207015

Check Safety Input Status

Navigate to HMI > Diagnostics > Safety > Safety Inputs to view real-time status of all safety input channels and identify which input is faulted.

Use the safety input visualization to see which inputs are active/inactive in real-time

Verify Physical Safety Devices

Physically inspect emergency stops, safety door switches, and light curtains for proper operation. Check for stuck buttons, damaged switches, or obstructed light beams.

Always follow LOTO procedures when inspecting safety devices

Test Safety Input Wiring

Use multimeter to verify 24VDC supply and continuity on safety input wiring. Check X121/X122 safety I/O terminal connections for loose or corroded contacts.

Safety inputs typically require dual-channel wiring - verify both channels are functioning

Reset Safety System

After resolving input issues, perform safety acknowledgment via HMI > Safety > Acknowledge or press the designated safety reset button on the machine.

Only reset after confirming all safety devices are functioning properly

Check STO Status in Drive Diagnostics

Access HMI > Diagnostics > Drives > [Drive Number] > Safety and verify STO1/STO2 channel status. Both channels must show consistent states.

STO channels should mirror each other - any discrepancy indicates a fault

Inspect STO Wiring Connections

Verify STO input connections on drive terminals (typically X9/1-2 for STO1 and X9/3-4 for STO2). Check for 24VDC supply voltage and proper contact closure.

STO circuits are safety-critical - use only qualified personnel for modifications

Test STO Functionality

With machine in safe state, manually activate STO inputs and verify drive immediately removes enable signals. Monitor p9601/p9602 (STO status parameters) during test.

STO response should be immediate (<10ms) - delayed response indicates component wear

Clear Drive Safety Faults

Reset drive faults via HMI > Diagnostics > Drives > Reset or by cycling STO inputs. Verify parameter r0945 (drive fault buffer) is cleared.

Ensure root cause is resolved before clearing safety faults

Verify Safety Machine Data

Check HMI > Parameters > Machine Data > Safety and verify MD36700-36799 (Safety Integrated parameters) match machine safety requirements and approved safety plan.

Compare current settings with documented safety configuration from commissioning

Validate Safety Logic Configuration

Review MD36710 (safety input assignment) and MD36720 (safety output assignment) to ensure proper mapping between physical I/O and safety functions.

Safety parameter changes require safety validation and may need TÜV approval

Check Safety Signature

Verify safety signature in MD36701 matches the calculated CRC for current safety configuration. Mismatched signatures indicate parameter corruption.

Use SINAMICS Safety Integrated commissioning tool to recalculate safety signature

Restore Safety Configuration

If parameters are corrupted, restore from known good backup or re-enter safety parameters according to approved safety documentation. Recalculate and update safety signature.

Safety parameter restoration must be performed by qualified safety personnel only

Check Safety Module LED Status

Inspect LED indicators on Safety Integrated module (typically TM54F). Red LEDs indicate hardware faults, while flashing patterns provide specific fault codes.

Refer to TM54F manual for LED fault code interpretation - different patterns indicate specific failure modes

Verify Module Power Supply

Check 24VDC supply voltage to safety module at terminals L+ and M. Voltage should be stable 24VDC ±10% with minimal ripple.

Use isolated measurement equipment when checking safety module power

Test Module Communication

Verify PROFINET/PROFIBUS communication between safety module and NCK via HMI > Diagnostics > Hardware > Safety Module. Check for communication timeouts or data errors.

Safety communication uses black channel protocol - any data corruption triggers immediate fault

Replace Safety Module

If hardware fault is confirmed, replace safety module with identical part number. Transfer safety configuration and recalculate safety signature after replacement.

Safety module replacement requires complete safety validation and may need certification body approval