Configuring SINAMICS S210 STO via PROFIsafe in TIA Portal

Overview: SINAMICS S210 Safety Integrated Functions over PROFIsafe

The SINAMICS S210 servo drive (6SL3210-5HB series) integrates Safety Integrated Extended Functions including STO (Safe Torque Off), SS1 (Safe Stop 1), SOS (Safe Operating Stop), SLS (Safely-Limited Speed), SDI (Safe Direction), SSM (Safe Speed Monitor) and SLA (Safely-Limited Acceleration). Two paths exist to trigger these functions:

1. Fail-safe digital inputs on the F-TM ServoDrive ST module inside the ET 200SP station (terminals STO+ / STO-).
2. PROFIsafe over PROFINET from a SIMATIC F-CPU acting as PROFIsafe host.

When the STO function is wired via PROFIsafe, the safety control word (S_STW) travels inside a PROFIsafe telegram between the F-CPU and the drive. Selecting (activating) or deselecting (releasing) STO is therefore a matter of writing the correct bit pattern into the corresponding safety data block, not toggling a 24 V terminal. The Telegrams supported on the S210 with Safety Integrated are 30, 31, and the vendor-specific telegrams 900, 901, 902, 903. Telegram 30 is the standard two-word safety telegram; telegram 31 extends the payload for SLS with multiple limits; telegram 900 carries a compact one-word safety image for S210. The Telegram selection must match the configured Safety Integrated mode on the drive (Basic or Extended).

If the F-program is written directly against raw PROFIsafe payload bytes, the integrator must understand the bit assignment, byte order, and PROFIsafe CRC handling. To avoid that, Siemens publishes a library of ready-made F-blocks that wrap each telegram: SINAMICS S210 Safety Integrated Functions library (entry 109485794). The library contains one FB per telegram (e.g., SINA_SAFE_TLG30, SINA_SAFE_TLG31, SINA_SAFE_TLG900) that exposes a structured interface where the engineer selects or deselects STO with a Boolean input.

Prerequisites

• Hardware: SINAMICS S210 (6SL3210-5HB...), ET 200SP baseUnit, F-TM ServoDrive ST module (article number 6FE1202-... for the safety terminal module referenced in the F-DI documentation), PROFINET cable, and a SIMATIC F-CPU (e.g., CPU 1510SP F-1 PN / 1512SP F-1 PN / 1515SP PC F).
• Software: TIA Portal V17 or newer (V18/V19 recommended for the latest S210 HSP). STEP 7 Safety Advanced option package must be installed for F-programming.
• Library: SINAMICS S210 Safety Integrated Functions block library, installed into TIA Portal master data library.
• S210 firmware: V5.2 or newer (V5.2 SP3 recommended) for full Extended Functions coverage.
• GSD / HSP: SINAMICS S210 GSDML installed, or the matching Hardware Support Package imported in TIA Portal.
• Engineering rights: The Safety password for the S210 and the F-CPU must be known. Both the drive safety configuration and the F-program are password-protected; the password must be entered before each commissioning cycle.

Step 1: Configure the S210 and PROFIsafe Channel in the Device View

1. Open the TIA Portal project and add the SINAMICS S210 from the hardware catalog. Use the latest GSD or HSP so that all safety telegrams (30, 31, 900) appear in the Telegram configuration drop-down.
2. Right-click the S210 and open Properties → Safety Integrated. Select Extended Functions if you intend to use SS1, SLS, SS2, SDI, SLA, or SOS in addition to STO. Keep Basic Functions if only STO and SS1 are required.
3. In the Telegram configuration, set Telegram 30 (Standard) for a typical STO-only or STO+SS1 setup. Use Telegram 31 if multiple SLS limit values must be transmitted. Use Telegram 900 for the S210 compact safety image.
4. Assign a unique PROFIsafe address to the F-DI module (or the integrated PROFINET safety slot on the S210) in the range 1..1023. The address must match the F-DI DIP switch on the physical module, or be set by the PROFINET assignment tool (DCP) if Address assignment via PROFINET is enabled.
5. Compile the hardware configuration. TIA Portal automatically generates the safety I/O tags (S_STW1, S_ZSW1, etc.) in the PLC tag table.

Assigning the PROFIsafe Address via TIA Portal (per official Siemens PDF)

The reference application Controlling SINAMICS S210 Safety Integrated Functions using TO Axis (PDF, 109760341) documents the procedure:

1. Switch to Device view in the project tree under Device configuration.
2. Right-click the F-DI module of the F-TM ServoDrive ST station.
3. Select Assign PROFIsafe address from the context menu.
4. Confirm the proposed F-address matches the rotary switches on the physical module, or set it via DCP if the slot is configured for network-assigned F-addresses.

Step 2: Install and Instantiate the Safety Block Library

The library referenced in the application manual is entry 109485794. After download, open the master data library in TIA Portal and drag the FB matching the chosen telegram into the F-program folder:

The block takes care of bit-stuffing the control word, calculating the PROFIsafe CRC, and routing the payload through the F-CPU's safety stack to the drive. The integrator only interacts with Boolean inputs.

Step 3: STO Select / Deselect Bit Mapping in Telegram 30

If the F-program is written at the raw PROFIsafe level rather than using the library FB, the following bit positions apply for S_STW1 in Telegram 30:

Bit semantics are low-active: writing 0 to bit 0 selects STO, writing 1 to bit 0 deselects STO. The default deselected state (drive ready to enable) is therefore S_STW1 = 16#0000_0000_0000_0000 if no other safety function is requested. The simplest ladder logic to deselect STO from the F-program is:

// F-program (FBD or STL)
// Always deselect STO when the safety door is closed and emergency stop is released
// Library FB: SINA_SAFE_TLG30 (DB instance: iDB_SafetyTlg30)

      iDB_SafetyTlg30.iSelectSTO     := FALSE;        // 0 → STO active
      iDB_SafetyTlg30.iSelectSS1     := TRUE;         // 1 → SS1 deselected
      iDB_SafetyTlg30.iAcknowledge   := bAckFault;
      iDB_SafetyTlg30(oSelectSTO     => qSelectSTO,   // diagnostic only
                      oSelectSS1     => qSelectSS1);

Use the FB instance for Telegram 30 unless SLS with multiple limit levels is required; in that case switch to Telegram 31 or the S210-specific Telegram 900.

Step 4: Compile the F-Program and Download

1. Right-click the F-CPU → Compile > Safety Program. TIA Portal performs a safety check on every F-block (F-validity check, signature, runtime group assignment).
2. Enter the Safety password for the F-CPU when prompted.
3. Download the F-program to the F-CPU. The runtime group that contains the S210 safety FB must be assigned to a cyclic OB (typically OB 35 with 100 ms cycle).
4. Download the standard PLC program (HMI tags, axis configuration, technology objects) separately. The safety download is independent and requires the Safety password.

Step 5: Resolve the Acceptance Test Required Fault

The Acceptance Test Required fault appears on the S210 when Safety Integrated Extended Functions have been configured but the mandatory safety acceptance test has not yet been completed and signed off. The fault is latched and blocks the safety handshake between the F-CPU and the drive, which means STO will stay selected and the axis will not move. It is the most common first-time-commissioning block on S210 projects.

Procedure to Clear the Fault and Complete the Acceptance Test

1. Open Startdrive > Commissioning > Safety Integrated > Acceptance test on the S210.
2. Select PROFIsafe as the safety channel for the test (the test would be slightly different for F-DI based wiring).
3. Run the wizard: it steps through STO select/deselect, SS1 stop time, SLS limit verification, and SDI direction check. Each step must be physically verified (motor coasts to standstill for STO, decelerates on SS1, holds at limit for SLS).
4. From the F-CPU, force STO active (write 0 to S_STW1 bit 0) and verify that the drive pulses are removed within the configured safe stop time (typically < 5 ms for STO).
5. Deselect STO (write 1 to S_STW1 bit 0) from the F-program; verify the drive releases the pulses and the safety status word bit 0 returns to 1 (STO inactive).
6. Sign off the acceptance test report. Startdrive generates a PDF that documents each step, the test results, the S210 serial number, the F-CPU serial number, and the Safety signature CRC.
7. Save the report and archive it with the machine dossier. TIA Portal also stores the acceptance test status in the drive project; after successful completion, the Acceptance Test Required fault clears on the next power-up or after the safety acknowledgment bit is set.

Step 6: Verification and Commissioning Checklist

Troubleshooting Matrix

Safety and Regulatory Notes

• The PROFIsafe protocol version configured on the F-CPU must be V2.4 or higher when communicating with a current S210 firmware. Mismatched PROFIsafe versions are rejected by the F-host at startup.
• STO via PROFIsafe must not be the only safety measure if the application requires a category higher than SIL 2 / PL d. Refer to the S210 Safety Integrated Functions manual for the achievable safety level per safety function.
• Always use the Safety password to lock the drive configuration after commissioning. Without a password, anyone with TIA Portal access can modify the safety configuration, which will trigger the Acceptance Test Required fault on the next startup.
• The Safety signature of the F-program must be archived alongside the acceptance test report. Any later change to the F-program invalidates the acceptance test and requires a new test run.

FAQ