the same supply network.
According to EN 61000-4-5 (Surge Immunity Test), asymmetric surge voltages up

to ± 1 kV must be expected for installation class 2, up to ± 2 kV for installation class
3 and up to ± 4 kV for installation class 4.

Safety Integrated
Class 2: Electrical environment in which high voltage cables and signal cables
are well separated from one another, even at short runs.
Class 3: Electrical environment in which high voltage cables and signal cables
run in parallel (this is generally the case)
Class 4: Electrical environment in which interconnections are run as outdoor

cables along with high voltage cables, and cables are used for both
electronic and electrical circuits.
Power is supplied to the Safety Unit TM 121C by an external, electrically isolated

power supply unit of 230 V AC/24 V DC, e.g. of the SITOP family. The primary side
of SITOP power supply units resists surge voltage of symmetric ± 2 kV (conductor-
conductor) and asymmetric ± 4 kV (conductor-ground).
The 24 VDC signal inputs and outputs of the Safety Unit are designed for
asymmetric surge voltages of up to ± 2 kV, so that the "Safety Unit with SITOP
Power Supply" system features a high degree of surge immunity and meets the
requirements of installation class 3 according to EN 61000-4-5 (see Fig. 2-1).
Power supply units Safety Unit TM 121C
230V AC 24V DC
L1 L1 L+
N N M X1 X5
PE PE 1 2 3 1 2 3
PE PE
Surge voltage protection for installation class 3 as per EN 61000-4-5)
Fig. 2-2 Safety Unit power supply

Safety Integrated
Notes

3 Description
3
Fig. 3-1 SIMOTION Safety Unit TM 121C
3.1 General information

The safety system encompasses hardware, internal firmware routines such as
short-circuit testing, and safety modules approved by the German trade
association, e.g.:
• Two-handed engaging
• Foot switch
• Operating mode selection
• Safety guard monitoring
• Engagement lockout
• Safety door monitoring
• EMERGENCY STOP
• Motion monitor control
• TDC switch-off
• Valve/relay monitoring
• Mechanical / hydraulical / bending function
• Light curtain (ESPE)

Description
3.2 Features
The robust metal enclosure contains the processors, the power supply and the
inputs and outputs. The processors have synchronous cycles and perform mutual
checks. States and results are compared to each other cyclically. In the event of a
deviation, the system immediately enters a safe state.
The hardware of the Safety Unit features:

• a two-channel, fail-safe press safety control system.
• integrated electronic components instead of parts that are subject to wear and
tear such as relays and contactors.
• compact control unit, small space requirements.
• direct interfacing of all operating elements and feedback signals from the
press.
3.2.1 Hardware
The onboard I/O provides a basic configuration of inputs and outputs needed to
meet the safety requirements for presses.
The onboard I/O contains:

• 24 V DC/5 V DC power supply with electrical isolation for internal logic circuit
with 2-channel overvoltage and undervoltage monitoring
• 2-channel controller with mutual synchronization and data comparison
• 12 safety-oriented digital inputs, 2-channel, that can also be connected via 1
channel if required:
- max. 12 inputs SIL3 as per IEC 61508/Cat. 4 as per EN 954-1
or max. 24 inputs SIL2 or Cat. 1
- type 2 as per DIN EN 61131-2
• extension option (additional printed circuit board): 4 safety-oriented digital
inputs, 2-channel, that can also be connected via 1 channel if required:
- 4 inputs SIL3 as per IEC 61508/Cat. 4 as per EN 954-1
or 8 inputs SIL2 or Cat. 1
- type 2 as per DIN EN 61131-2
• 2 digital counter inputs: 24 V, max. 500 Hz (e.g. for motion monitor)
• 4 digital outputs, P/M-switching = 2 channel:
- SIL3 as per IEC 61508/Cat. 4 as per EN 954-1
- rated current of 2 A as per DIN EN 61131-2
• 8 digital outputs, P - switching:
- 4 outputs for sensor supply (short-circuit clocking)
- 1 output for fault lamp (can be parameterized)
- 3 outputs as reserve
- rated current of 0.5 A as per DIN EN 61131-2
• keyswitch with three positions
- PARA
- STOP
- RUN
• 2 LED displays:
- green LED for RUN status
- red LED for STOP status
• integrated display (for individual functions, see "Diagnosis"):
- 4-digit 7-segment display for error messages

Description
• plug-in memory card for configuration data (parameters)

• RS 232 interface for parameterization/diagnosis and back documentation
• 6 COMBICON connectors for power supply and I/O signals
• 9-pin D-SUB connector for motion monitor
3.2.2 Operating states

The following two operating states are signalized by two status LEDs:
Operating state RUN LED (green) STOP LED (red)
INIT On (lit continuously) On (lit continuously)
STOP Off Blinks at 2 Hz
RUN On (lit continuously) Off
PARA Blinks at 2 Hz On (lit continuously)
3.3 Interfaces
SIEMENS Display
Memory-Card PARA
STOP
RUN
Keyswitch
RUN
STOP LED
SIMOTION Safety Unit
X1 X5
X8 X9
X2 1 3 X3 X4 1 3 X6
1 1
1 8 1 16 1 16 1 8
X1: 1L+, 1M (24 V DC) supply

X2: Digital outputs 0.5 A
X3: Digital inputs
X4: Digital inputs
X5: 2L+, 2M (24 V DC) supply
X6: Digital outputs 2 A
X8: RS232
X9: Frequency inputs (max. 500 Hz)
Fig. 3-2 Operating elements on front panel

Description
3.3.1 Connecting terminals
Table 3-1 Safety Unit connecting terminals

Connector X1: Supply 1, 24V DC
Term. Description
X1.1 24V DC supply for power supply unit, sensor power supplies, signal output and binary inputs
X1.2 0V (ground)
X1.3 Ground terminal (enclosure/structure)
Connector X2: Outputs 0.5 A, P-switching

Term. Description Term. Description
X2.1 Output (sensor power supply 1) X2.5 Output (sensor power supply 3)
X2.2 Output (sensor power supply 2) X2.6 Output (sensor power supply 4)
X2.3 Output (parameterizable) X2.7 Output (parameterizable)
X2.4 Output (parameterizable) X2.8 Output (fault message)
Inputs (sensors) 1)
Connector X4 Connector X3
Term. Description Sensor Term. Description Sensor
power power
supply supply
X4.1 Input X2.1 X3.1 Input X2.5
X4.13 Input (option) X2.1 X3.13 Input (option) X2.5
Connector X5: Supply 2, 24V DC

Term. Description
X5.1 24V DC supply for P/M-switching binary outputs, 2A
X5.2 0V (ground)
X5.3 Ground terminal (enclosure/structure)
Connector X6: Outputs, 2A, 2-channel (actuators)

P-switching M-switching
Term. Description Term. Description
X6.1 Output X6.2 Output
X6.3 Output X6. 4 Output
1) Please note that for two-channel sensor inputs, the terminal numbers of both input channels must coincide:
e.g. X3.1 and X4.1.

Description
Table 3-2 Counter inputs

Connector X9: Counter inputs, 9-pin SUB D connector (sockets)
Pin Assignment
1
2 DI 1Z+, counter input/frequency input 1
3 DI 1Z-
4
5
6
7 DI 2Z+, counter input/frequency input 2
8 DI 2Z-
9
Use a shielded cable.
3.3.2 RS 232 interface

Table 3-3: Pin assignment of SUB D connector, RS 232
Connector X8: 9-pin SUB D connector (sockets)
Pin Assignment Faulty wiring Assignment Pin
1 1
2 Receive Data Receive Data 2
3 Transmit Data Transmit Data 3
4 4
5 Ground (0 V) Ground (0 V) 5
6 6
7 7
8 8
9 9
Safety Unit PC/Laptop
Use a shielded cable.

Description
Notes

4 Mounting and Cabling
4
4.1 Mounting
The Safety Unit is mounted on the control cabinet panel with 4 screws.
365
52.5 260
SIEMENS
PARA
STOP
135.5
144.5
RUN
120
RUN
STOP
SIMOTION Safety Unit
Fig. 4-1 Dimensions as viewed from the front
Attention
To ground the enclosure, ensure that there is a conductive interface between the
switching cabinet and the Safety Unit. For this purpose, mount the enclosure with
toothed washers.

Mounting and Cabling
112.65
104.5
78
144.5
120
Fig. 4-2 Dimensions as viewed from the side
4.2 Cabling
Introduction
In this chapter, we will show you what you need to pay special attention to as you
connect the Safety Unit. At the very least, these basic rules must be adhered to in
order to ensure faultless operation of the Safety Unit.
Cables
You can use flexible cables with the cross sections specified in the data sheet.
A cable lug is not required.
Table 4-1 Cabling rules for the Safety Unit

Cabling rules for ... Safety Unit
Connectable cable cross sections for No
solid cables
Connectable cable Without cable lug 0.25 to 0.75 mm2
cross sections for With cable lug 0.25 to 0.75 mm2
flexible cables Voltage supply: 0.75 to 1.5 mm2

Specific applications
When connecting the system, please note the safety and accident prevention
regulations that apply to the specific application, e.g. Safety of Machinery
regulations.
EMERGENCY STOP systems

EMERGENCY STOP systems in accordance with IEC 204 must be connected in
such a way that they remain effective in all operating modes.
120/230 V AC supply of the power supply unit

The table below shows the points you should watch out for when connecting the
external power supply (e.g. SITOP) to a 120/230 V AC line.
For... ...ensure that...

Buildings suitable external lightning protection devices are in
place.
AC supply lines of the power suitable external and internal lightning protection
supply unit devices are in place.
Permanently installed systems there is a line disconnector (switch) in the installation.
without all-pole mains switch
Power supply units for supplying the set rated voltage range corresponds to the local
the Safety Unit with 24 V DC line voltage.
Residual current-operated the F1 circuit breaker is suitable for the sum of the
protective device leakage currents of the system.
24 V DC supply of Safety Unit

The table below shows the points you should watch out for when connecting the
Safety Unit to the 24 V DC supply.

24 V DC supplies the supply voltage is generated as a reliably electrically
isolated extra-low voltage.
24 V DC signal lines suitable external and internal lightning protection
devices are in place.
Protection against external electrical influences

The following table lists the points that require special attention in order to protect
the system against electrical influences or faults.

All units or systems in which the the unit and system components are properly
Safety Unit is installed connected to protective ground to enable the leakage
of electromagnetic disturbances.
Connection and signal lines all lines are correctly laid and connected.
Signal lines a breakage in a signal line does not put the system in
an undefined state.

Notes

5 Parameterization and Diagnosis
5
5.1 Parameterization
5.1.1 General information
Prerequisites
The Safety Unit is parameterized using a parameterization tool. The tool is included
on the CD of the software package that can be ordered (see "Accessories") and
has to be installed on your PC. The tool requires approx. 5 MB of hard disk space.
Your PC/laptop must meet the following minimum requirements:

Interface COM1 or COM2
Processor 233 MHz
RAM 64 MB
Operating system Windows NT 4.0
Windows 2000
Windows XP
Other operating systems upon request
Procedure
When loading, the parameters are transferred into the Safety Unit from the PC and
stored there. The basic procedure is described in 2.2.
5.1.2 Setting parameters with the "Parameterization tool"
Operating instructions
• Terminal assignments and time settings are stored by activating the "Accept"
button.
• To delete the terminal assignments or time settings that have been made,
activate the "Accept" button with the input box empty.
• The associated functions are not enabled until you have specified the terminal
number.
• When you assign the terminals, the parameterization tool makes you aware of
duplicate assignments or incorrect inputs.
• Whenever the parameter setting is made using radio buttons, only one setting
can be activated.
A brief description of the parameterization tool menus follows.

Parameterization and Diagnosis
Press type
Select Mechanical press/Hydraulic press/Press brake to make a preselection and
to activate the Mechanical/Hydraulic/Bending function.
Operating modes
Assign a terminal to each required operating mode.
• Operating mode 1 is always "Set up"
• Operating modes 2 to 6 (single stroke/continuous
stroke/changeover/continuous stroke, automatic/single stroke, ESPE) are
freely selectable.
Safety functions
• EMERGENCY STOP (max. 4 with, max. 4 without reclosing lockout)
- Define the terminal pair
- Enter the discrepancy time
- Deactivate the function for the required operating modes
• Safety guards (max. 4 with, max. 4 without reclosing lockout)
- Same procedure as for EMERGENCY STOP.
• Safety gates (max. 3 with, max. 3 without acknowledgement)
- For safety gate with acknowledgement, define the terminal for the
acknowledge button
• Engagement lockout (max. 2)
- Same procedure as for EMERGENCY STOP.
Operation
• Acknowledge button (for error messages and restart lockout)
- Define the terminal
• Two-hand (max. 3 operator panels)
- Define the terminal pairs for the NC and NO contacts.
- If it is to be possible to switch off the operator panel, select the terminal
and assign the NC or NO contact element.
- Deactivate the function for the required operating modes.
• Foot switch (max. 3 foot switches)
- Define the terminal for the NC and NO contacts.
- If it is to be possible to switch off the foot switch, select the terminal and
assign the NC or NO contact.
- Deactivate the function for the required operating modes.
• Light curtain
To be able to activate the function, "Single stroke EPSE" must be selected as
the operating mode.
- Enter the discrepancy time
- Define the terminals for the operating mode selector switch, single
break/double break.
- Define either the "Standard Mode" or "Schweden Mode".
- Define the acknowledgement of the restart lockout:
either via previously activated two-hand operation/foot switch or via a
button (if acknowledgement takes place via a button, define the terminal).
- Select whether or not it should be possible to switch off the safety
operation (if it can be switched off, define the terminal).

Forming enables (example for mechanical press)

Under "Forming enables", you can set whether certain signals that are required for
starting/stopping and operating the press are predefined or whether they are read
in through an input (terminal). The following settings must be specified for each
parameterized operating mode:
• Start condition (must have state "1" at start)
- Set the start condition permanently to signal "1"
- Read in the start condition at a terminal and define the terminal.
• Only for continuous stroke operating modes! Continuous stroke
"Immediate STOP" (must have state "0" when stopped)
- Set the continuous stroke STOP permanently to signal "1" (no stop!)
- Read in at a terminal and define the terminal
• Only for continuous stroke operating modes! Continuous stroke "STOP in
TDC" (must have state "0" when stopped)
- Set the continuous stroke STOP in TDC permanently to signal "1" (no
stop!) or
- Read in at a terminal and define the terminal
• Only for single stroke operating modes! Acceptance of START command
- No acceptance indicates inching operation
- Acceptance with run-up cam or acceptance point
- Read in acceptance at the input and define the terminal
• Safe movement (safety devices not operative with "1" signal)
- Connect safe movement to "0" (safety devices always operative)
- Read in safe movement via the input (action of safety devices can be
switched off via input) and define the terminal
• Not for single stroke ESPE! Start enable
- Enabling of the operator panel/foot switch (start the press using two-
hand/foot)
- Read in the enable via the input (external start) and define the terminal
• External safety device 1/2 ("0" signal shuts off the valve outputs)
- Connect the input to signal "1" (safety device not active)
- Read in via a terminal (connect the safety device to one-channel input) and
define the terminal
Note
For information on the individual functions of Mechanical/Hydraulics/Bending
see the "Application manual", Edition 06.2003 (contained on the CD-ROM of the
software package).

5.2 Diagnosis
The Safety Unit monitors all incoming and outgoing signals. Error messages are
• shown on the display,
• indicated by a fault lamp and
• can be read out via the RS 232 interface of your PC.
The diagnosis can be performed in all operating states (diagnosis may not be
possible in the event of a HW fault).
5.2.1 Diagnosis using display

The 4-digit display shows error messages or operating states. If the system is
functioning properly, the Safety Unit display shows the current operating state.
To indicate an error, the first place (F) blinks at 2 Hz.
Since several errors may occur simultaneously, it makes sense to read out the
diagnosis buffer (see Chap. 5.2.3).
5.2.2 Diagnosis using pilot lamp

The connected fault pilot lamp can indicate the following conditions:
Signal output Condition Indication

Connector X2.8 INIT/PARA/STOP Lights up
permanently
Errors requiring acknowledgement or self- Blinks at 2 Hz
acknowledging errors
Fault-free operation in RUN Off
5.2.3 Reading out diagnosis messages

All of the error information is contained in the diagnosis buffer, which can be read
out through the RS 232 interface using the parameterization tool.
The following diagnosis data can be called up:
System data
The parameterization tool reads out the following system data:
• Firmware status: version and date
• Current operating state: PARA, STOP or RUN
• Position of keyswitch: PARA, STOP or RUN
• Signature for CRC "EPROM1" (program memory)
• Signature for CRC "EPROM2" (program memory)
• Signature for CRC "MEMORY CARD" (program memory)
• User operating mode 1 ... 6 that was last selected
• Cycle times of the last 10 RUN cycles in ms

Error messages
A diagnosis buffer with a maximum of 64 error entries is created for the purpose of
error diagnosis. All errors are collected there as either incoming or outgoing
messages.
• The diagnosis buffer is only cleared when in the INIT operating state.
• All errors that are currently still active and those that have already been
eliminated can be tracked by diagnosis.
A description of all error messages is provided in the following tables.
Table 5-1 System errors

Display Error description Action
F001 Error in internal RAM of CPU see 1)
F002 Error in RAM see 1)
F003 Error in EPROM see 1)
F004 Data error in dual port RAM see 1)
F005 Data error in memory card or empty memory card see 1)
F006 Different FW versions see 1)
F007 Internal synchronization error see 1)
F008 Watchdog has responded see 1)
F009 Undervoltage error of the 5V supply see 1)
F010 ODIS signal error see 1)
F011 PLD error see 1)
F012 Subsystem ID error see 1)
F013 Error from plug-in monitor of memory card see 1)
F014 Keyswitch error see 1)
F015 Error in the CPU see 1)
F016 Error in the system data see 1)
F017 Error in program execution see 1)
F018 Error in the application see 1)
F019 Error at the serial interface see 1)
F020 Error at input X4.1 see 2)
F036 – F039 Not assigned -

Display Error description Action

F060 Error at output X6.1 see 3)
Corrective measures to take in the event of a system error:

1) Restart the device (INIT); replace the device if the error occurs repeatedly.
2) Check the wiring and correct if necessary. In particular, check the
parameterization of the sensor supply (external/internal) carefully. A more
precise statement on the cause of the error can only be made by evaluating
the error entries in the diagnosis buffer.
3) Check the wiring and correct if necessary. A more precise statement on the
cause of the error can only be made by evaluating the error entries in the
diagnosis buffer.

Table 5-2 Error messages requiring acknowledgement

Display Error description
F101 Overtravel cam, static "1"
F102 Overtravel cam failure
F103 Overtravel cam, static "0"
F104 Overtravel distance too long
F105 Run-up cam failure
F106 Change in operating mode not in TDC
F107 Short circuit at operating mode selector switch
F108 Motion monitor
F109 Run-time error, channel 1 (valve 1)
F112 Run-time error, channel 4 (EMERGENCY STOP relaying)
F113 Operating mode selection, light curtain (single break/double break)
F114 Short circuit or "0" at operating mode selector switch, light curtain
F115 Setting - dynamic cam
F122 Discrepancy error, acceptance point
F123 Error, dynamic valve control, channel 1
F316 Restart lockout set for EMERGENCY STOP
F317 Restart lockout set for safety guard
F318 Restart lockout set for light curtain
F319 Restart lockout EMERGENCY STOP relaying
*)
F320 Safety gate closed, not ready for acknowledgement (blocking)
*)
F321 Safety gate closed, ready for acknowledgement
This error can only be acknowledged in the setup mode
*)
If the safety gate display is parameterized via the fault lamp.

Table 5-3 Self-acknowledging error messages

Display Error description
F201 Discrepancy error, EMERGENCY_STOP 1
F209 Discrepancy error, safety guard 1
F217 Contact error, two-hand 1
F220-F222 Not assigned
F223 Discrepancy error, engagement lockout 1
F224 Discrepancy error, engagement lockout 2
F225 Discrepancy error, light curtain
F226 Contact error, foot switch 1
F229 Discrepancy error, access protection 1
F230 Discrepancy error, access protection 2
F231 Contact monitor, two-hand 1
F234 Contact monitor, foot 1
F237 Operating error (two-hand 1 was activated but is not active)
F240 Operating error (foot 1 was activated but is not active)

6 Technical Data
6
6.1 Standards and certifications
Introduction
In this section you will find the most important standards and certifications with
which the Safety Unit must comply. The current status and the current version of
the standards, as well as the current editions, are contained in the report to the
*)
BG certificate.
DIN EN 61131-2
The Safety Unit meets the requirements and criteria of the DIN EN 61131
Standard, Part 2 (2001).
CE marking
Our products meet the requirements and protective targets of the following EC
directives and correspond to the harmonized European Standards (EN) that were
published for programmable logic controllers in the Official Journal of the European
Community:
• 89/336/EEC "Electromagnetic Compatibility" (EMC Directive)
• 73/23/EEC "Electrical Equipment for Use Within Specific Voltage Limits" (Low
Voltage Equipment Directive)
The EC Declarations of Conformity are made available online by the competent
authorities.
Area of application
The Safety Unit is designed for use in the industrial environment.
Area of application Requirements regarding

Emission Interference
immunity
Industry EN 61000-6-4: 2001 EN 61000-6-2: 2001
CULUS certification
UL 508, CAN/CSA C22.2 No. 14-95
BG∗) certificate
The current report to the BG certificate is available from your local sales office.
∗)
Berufsgenossenschaft = German trade association

Technical Data
6.2 Safety extra low voltage

Safety extra low voltage
! Warning
The Safety Unit must be operated with a safety extra low voltage (SELV). This
means that, even in the event of a malfunction, the maximum voltage that may
act on this module must not exceed 60 V DC .
Additional information on safety extra low voltages may be found in the data
sheets of the power supplies in use.
All system components that are capable of supplying electrical energy in one form
or another must comply with these conditions. Each additional circuit (24 V DC)
used in the system must feature a safety extra low voltage. Please refer to the
respective data sheets or consult the manufacturer.
Please note also that it is possible to connect encoders and actuators with an
external power supply to the Safety Unit. Ensure that the safety extra low voltage is
complied with for these devices. The process signal of a 24 V digital module may
not exceed a fault voltage of 60 V DC in the event of a malfunction.
Requirements regarding power supplies
Note
Only use power supply units/power packs (230 V AC --> 24 V DC) with a voltage
breakdown buffer time of at least 20 ms. We offer 1-phase industrial standard
power supplies 24 V (order no. 6EP1334-2AA00 and 6EP1333-2AA00) of the
SITOP device series.
Additional information is found on our homepage:

http://www.ad.siemens.de/sitop/index.shtml
• Technical details are found under "Support".

• You can place orders under "E-Commerce".
6.3 Electromagnetic compatibility

Definition
The electromagnetic compatibility is the ability of an electrical system to operate
satisfactorily in its electromagnetic environment without having an influence on this
environment.
The Safety Unit is in compliance with the requirements of the EMC law of the
European domestic market.
Below you will find information on interference immunity and RFI suppression.

Technical Data
Requirements regarding emission

Table 6-1 Emission
Requirements In accordance with EN
61000-6-4
Device group 1 as per EN 55011
Class A as per EN 55011
Pulsed transients
The following table presents the electromagnetic compatibility of the Safety Unit
with respect to pulsed transients.
Table 6-2 Pulsed transients

Pulsed transients Tested with Corresponds
to severity
level
Electrostatic discharge as per 15 kV contact discharge 4
EN 61000-4-2 8 kV air discharge 4
Burst as per EN 61000-4-4 2 kV, power supply lines 24 V DC 3
2 kV, I/O lines 4
4 kV, power supply lines 230 V AC 4
(SITOP power supply)
Surge as per EN 61000-4-5
Cable/cable (symmetric) 0.5 kV, power supply lines 24 V DC 1
Line/ground (asymmetric) 0.5 kV, power supply lines 24 V DC 1
2 kV, I/O lines 3
Sinusoidal transients
Device in radiated RF field as per IEC 61000-4-3:
• Electromagnetic RF field, amplitude-modulated
- from 80 to 1000 MHz
- 10 V/m; severity level 3
- 80 % AM (1 kHz)
• Electromagnetic RF field, pulse-modulated (mobile phone range)

- 800 to 960 MHz and 1.4 to 2.06 GHz
- 30 V/m; severity level X
- 50 % ESD
- 200 Hz repetition frequency
• RF disturbances on signal and data lines, etc., as per IEC 61000-4-6, high
frequency, asymmetric, amplitude-modulated
- from 0.15 to 80 MHz
- 10 V RMS, unmodulated; severity level 3
- 80 % AM (1 kHz)
- 150 Ω source impedance

Technical Data
6.4 Mechanical and climatic ambient conditions

6.4.1 Transport and storage
The Safety Unit exceeds the requirements of the DIN EN 61131, Part 2, with
regard to transport and storage conditions. The following specifications apply to
transport and storage in the original packaging.
Type of condition Allowable range

Free fall (with packaging) ≤ 75 cm
Temperature - 40 °C ... + 70 °C
Air pressure 1080 ... 660 hPa
(corresponds to an altitude of -1000 ...
3500 m)
Relative humidity From 5 to 95 %, without condensation
6.4.2 Operation
Operating conditions
The Safety Unit is designed for use in a weather-protected, stationary installation.
The operating conditions exceed the requirements as per DIN EN 61131-2.
The Safety Unit is in compliance with the operating conditions of Class 3C3 as per
DIN EN 60721-3-3 (installation in locations with a high traffic density and in the
immediate vicinity of industrial plants with chemical emissions).
Limitations
The Safety Unit may not be used without the implementation of supplementary
measures:
• in locations with a high degree of ionizing radiation.
• in locations with severe operating conditions, e.g.
- due to dust formation,
- corrosive vapors or gasses.
• in systems that require special monitoring, such as electrical systems in
especially hazardous areas.
Mechanical ambient conditions
The mechanical ambient conditions for the Safety Unit are listed in the following table
(the values describe sinusoidal vibrations):
Frequency range (Hz) Continuous Occasional

10 ≤ f ≤ 58 0.075 mm amplitude 0.15 mm amplitude
1)
58 ≤ f ≤ 200 1 g constant acceleration 2 g constant
1)
acceleration
1) 2
Gravitational acceleration g equals approx. 9.81 m/s

Technical Data
Tests for mechanical ambient conditions

The following table provides information on the type and scope of tests for
mechanical ambient conditions.
Table 6-3 Mechanical ambient conditions

Test for... Remarks
Vibrations as per IEC Vibration type: sweep at a rate of 1 octave per minute.
60068 Part 2-6 (sinus) 10 Hz ≤ f ≤ 58 Hz, const. amplitude 0.15 mm
1)
58 Hz ≤ f ≤ 200 Hz, const. acceleration 2 g
Period of oscillation: 20 sweeps per axis in each of the three
axes that are perpendicular to one another
Vibrations as per IEC Vibration type: sweep at a rate of 1 octave per minute.
60068 Part 2-6 (sinus) 10 Hz ≤ f ≤ 55 Hz, max. amplitude 0.35 mm
1)
max. acceleration 5 g
Period of oscillation: 20 sweeps per axis in each of the three
axes that are perpendicular to one another
Surge as per IEC 60068 Type: half-sinusoidal
1)
Part 2-27 Strength: 30 g peak value , 11 ms duration
Surge direction: 3 surges in each +/- direction in each of the
three axes that are perpendicular to one another
Surge as per IEC 60068 Type: half-sinusoidal
1)
Part 2-29 Strength: 10 g peak value , 16 ms duration
Surge direction: 1000 surges in each +/- direction in each of the
three axes that are perpendicular to one another
Climatic ambient conditions

The Safety Unit may be used under the following climatic conditions:
Table 6-4 Climatic ambient conditions for operation

Ambient conditions Permissible range
Allowable ambient temperature 0 ... 60 °C
Condensation Not permissible
Relative humidity Without condensation
• ≤ 1 month/year 5 ... 95 %
• ≤ 11 months/year 5 ... 75 %
Air pressure 1080 ... 795 hPa
(corresponds to an altitude of -1000 ... 2000 m)
2)
Contaminant limits (according to Limit value < 30 min. per day
IEC 60723-3-3, class 3C3)
3 3
• Sulfur dioxide SO2 Average value 5.0 mg/m , limit value < 10.0 mg/m
3 3
• Hydrogen sulfide H2S Average value 3.0 mg/m , limit value < 10.0 mg/m
3 3
• Chlorine Cl2 Average value 0.3 mg/m , limit value < 1.0 mg/m
3 3
• Hydrogen chloride HCl Average value 1.0 mg/m , limit value < 5.0 mg/m
3 3
• Hydrogen fluoride HF Average value 0.1 mg/m , limit value < 2.0 mg/m
3 3
• Ammonia NH3 Average value 10.0 mg/m , limit value < 35.0 mg/m
3 3
• Ozone O3 Average value 0.1 mg/m , limit value < 0.3 mg/m
3 3
• Nitrogen oxide NOx Average value 3.0 mg/m , limit value < 9.0 mg/m
1) 2
Gravitational acceleration g equals approx. 9.81 m/s
2)
the specified values apply at 20 °C and 101.3 kPa

Technical Data
6.5 Technical data

Function and area of application
Function Parameterizable compact safety minicontroller.
Area of Application Fail-safe applications as per EN 951 and IEC 61508.
Technology Two-channel control unit with data comparison and
automatic check in the 1oo2 architecture as per IEC
61508, i.e. each partial controller can initiate the safety
function.
Pilot application Safety-related part of mechanical presses (EN 692) and
hydraulic presses (EN 693)
Dimensions and weight

Dimensions H x W x D 125 mm x 365 mm x 115 mm
Weight 1.7 kg
Protection and safety requirements

As per EC directive 98/37/EC for machines and low voltage directive 72/23/EEC
Degree of protection as per EN 60529 IP 20 (protection against contact
with standard probes)
Protection class as per IEC 60536 I (protective ground connection
(VDE 0106-1) using toothed screws is required)
Maximum classification in fail-safe operation
• As per IEC 61508 (Safety Integrity SIL 3
Level) Cat. 4
• As per EN 954 (Category)
Protection against foreign bodies and water protection

Protection against Remark
...
Contact Degree of protection IP 20 as per EN 60529 with standard
probes
Foreign bodies With diameters over 6 mm
Water No special protection
Specific data
Allowable ambient temperature 0 °C to +60 °C
Condensation Not permissible
Allowable cable length for 24 V supply Max. 10 m
Allowable cable length for I/O signals
• Unshielded Max. 50 m
• Shielded Max.100 m (counter input max. 50 m)
Recommended cable cross sections (flex.)
2
• Voltage supply, connector X1 or X5 0.75 to 1.5 mm (≈AWG 18 to 16)
2
• Digital inputs, connector X3 or X4 0.25 to 0.75 mm (≈AWG 22 to 18)
2
• Digital outputs 0.5A, connector X2 0.25 to 0.75 mm (≈AWG 22 to 18)
2
• Digital outputs 2A, connector X6 0.75 mm (≈AWG 18)

Technical Data
Digital inputs
Quantity System 1 System 2
Standard digital inputs
• Basic device 12 (X4.1 to X4.12) 12 (X3.1 to X3.12)
• Extension options 4 (X4.13 to X4.16) 4 (X3.13 to X3.16)
Differential/counter inputs 1 (X9.2 and X9.3) 1 (X9.7 and X9.8)
Input voltage as per EN 1131-2
Type 2 24 V DC
• Rated value -30V ... 5V
• Signal "0" 11V ... 30V
• Signal "1"
Input current at signal "1" Typ. 8 mA
Connection of 2-wire proximity Possible (passive encoder clock)
switch Max. 2 mA
• Allowable residual current
Digital outputs 0.5 A, P-switching

Quantity System 1 System 2
Sensor power supplies 2 (X2.1 and X2.2) 2 (X2.5 and X2.6)
Reserve (can be parameterized) 1 (X2.3) 1 (X2.7)
Pilot lamp, fault — 1 (X2.8)
Reserve (can be parameterized) 1 (X2.4) —
Voltage drop at signal "1" Max. 1.5 V at 0.5 A
Output current at signal "1"
• Rated value as per EN 1131-2 0.5 A
• Allowable range 0 ... 0. 6 A
Load resistance at 1L+ = 28.8 V ≥ 48 Ω
Allowable sum current 3.2 A
Residual current at signal "0" Max. 0.1 mA
Short circuit and overload protection Electronic
Digital outputs 2 A, P/M-switching

System 1/P-driver System 2/M-driver
Quantity 4 (X6.1/3/5/7) 4 (X6.2/4/6/8)
Voltage drop at signal "1" Max. 1.0 V at 2 A Max. 0.5 V at 2 A
Output current at signal "1"
• Rated value as per EN 1131-2 2A
• Allowable range 7 mA ... 2.4 A
Load resistance range
• 2L+ = 20.4 V ≤ 2.7 kΩ
• 2L+ = 28.8 V ≥ 12 Ω
Allowable sum current 6.4 A
Residual current at signal "0" Max. 0.5 mA —
Conductor breakage detection Electronic —
Monitoring of supply voltage Electronic —
Short circuit and overload Electronic
protection

Technical Data
Voltages, potentials
Rated voltage (1L+, 2L+) 24 V DC (X1.1, X5.1)
Reference potential (1M, 2M) 0 V DC (X1.2, X5.2)
Protective ground connection (1, 2) Ground (X1.3, X5.3)
Allowable range 1L+, 2L+ (average value) 20.4 V ... 28.8 V
Voltage loss ride-through
• 1L+, 2L+, digital outputs No
• Int. 5 V supply ≥ 5 ms (ext. 24 V power supply unit
≥ 20 ms)
Electrical isolation
• Between 1L+, 2L+ and int. 5 V Yes
• Between the inputs/outputs and bus Via optocoupler
• Test voltage 500 V AC
• Rated insulation voltage 50 V AC
Power loss
Idle without inputs and outputs (RUN) Typ. 10 W
Power loss of inputs at signal "1" Typ. 0.2 W / input
Power loss of outputs
• Digital outputs, 0.5 A, P-switching Typ. 0.9 W / output
• Digital outputs, 2 A, P/M-switching Typ. 0.8 W / output
Current consumption
From 1L+, 24 V (RUN operating state) Fault-free operation
• Without load Max. 0.5 A
• At 3 A sum current of the 0.5 A outputs Max. 3.5 A
Current consumption from 2L+, 24 V Fault-free operation
• Without load Max. 0.1 A
• At 6 A sum current of the 2 A outputs Max. 6.1 A

Technical Data
Time, frequency
System error detection time
• Selftests CPU, RAM, EPROM, memory ≤ 2 min
card (INIT/STOP/RUN/PARA)
• DI selftests (standstill and upward 360 ms (cycle time 10 ms)
movement in RUN; 36 test steps)
Required number of strokes for one test
run (mech. press) with
– 80 strokes/min → 1; rounded
• DO selftests (standstill and upward 120 ms (cycle time 10 ms)
movement in RUN; 12 test steps)
Required number of strokes for one test
run (mech. press) with
System error response time ≤ 1ms
(time from system error recognition to shutoff
of outputs)
1)
Cycle time Typ. 7 ms (downward movement,
otherwise typ. 10 ms)
1)
Reaction time input/output Max. 16 ms (downward
incl. HW delays movement, otherwise max.
(without switching times of sensors/actuators) 20 ms)
Input delay
• Standard digital inputs 1.7 ... 2.7 ms
• Differential/counter inputs 0.5 ... 0.9 ms
Differential/counter inputs
• Minimum pulse duration 1 ms
• Maximum frequency 500 Hz
Output delay for Max. 0.3 ms
RLoad ≤ 1 kΩ; CLoad ≤ 10 nF
Switching frequency of outputs
• For ohmic load Max. 30 Hz
• For inductive load (IEC 947-5-1, DC 13) Max. 2 Hz
• For lamp load Max. 10 Hz
Test pulse, sensor clock (obscuration time) 4 ... 6 ms
Test pulse, digital outputs ≤ 1ms
(illumination/obscuration times)
Data for selection of an actuator

Rated voltage 24 V DC
Pickup voltage/switch-on voltage ≤ 16.8 V (70 % x UN)
Drop-out voltage/switch-off voltage ≥ 2.4 V (10 % x UN)
Pickup/switch-on time for active output test ≥ 1.1 ms
Drop-out/switch-off time for active output test ≥ 1.1 ms
1)
The times are dependent on the parameterization; they were measured with the following
parameterization: Mechanical press in continuous stroke operating mode with one-man
operation and 1 two-hand, 1 foot switch, 1 safety guard, 1 safety gate, 1 EMERGENCY
STOP, 1 ESPE.

Technical Data
Status, diagnosis
Status displays
• Status display, RUN (operation) Green LED
• Status display, STOP Red LED
Error display Via display
Diagnosis information can be called up Via RS 232 interface

A Accessories, Order Numbers
A
A.1 Spare parts
Item Order no. Comment
Safety Unit 6AU1121-2CA00-0AA0 24 digital inputs
Safety Unit with option 6AU1121-3CA00-0AA0 32 digital inputs
Memory card 6AU1712-1MA00-0AA0 128 kByte
A.2 Accessories
Item Order no. Comment
Software package 6AU1810-0XA20-0XA0 Contains:
V2.0 • CD-ROM
(parameterization tool +
manual)
• Link cable
5 connector sets 6AU1712-1CB00-0AA0 With 4 connectors each

SIMOTION Safety Unit (SU) - Edition 06/2003 A-49
Accessories, Order Numbers
Notes

A-50 SIMOTION Safety Unit (SU) - Edition 06/2003
B Glossary
B
1v1 evaluation
Type of encoder evaluation - In 1v1 evaluation, there is one encoder and it is
connected to the module via 1 channel.
2v2 evaluation
Type of encoder evaluation - In 2v2 evaluation, the inputs are internally compared
with regard to their signal states (equivalence or non-equivalence).
see: Discrepancy analysis
ACK
Acknowledgement message.
Actuator
Actuators are, for example, power relays or contactors for switching on load
equipment, or they are the load equipment itself, e.g. directly-controlled solenoid
valves.
B
BDC
Bottom dead center
C
Category
Category as per EN 954
The Safety Unit allows safe operation up to Category 4.
CRC
Cyclic Redundancy Check -> CRC checksum

SIMOTION Safety Unit (SU) - Edition 06/2003 B-51
Glossary
CRC checksum
The validity of the process values contained in the safety telegram, the correctness
of the associated address relationships and the safety-related parameters are
guaranteed by a CRC checksum contained in the safety telegram.
Critical to safety
This term refers to a feature of functions or parts that are directly involved in the
execution of a safety function.
D
DI
Digital inputs
Discrepancy analysis
The discrepancy analysis is used to identify faults on the basis of the variations
over time of two signals with the same functionality. The discrepancy analysis is
started when different levels are determined for two associated input signals. The
test establishes whether or not the difference has disappeared after a
parameterizable time period, the so-called discrepancy time. If not, a discrepancy
error has occurred.
The Safety Unit only performs a discrepancy analysis during a 2v2 evaluation.
Discrepancy time
This is the time that can be parameterized for the discrepancy analysis.
DO
Digital outputs
E
Encoder
Encoders precisely register distances, positions, speeds, rotational speeds,
volumes, etc.
Encoder evaluation
There are two types of encoder evaluations:
• 1v1 evaluation – encoder signals are read in once
• 2v2 evaluation – in order to increase system availability, encoder signals are
read in twice by the same module and compared within the module

B-52 SIMOTION Safety Unit (SU) - Edition 06/2003
Glossary
ESPE
Electro-sensitive protection equipment (see VBG 7n5.2: Hydraulic presses, § 7)
F
Fail-safe systems
Fail-safe systems are characterized by the fact that they remain in a safe state or
immediately go into a safe state in the event of certain malfunctions.
FM
Fault message
I
Illumination time
The illumination times occur during complete bit pattern tests. Test-dependent 1
signals are switched onto the output by the fail-safe output module while the output
is inactive (output signal "0"). The output is then briefly switched on (= "illumination
time"). Any actuator that is sufficiently slow will not react and remains off.
O
Obscuration time
Obscuration times occur during switch-off tests and complete bit pattern tests.
Test-dependent 0 signals are switched onto the output by the Safety Unit while the
output is active. The output is then briefly switched off (= "obscuration time"). Any
actuator that is sufficiently slow will not react and remain on.
ODIS
Output disable
P
PLD
Programmable logic device
R
Relevant to safety
This term refers to a feature that is in some way related to functional safety.

SIMOTIONSafety Unit (SU) - Edition 06/2003 B-53
Glossary
S
Safe state
The safety concept is based on there being a safe home position for all process
parameters. For binary signal modules, this is always the value "0".
Safety function
As per IEC 61508: A function that is implemented by a safety device in order to
maintain the system in a safe state or to bring the system into a safe state in the
event of a certain malfunction.
Safety integrity level

Safety integrity level SIL as per IEC 61508
The Safety Unit allows operation up to safety integrity level SIL 3.
SELV
Safety Extra Low Voltage
SRS
Safety-related systems
T
TDC
Top dead center

B-54 SIMOTION Safety Unit (SU) - Edition 06/2003
I Index
I
1 E
1v1 evaluation....................................... 2-15 EMC.......................................................6-40

Emission ................................................6-41
Encoder ....................................... 2-17, 6-40
2 Encoder evaluation
1v1 evaluation ....................................2-15
2v2 evaluation....................................... 2-15 2v2 evaluation ....................................2-15
Error diagnosis ............................ 5-34, 5-35
A Error display ................................ 2-17, 5-34
Error messages .....................................5-35
Actuator..................... 2-16, 2-17, 6-40, 6-47 Error responses .....................................2-16
Ambient conditions ............................... 6-42 Errors
climatic............................................... 6-43 Corrective measures ..........................5-36
mechanical......................................... 6-42 Errors requiring acknowledgement2-16,
Area of application ................................ 6-39 5-36
Self-acknowledging errors ....... 2-16, 5-38
System errors........................... 2-16, 5-35
B Errors requiring acknowledgement2-16, 5-
36
BG certificate ........................................ 6-39
F
C
Fail-safe applications.............................6-44
Cables................................................... 4-28 Features ................................................1-10
Cabling rules ......................................... 4-28 Function test ..........................................2-14
CE marking ........................................... 6-39
Connecting terminals ............................ 3-24
Continuous mode.................................. 2-13
H
CRC checksum ..................................... 2-14
Hardware ...............................................3-22
D
I
Demand mode ...................................... 2-13
Design specifications .............................. 1-9 Illumination time .......................... 2-16, 2-17
Diagnosis buffer.................................... 5-34 Inputs.....................................................3-24
Directives ................................................ 1-9 Installation .............................................2-18
Discrepancy analysis ............................ 2-15 Interfaces...............................................3-23
Display .................................................. 5-34

SIMOTION Safety Unit (SU) - Edition 06/2003 I-55
Index
M Responsibilities and qualifications ........2-14

Risk chart ..............................................2-11
Malfunction probability .......................... 2-13 Risk parameters ....................................2-12
Mounting ............................................... 4-27 RS 232 interface....................................3-25
O S
Obscuration time.......................... 2-16, 2-17 Safe home position................................2-16

Onboard I/O .......................................... 3-22 Safe state .................................... 2-16, 3-22
Operating conditions............................. 6-42 Safety certificate....................................6-39
Operating states ................................... 3-23 Safety extra low voltage ........................6-40
Operation Safety function.......................................6-44
in high demand or continuous mode . 2-13 Safety functions .....................................2-15
in low demand mode ......................... 2-13 Safety integrity level ..2-11, 2-13, 2-15, 2-16
Outputs ................................................. 3-24 Safety minicontroller..............................6-44
Safety modules......................................3-21
Safety requirements ..............................2-11
P Self-acknowledging errors........... 2-16, 5-38
Status LED ............................................3-23
Parameter list........................................ 2-14 System data...........................................5-34
Parameterization................................... 2-13 System errors .............................. 2-16, 5-35
Parameterization tool............................ 5-31 System requirements ............................5-31
Parameters ........................................... 5-31
Pilot lamp ............................................ 5-34
Positive-action contacts ........................ 2-18 T
Power supply ......................2-18, 4-29, 6-40
Protective measures ............................. 4-29 Transients, pulsed .................................6-41
Pulsed transients .................................. 6-41 Transients, sinusoidal............................6-41
Transport and storage conditions..........6-42
Q
V
Qualification .......................................... 2-14
Voltage supply to power supply unit......4-29
Reading out diagnosis messages......... 5-34

Report ................................................... 2-14

I-56 SIMOTION Safety Unit (SU) - Edition 06/2003
To
SIEMENS AG
A&D MC BMS
P.O. Box 3180
D-91050 Erlangen
Tel. +49 (180) 50 50 222

Fax +49 (9131) 98 2176
E-Mail: motioncontrol.docu@erlf.siemens.de
Return address:
Your name: ___________________________________
Your position: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
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SIMOTION Safety Unit (SU) - Edition 06/2003 57

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58 SIMOTION Safety Unit (SU) - Edition 06/2003
Siemens AG
Automation and Drives
Motion Control Systems
P.O. Box 3180, D – 91050 Erlangen © Siemens AG 2003
Subject to change without prior notice
Federal Republic of Germany
Order no.: 6AU1900-0CM20-0XA0
www.ad.siemens.de Printed in the Federal Republic of Germany

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Device Manual Edition 06/2003

Parameterization and Diagnosis 5

Accessories, Order Numbers A

Copyright Siemens AG 2003All Rights Reserved Liability exclusion

Siemens AG Safety Unit TM 121C

Purpose of this manual

For whom is this manual intended?

© Siemens AG 2003 All Rights Reserved

© Siemens AG 2003 All Rights Reserved

1 Area of Application ......................................................................... 1-9

1.1 Introduction.................................................................................... 1-9

1.2 Features ........................................................................................ 1-10

1.3 Compatibility of firmware to software ............................................ 1-10

2 Safety Integrated ............................................................................. 2-11

2.1 Safety requirements ...................................................................... 2-11

2.2 Acceptance of parameterization.................................................... 2-13

2.3 Safety functions............................................................................. 2-15

2.4 Responses to errors...................................................................... 2-16

2.5 Requirements regarding encoders and actuators......................... 2-17

2.6 Requirements regarding the power supply ................................... 2-18

2.7 Power supply requirements........................................................... 2-18

3.1 General information....................................................................... 3-21

3.2 Features ........................................................................................ 3-22

3.3 Interfaces....................................................................................... 3-23

4 Mounting and Cabling .................................................................... 4-27

4.1 Mounting........................................................................................ 4-27

4.2 Cabling .......................................................................................... 4-28

5 Parameterization and Diagnosis.................................................... 5-31

5.1 Parameterization ........................................................................... 5-31

© Siemens AG 2003 All Rights Reserved

5.1.2 Setting parameters with the "Parameterization tool" ................. 5-31

5.2 Diagnosis....................................................................................... 5-34

6 Technical Data ................................................................................. 6-39

6.1 Standards and certifications.......................................................... 6-39

6.2 Safety extra low voltage ................................................................ 6-40

6.3 Electromagnetic compatibility........................................................ 6-40

6.4 Mechanical and climatic ambient conditions................................. 6-42

6.5 Technical data ............................................................................... 6-44

A Accessories, Order Numbers ........................................................ A-49

A.1 Spare parts ................................................................................... A-49

A.2 Accessories................................................................................... A-49

B Glossary .......................................................................................... B-51

I Index .................................................................................................. I-55

© Siemens AG 2003 All Rights Reserved

Safety measures must be implemented on all product machines, especially on

Such control systems must be constructed in accordance with the specified

• Simple handling (like contactor)

© Siemens AG 2003 All Rights Reserved

• Smaller switching cabinet

• Short response times

1.3 Compatibility of firmware to software

© Siemens AG 2003 All Rights Reserved

Risk chart as per IEC 61508

© Siemens AG 2003 All Rights Reserved

© Siemens AG 2003 All Rights Reserved

Safety integrity level as per IEC 61508

Safety Low demand mode of High demand or continuous

2.2 Acceptance of parameterization

© Siemens AG 2003 All Rights Reserved

Responsibilities and qualifications

© Siemens AG 2003 All Rights Reserved

2.3 Safety functions

2.3.1 Fail-safe digital inputs