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Xenus Plus
Compact Manual
31 pgs1.45 Mb0

Copley Controls Xenus Plus Compact Manual

Xenus Plus Compact STO Manual
P/N 16-01553 Rev 00
September 12, 2016
Xenus Plus Compact STO Manual 16-01553 Rev 00
Table of Contents
1.0 About This Manual .................................................................................................................................................... 4
1.1 Title, Number, Revision ........................................................................................................................................... 4
1.2 Revision History ...................................................................................................................................................... 4
1.3 EC Declaration of Conformity .................................................................................................................................. 4
1.4 Original Instructions................................................................................................................................................. 4
1.5 Purpose and Scope of This Document ................................................................................................................... 5
1.6 Product Naming....................................................................................................................................................... 5
1.7 Disclaimer ................................................................................................................................................................ 5
1.8 Related Documentation ........................................................................................................................................... 6
1.9 Reference Standards .............................................................................................. Error! Bookmark not defined.
2.0 Risk Assessment & Responsibility of the Installer ............................................................................................... 8
3.0 Warnings .................................................................................................................................................................... 8
3.1 Operate drives within the specifications provided in the relevant hardware manual or data sheet. ....................... 8
3.2 Risk of electric shock .............................................................................................................................................. 8
3.3 Disclaimer ................................................................................................................................................................ 8
3.4 Installation Overview ............................................................................................................................................... 9
3.5 Definitions ................................................................................................................................................................ 9
4.0 Introduction to the Xenus Plus COMPACT ........................................................................................................... 10
4.1 Product Description ............................................................................................................................................... 10
4.2 Model Overview & Numbering .............................................................................................................................. 10
5.0 Specifications Overview ......................................................................................................................................... 11
5.1 Control Modes ....................................................................................................................................................... 11
5.2 Command Sources................................................................................................................................................ 11
5.3 Power Sources ...................................................................................................................................................... 11
6.0 STO Architecture and Function ............................................................................................................................. 12
6.1 STO Channel Operation ........................................................................................................................................ 13
6.2 STO Function Specifications ................................................................................................................................. 14
6.3 Environmental Specifications ................................................................................................................................ 14
6.4 Safety Related Parameters ................................................................................................................................... 15
6.5 Regulatory Specifications ...................................................................................................................................... 15
6.6 Limitations and Necessary Risk Reductions ......................................................................................................... 16
6.6.1 Electrical Isolation ......................................................................................................................................... 16
6.6.2 DC Brush Motors ........................................................................................................................................... 16
6.6.3 180 Degree Electrical Movement .................................................................................................................. 16
6.6.4 Loads and Other Torque/Force Producing Sources ..................................................................................... 16
6.6.5 STO Input Signal Level ................................................................................................................................. 16
6.6.6 Control Modes and STO ............................................................................................................................... 16
6.6.7 24V DC Power Supply................................................................................................................................... 17
Xenus Plus Compact STO Manual 16-01553 Rev 00
6.6.8 AC Mains Over-Voltage Category ................................................................................................................. 17
6.6.9 Wiring to the STO Inputs ............................................................................................................................... 17
6.6.10 Periodic Test Requirements ......................................................................................................................... 17
7.0 Installation Using STO for Xenus Plus Compact ................................................................................................. 18
7.1 STO Wiring Overview ............................................................................................................................................ 18
7.1.1 STO Power Requirements ............................................................................................................................ 18
7.1.2 STO Wiring Requirements ............................................................................................................................ 18
7.1.3 STO (Safety) Cable Connector ..................................................................................................................... 19
7.1.4 Wiring Example:SIL 3/Cat. 3 PL d Emergency Stop - Stopping Category 1 ................................................. 20
7.1.5 XENUS PLUS COMPACT Configuration ...................................................................................................... 20
7.1.6 Example STO Timing .................................................................................................................................... 21
7.2 Start-Up Checklist ................................................................................................................................................. 22
7.2.1 Preliminary checks ........................................................................................................................................ 22
7.2.2 Start-Up Checklist ......................................................................................................................................... 23
7.3 STO Status Indications ......................................................................................................................................... 24
7.3.1 J8 AMP LED .................................................................................................................................................. 24
7.3.2 STO Circuit Status Data Objects ................................................................................................................... 24
7.3.3 CME2 Control Panel...................................................................................................................................... 25
7.4 Troubleshooting..................................................................................................................................................... 26
7.4.1 How to tell if the STO function is active......................................................................................................... 26
7.4.2 How to tell if the STO function is inactive ...................................................................................................... 26
7.4.3 Why can’t the STO function be deactivated? ................................................................................................ 26
7.4.4 Why can’t the STO function be activated? .................................................................................................... 26
7.4.5 The drive is hardware-enabled but the motors don’t move. .......................................................................... 26
8.0 Maintenance ............................................................................................................................................................. 27
8.1 Accessibility and Replacement of Internal Parts ................................................................................................... 27
8.2 Periodic STO Testing Interval ............................................................................................................................... 27
8.3 Periodic Testing Checklist ..................................................................................................................................... 28
9.0 Muting & Suspension of Safety Functions ........................................................................................................... 29
9.1 STO Muting ........................................................................................................................................................... 29
10.0 Decommissioning ................................................................................................................................................... 30
Xenus Plus Compact STO Manual 16-01553 Rev 00
Title
Xenus Plus Compact STO Manual
Document Number
16-01553
Current Revision
00
Revision
Date
ECO #
Comments
00
9/12/2016
ECO-063895
Originated
Table 1
Table 2
1.0 About This Manual
1.1 Title, Number, Revision
1.2 Revision History
1.3 EC Declaration of Conformity
The products covered by this manual comply with the EC Directives 2014/30/EU (EMC Directive), 2014/35/EU (Low Voltage Directive), 2006/42/EC (Machinery Directive) and 2011/65/EU (RoHS Directive). The complete EC Declaration of Conformity is available on the internet at www.copleycontrols.com.
Name and Address of the Manufacturer: Name and Address of the authorized representative: Analogic Corporation d/b/a Copley Controls BK Medical ApS 20 Dan Road Mileparken 34, DK-2730 Canton, MA 02021 Herlev USA Denmark
1.4 Original Instructions
This manual is considered to be “original instructions” as defined in EC Directive 2006/42/EC and the contents have been verified by Copley Controls.
Xenus Plus Compact STO Manual 16-01553 Rev 00
1.5 Purpose and Scope of This Document
This document is intended to inform the reader about the Functional Safety features of the Xenus Plus Compact servo drive models and to provide information on the steps required to install it into systems so that a target level of Functional Safety performance can be achieved. The scope of this document is limited to those aspects of Functional Safety that relate to the installation, operation, and maintenance of the Xenus Plus Compact.
1.6 Product Naming
The STO function is the same in XEC, XPC, 801-1891, 801-1892, and 801-1893 models. References to Xenus Plus Compact in this document should be understood as references to all of these models.
1.7 Disclaimer
This manual contains information on the Safe Torque Off (STO) feature of the Xenus Plus Compact servo drive and how it may be incorporated into an industrial motion control system. While every effort has been made to ensure the completeness and accuracy of this manual it must be emphasized that the responsibility for functional safety in the overall system into which the drive is installed rests ultimately with the manufacturer of the system into which the Xenus Plus Compact is installed.
The equipment manufacturer which must take into account all the aspects of the system of which the Xenus Plus Compact is a component.
Copley Controls does not accept any liability for direct or indirect injury or damage caused by the use of information in this document. The equipment manufacturer is always responsible for the safety of its product and its suitability under applicable laws. Copley Controls hereby disclaims all liabilities that may result from this document.
Xenus Plus Compact STO Manual 16-01553 Rev 00
1.8 Related Documentation
These documents have additional information on the Xenus Plus Compact and are required for proper installation and commissioning of the drives. Available upon request from Copley Controls:
User Guide
Xenus Plus Compact User Guide (Document No. 16-01552)
Datasheet
Xenus Plus XEC Datasheet (Document No. 16-01435) Xenus Plus XPC Datasheet (Document No. 16-01436)
Available on the Copley Controls web site:
http://www.copleycontrols.com/Motion/Downloads/index.html Downloads > Documents > Xenus Plus > Manual:
Absolute & Serial Encoder Guide CME 2 User Guide Indexer 2 User Guide ASCII Programmer’s Guide CMO Programmer’s Guide
1.9 Reference Standards
ISO 13849-1: 2015
Safety of machinery Safety-related parts of control systems
Part 1: General Principles for Design
ISO 13849-2: 2012
Safety of machinery
Safety-related parts of control systems — Part 2: Validation
IEC 61508-1: Ed. 2.0 2010
Functional safety of electrical/electronic/programmable electronic safety-related systems
Part 1: General requirements
IEC 61508-2: 2010, 2nd Ed.
Functional safety of electrical/electronic/programmable electronic safety-related systems
Part 2: Requirements for electrical/electronic/programmable electronic safety related systems
IEC 61800-5-1: 2007, 2nd Ed.
Adjustable speed electrical power drive systems
Part 5-1: Safety requirements – Electrical, thermal and energy
IEC 61800-5-2:2007
Adjustable speed electrical power drive systems
Part 5-2: Safety requirements – Functional
Xenus Plus Compact STO Manual 16-01553 Rev 00
Acronym
Description
Safety-Related
a,b,c,d,e
Denotation of performance level (PL)
Cat.
Category
CCF
Common Cause Failure
DC
avg
Diagnostic Coverage, Average
FS
Functional Safety
HFT
Hardware Fault Tolerance
MTTF
Mean Time to Failure
MTTFd
Mean Time to Dangerous Failure
OVC
Over-Voltage Category
PDS(SR)
Power Drive Systems (Safety Related)
PELV
Protected Extra Low Voltage (power supply)
PFD
Probability of Dangerous Failure upon Demand
PFH
Probability of Failure per Hour
PL
Performance Level
PLr
Performance Level requirement
S, S1, S2
Severity of Injury
SELV
Safety Extra Low Voltage (power supply)
SFF
Safety Failure Fraction
SIL
Safety Integrity Level
SIL CL
Safety Integrity Level Limit or Capability Level
SPD
Surge Protection Device
STO
Safe Torque Off
Copley Controls Related
XEC
Xenus Plus XEC EtherCAT
XPC
Xenus Plus XPC CANopen
Table 3
1.10 Abbreviations and Acronyms
Xenus Plus Compact STO Manual 16-01553 Rev 00
2.0 Risk Assessment & Responsibility of the Installer
The STO feature of the Xenus Plus Compact is capable of the safety integrity level and category/performance level stated in this manual and operates in accordance with the characteristics and limitations described herein. But it must be noted that the drive STO function is intended to be used only as one element of an overall safety chain and is not a complete safety function unto itself. Therefore the suitability for use of the Xenus Plus Compact in a given application must be determined in part by one or more risk assessments of the overall safety of the end machine conducted in accordance with the applicable standards. Such risk assessments normally consist of a thorough review of overall machine operation to identify potential hazards. For each identified hazard, typical risk assessments take into account the severity of any potential injury resulting from the hazard, the frequency of exposure of persons to the hazard and the probability that persons are able to avoid the hazard if it were to occur. The machine designer is solely responsible for conducting any necessary risk assessments and for the ultimate determination as to the suitability of the Xenus Plus Compact and its STO function for use in realizing a given overall safety function. The installer should be experienced in motion control and functional safety.
3.0 Warnings
The user must take into consideration the necessary risk reductions, installation requirements, and other information contained in this manual in order to achieve the stated functional safety capabilities. Failure to do so could result in equipment damage, injury, or death.
3.1 Operate drives within the specifications provided in the relevant hardware manual or data sheet.
The information in this manual is specific to the functional safety features of the Xenus Plus Compact servo drives. The user must use this manual along with the Xenus Plus Compact User Guide and the datasheets for the Xenus Plus Compact models for proper and safe installation and overall commissioning of the drives.
3.2 Risk of electric shock
The Xenus Plus Compact servo drives are made for operation from 100~240 Vac mains power. Therefore hazardous voltages are connected to and exist within these drives under normal operating conditions. Persons responsible for installing and commissioning these drives must be experienced in all aspects of electrical equipment installations.
3.3 Disclaimer
There are no user serviceable parts in the Xenus Plus Compact servo drives. Removal of the cover or tampering with internal components will void the warranty.
Xenus Plus Compact STO Manual 16-01553 Rev 00
Fig. 1
3.4 Installation Overview
This graphic shows all of the elements in a complete Xenus Plus Compact installation. The STO feature and interface to the machine-level functional safety equipment are highlighted in red to emphasize the aspects of the installation that are addressed in this manual.
A UL RC (Recognized Component) SPD (Surge Protective Device) type 1CA, 2CA, 3CA or a UL Listed (VZCA) SPD type 1, 2, or 3 rated 2500 V, with a minimum SCCR of 5 kA, 240 Vac, and surge voltage monitoring needs to be provided. The purpose of the SPD is to establish an OVC II environment. Example parts are Cooper Bussman BSPM3240DLG (3 phase) or BSPM2240S3G (two-pole). Alternatively, an isolation transformer may be used between AC mains and the drive to establish an OVC II environment.
3.5 Definitions
There are certain terms used throughout this document that serve an important role in describing the operation and behavior of the Xenus Plus Compact STO feature. These terms are discussed and defined as follows:
Activate – This term is used to refer to action taken that results in the safe state being entered. In the case of the STO feature, the STO function is activated (made active) by making the voltage at one or both STO inputs less than or equal to the maximum rated de-energize threshold voltage.
De-Activate – This term is used to refer to action taken that results in the safe state being exited. In the case of the STO feature, the STO function is de-activated (made inactive) by making the voltage at both STO inputs greater than or equal to the minimum rated energize threshold voltage.
Energize – This term refers to the application of voltage greater than or equal to the minimum rated energize threshold voltage to an individual STO input. Note that simultaneously energizing both STO inputs results in the STO function being de-activated.
De-Energize – This term refers to the application of voltage less than or equal to the maximum rated de-energize threshold voltage to an individual STO input. Note that de-energizing an STO input results in the STO function being activated.
Xenus Plus Compact STO Manual 16-01553 Rev 00
EtherCAT
CANopen
Feedback
XEC-230-09
XPC-230-09
Encoder
XEC-230-12
XPC-230-12
XEC-230-15
XPC-230-15
XEC-230-09-R 801-1891
XPC-230-09-R
Resolver
XEC-230-12-R 801-1892
XPC-230-12-R
XEC-230-15-R 801-1893
XPC-230-15-R
Table 4
4.0 Introduction to the Xenus Plus Compact
4.1 Product Description
The Xenus Plus Compact models are intended to be operated from single or three phase power in the 100 Vac to 240 Vac range and can drive motor currents up to 15 Adc. These drives have a Safe Torque Off (STO) function. When the STO function is activated, the ability to drive motor current is cut-off. In the case of rotary motors, the torque produced by the motor is zero when the current is cut-off. In the case of linear motors, the force produced by the motor is zero when the current is cut-off. The Safe Torque Off (STO) function has been developed in accordance with IEC 61508, ISO 13849-1 and IEC 61800-5-2. The Xenus Plus Compact is certified by UL as meeting the stated SIL Capability, Category and Performance Levels and other requirements of the given standards. The Safe Torque Off (STO) function is realized in “hardware only” such that no software, firmware, or programmable device is involved in the execution or reliability of the STO function.
4.2 Model Overview & Numbering
The Xenus Plus Compact models have the same electrical specifications and differ primarily in the communications or the type of motor position feedback they support. XEC and 801-1891~1893 models work with EtherCAT, and XPC models work with CANopen. Models with the ‘-R” suffix and the 801-1891~1893 models support resolver feedback whereas those without the “-R” suffix support encoder feedback. All models have the same Safe Torque Off (STO) feature. Note that as a convenience to customers Copley offers a certain level of customization to tailor Xenus Plus Compact drives for a given application. This level of customization is most often limited to factory configuration of user programmable parameters, but can include signal level hardware differences to accommodate less common motor feedback devices. Drives with this customization carry the “Xenus Plus XEC” and “Xenus Plus
XPC” marking, but are assigned customer specific model numbers that begin with “800-“ followed by four or five alphanumeric characters. These “800” number models have the same STO feature as the standard Xenus Plus
Compact models and are included within the scope of this manual. The Xenus Plus Compact models are:
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