Rockwell Automation 2094-EN02D-M01-S1 User Manual

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Safety Reference Manual

Kinetix 6200 and Kinetix 6500 Safe Speed Monitoring Multi-axis Servo Drives

Catalog Numbers 2094-SE02F-M00-S1, 2094-EN02D-M01-S1

Original Instructions

Important User Information

IMPORTANT

Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/ important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

available from

) describes some

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.

Identifies information that is critical for successful application and understanding of the product.

Allen-Bradley, Guardmaster, Kinetix, Logix5000, MP-Series, PowerFlex, RSLogix, Rockwell Software, Rockwell Automation, Studio 5000, and TechConnect are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

This manual contains new and updated information.

Summary of Changes

New and Updated Information

This table contains the changes made to this revision.

Top ic Pa ge

Studio 5000™ Logix Designer application is the rebranding of RSLogix™ 5000 software. References to RSLogix 5000 software have been replaced by the Logix Designer application.

Updated descriptive text in Safety Certification and Important Safety Considerations for consistency with the text used in other Kinetix® servo drive safety documentation.

Added European Union Directives

Corrected the IOD-0 pin description and signal name. 27

Added IMPORTANT text and Response Time Settings table 47

Added descriptive text and example formulas to enhance the understanding of Safe Stop 1 and 2. 56…59

Deceleration Rate removed from Safe Stop Parameter tables throughout this publication. –

Corrected wiring to IOD-27 and IOD-28 in Figure 28

Added IMPORTANT text to Editing the Configuration

Added IMPORTANT text to Example Application.121

Replaced the Safe Stop tab screen capture. 129

Added bullet statement to FEEDBACK 1 in the Safe State Faults

to chapter 1. 16

.90

.118

table. 135

13 and 14

Rockwell Automation Publication 2094-RM001C-EN-P - May 2013 3

Summary of Changes

Notes:

4 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

Preface

About This Publication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Studio 5000 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Chapter 1

Safety Concept

About the Kinetix 6200 and Kinetix 6500 Safe Speed Monitoring Features

Safety Certification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Important Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Safety Category 4 Performance Definition. . . . . . . . . . . . . . . . . . . . . . 14

Stop Category Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Performance Level and Safety Integrity Level (SIL) CL3 . . . . . . . . . 15

European Union Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

EMC Directive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Functional Proof Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

PFD and PFH Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

PFD and PFH Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Safe State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Safety Reaction Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Considerations for Safety Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Considerations for Single-encoder Applications. . . . . . . . . . . . . . . . . 18

Understanding Commutation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Chapter 2

Safety Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Operation Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Disabled Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Lock Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Safe Maximum Speed, Safe Maximum Acceleration, and

Safe Direction Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Hardware Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Installation and Wiring

Chapter 3

General Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Power Supply Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Wiring the Safety Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Terminal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Compatible Encoders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Rockwell Automation Publication 2094-RM001C-EN-P - May 2013 5

Table of Contents

Chapter 4

Speed Monitoring I/O Signals

General Device and Feedback Monitoring Configuration

Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Safe Stop Input (SS_In) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Safe Limited Speed Input (SLS_In) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Door Monitor Input (DM_In) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Enabling Switch Monitor Input (ESM_In) . . . . . . . . . . . . . . . . . . . . . 33

Lock Monitor Input (LM_In) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Reset Input (Reset_In) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Safe Stop Output (SS_Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Safe Limited Speed Output (SLS_Out). . . . . . . . . . . . . . . . . . . . . . . . . 36

Door Control Output (DC_Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Chapter 5

Cascaded Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Operation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Reset Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Overspeed Response Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Speed Resolution Accuracy for Rotary Systems . . . . . . . . . . . . . . . . . . 43

Speed Resolution Accuracy for Linear Systems . . . . . . . . . . . . . . . . . . 45

General Parameter List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Feedback Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Feedback Polarity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Single Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Dual Encoders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Feedback Voltage Monitoring Range . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Feedback Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Feedback Parameter List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Chapter 6

Safe Stop and Safe Stop with Door Monitoring Modes

6 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

Safe Stop Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Stop Categories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Standstill Speed and Position Tolerance . . . . . . . . . . . . . . . . . . . . . . . . 61

Deceleration Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Safe Stop Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Door Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Lock Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Safe Stop Parameter List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Safe Stop Wiring Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Safe Stop with Door Monitoring Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Lock Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

SS Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Safe Stop with Door Monitoring Parameter List . . . . . . . . . . . . . . . . . . . . 69

Safe Stop with Door Monitoring Wiring Example. . . . . . . . . . . . . . . . . . . 69

Chapter 7

Table of Contents

Safe Limited Speed (SLS) Modes

Safe Limited Speed (SLS) Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Safe Limited Speed Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Safe Limited Speed Parameter List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Safe Limited Speed Wiring Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Safe Limited Speed with Door Monitoring Mode . . . . . . . . . . . . . . . . . . . 75

Safe Limited Speed Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

SLS with Door Monitoring Parameter List . . . . . . . . . . . . . . . . . . . . . . . . . 77

SLS with Door Monitoring Wiring Example . . . . . . . . . . . . . . . . . . . . . . . 77

Safe Limited Speed with Enabling Switch Monitoring Mode. . . . . . . . . 78

Safe Stop Reset (SS Reset) and Safe Limited Speed Reset

(SLS Reset) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

SLS with Enabling Switch Monitoring Parameter List. . . . . . . . . . . . . . . 79

SLS with Enabling Switch Monitoring Wiring Example . . . . . . . . . . . . . 79

Safe Limited Speed with Door Monitoring and Enabling Switch

Monitoring Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Behavior During SLS Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Behavior While SLS Monitoring is Inactive. . . . . . . . . . . . . . . . . . . . . 81

Behavior During SLS Monitoring Delay. . . . . . . . . . . . . . . . . . . . . . . . 81

Safe Stop Reset (SS Reset) and Safe Limited Speed Reset

(SLS Reset) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

SLS with Door Monitoring and Enabling Switch Monitoring

Parameter List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

SLS with Door Monitoring and Enabling Switch Monitoring

Wiring Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Safe Limited Speed Status Only Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Speed Hysteresis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

SLS Status Only Parameter List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

SLS Status Only Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Slave Modes for Multi-axis Cascaded Systems

Chapter 8

Cascaded Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Slave, Safe Stop Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Slave, Safe Stop Parameter List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Slave, Safe Stop Wiring Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Slave, Safe Limited Speed Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Slave, Safe Limited Speed Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Slave, Safe Limited Speed Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . 97

Slave, Safe Limited Speed Status Only Mode . . . . . . . . . . . . . . . . . . . . . . . 99

Slave, Safe Limited Speed Status Only Parameter List . . . . . . . . . . . . . . . 99

Slave, Safe Limited Speed Status Only Wiring Examples . . . . . . . . . . . . 100

Multi-axis Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Rockwell Automation Publication 2094-RM001C-EN-P - May 2013 7

Table of Contents

Chapter 9 Safe Maximum Speed and Direction Monitoring

Safety Configuration and Verification

Safe Maximum Speed (SMS) Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . 103

Safe Maximum Acceleration (SMA) Monitoring . . . . . . . . . . . . . . . . . . . 106

Safe Direction Monitoring (SDM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Max Speed, Max Accel, and Direction Monitoring Parameter List . . . 110

Chapter 10

Safety Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Configuration Signature ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Safety-lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Set and Change a Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Resetting the Password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Resetting the Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Basics of Application Development and Testing . . . . . . . . . . . . . . . . . . . 114

Commissioning the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Specifying the Safety Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Configure the Safe Speed Monitoring Drive . . . . . . . . . . . . . . . . . . . 116

Project Verification Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Confirm the Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Safety Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Verifying the Signature and Lock in the Safe Speed Monitor

Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Editing the Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Safety Configuration Example

Troubleshooting the Safe Speed Monitoring Drive

Chapter 11

Example Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Use the Initial Safety Main Tab Commands . . . . . . . . . . . . . . . . . . . 123

Configure the Safety Tab Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Feedback Tab Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Configure the Input Tab Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Configure the Safe Stop Tab Parameters. . . . . . . . . . . . . . . . . . . . . . . 129

Configure Safe Limited Speed Tab Parameters . . . . . . . . . . . . . . . . . 130

Configure Safe Max Speed Tab Parameters . . . . . . . . . . . . . . . . . . . . 131

Chapter 12

Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Nonrecoverable Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Fault Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Input and Output Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Fault Codes and Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Fault Reactions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Safe State Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Stop Category Faults and Fault While Stopping Faults. . . . . . . . . . 137

Status Attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Guard Status Attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

8 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

Specifications

Parameter Data

Table of Contents

I/O Diagnostic Status Attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Configuration Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Configuration Fault Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Appendix A

General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

Encoder Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

Appendix B

Parameter Groups. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Parameters and Settings in a Linear List . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Safety Attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Index

Rockwell Automation Publication 2094-RM001C-EN-P - May 2013 9

Table of Contents

Notes:

10 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

Preface

About This Publication

Audience

Conventions

This manual explains how the Kinetix 6200 and Kinetix 6500 drives can be used in Safety Integrity Level (SIL) CL3, Performance Level [PLe], or Category (CAT) 4 applications. It describes the safety requirements, including PFD and PFH values and application verification information, and provides information on configuring and troubleshooting the Kinetix 6200 and Kinetix 6500 drives with safe speed monitoring.

Use this manual if you are responsible for designing, configuring, or troubleshooting safety applications that use the Kinetix 6200 and Kinetix 6500 drives with safe speed monitoring.

You must have a basic understanding of electrical circuitry and familiarity with Kinetix 6200 and Kinetix 6500 drives. You must also be trained and experienced in the creation, operation, and maintenance of safety systems.

In this manual, configuration parameters are in brackets. For example, [Overspeed Response Time].

Terminology

Abbreviation Full Term Definition

1oo2 One out of Two Refers to the behavioral design of a dual-channel safety system. CAT Category –

EN European Norm

ESPE Electro-sensitive Protective Equipment

IEC International Electrotechnical Commission

IGBT Insulated Gate Bi-polar Transistors Typical power switch used to control main current.

ISO International Organization for Standardization

OSSD Output Signal Switching Device

PFD Probability of Failure on Demand The average probability of a system to fail to perform its design function on demand. PFH Probability of Failure per Hour The probability of a system to have a dangerous failure occur per hour. PL Performance Level EN ISO 13849-1 safety rating S1 2094-SE02F-M00-S1 and 2094-EN02D-M01-S1 Catalog numbers for Kinetix 6200 and Kinetix 6500 drives with Safe Speed Monitoring functionality. SFF Safe Failure Fraction The sum of safe failures plus the sum of dangerous detected failures divided by the sum of all failures. SIL Safety Integrity Level A measure of a products ability to lower the risk that a dangerous failure could occur.

This table defines common safety terms used in this manual.

European Standards (EN specifications) developed by the European Committee for Standardization for the European Union.

An assembly of devices and/or components working together for protective tripping or presencesensing purposes and compri sing as a minimum:

• Sensing devices

• Controlling/monitoring devices

• Output signal-switching devices (OSSD)

Non-profit, non-governmental international standards organization that prepares and publishes international standards for all electrical, electronic, and related technologies, collectively known as electrotechnology.

Voluntary organization whose members are recognized authorities on standards, each one representing a different country.

The component of the electro-sensitive protective equipment (ESPE) connected to the control system of a machine responds by going to the OFF-state when the sensing device is actuated during normal operation.

Rockwell Automation Publication 2094-RM001C-EN-P - May 2013 11

Preface

Studio 5000 Environment

The Studio 5000 Engineering and Design Environment combines engineering and design elements into a common environment. The first element in the Studio 5000 environment is the Logix Designer application. The Logix Designer application is the rebranding of RSLogix 5000 software and will continue to be the product to program Logix5000™ controllers for discrete, process, batch, motion, safety, and drive-based solutions.

The Studio 5000 environment is the foundation for the future of Rockwell Automation® engineering design tools and capabilities. It is the one place for design engineers to develop all the elements of their control system.

Additional Resources

These documents contain additional information concerning related Rockwell Automation products.

Resource Description

Kinetix 6200 and Kinetix 6500 Modular Multi-axis Servo Drive User Manual, publication 2094-UM002

Kinetix Safe-off Feature Safety Reference Manual, publication GMC-RM002

System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001

EMC Noise Management DVD, publication GMC-SP004

Kinetix Motion Control Selection Guide, publication GMC-SG001

Safety Guidelines for the Ap plication, Installation and Maintenance of Solid State Control, publication

SGI-1.1

Provides information on installing, configuring, starting up, troubleshooting, and applications for your Kinetix 6200 or Kinetix 6500 servo drive system.

Provides information on wiring and troubleshooting your Kinetix 5500 servo drives with the safe-off feature.

Provides information, examples, and techniques designed to minimize system failures caused by electrical noise.

Overview of Kinetix ser vo drives, motors, actuators, and motion accessories designed to help make initial decisions for the motion control products best suited for your system requirements.

Describes important differences between solid state control and hardwired electromechanical devices.

You can view or download publications at

http://www.rockwellautomation.com/literature

documentation, contact your local Rockwell Automation distributor or sales representative.

12 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

. To order paper copies of technical

Chapter 1

Safety Concept

This chapter describes the safety performance level concept and how the Kinetix 6200 and Kinetix 6500 drives can meet the requirements of Performance Level e (PLe) and safety category 4 (CAT 4) per EN ISO 13849-1 and SIL CL3 per IEC EN 61508, EN 61800-5-2, and EN 62061.

Top ic Pag e

Safety Certification 13

Funct ional Proof Tests 16

PFD and PFH Definitions 17

Safe State 17

Safety Reaction Time 18

Considerations for Safety Ratings 18

Safety Certification

The TÜV Rheinland group has approved the Kinetix 6200 and Kinetix 6500 servo drives for use in safety-related applications up to ISO 13849-1 Performance Level e (PLe) and category 4, SIL CL3 per IEC EN 61508, EN 61800-5-2 and EN 62061 where removing the motion producing power is considered to be the safe state. All of the examples related to I/O included in this manual are based on achieving de-energization as the safe state for typical Machine Safety and Emergency Shutdown (ESD) systems.

Rockwell Automation Publication 2094-RM001C-EN-P - May 2013 13

Chapter 1 Safety Concept

IMPORTANT

Important Safety Considerations

The system user is responsible for the following:

• Validation of any sensors or actuators connected to the system

• Completing a system-level risk assessment

• Certification of the machine to the desired EN ISO 13849-1 performance

level or EN 62061 SIL level

• Project management and proof testing

• Programming the application software and the drive configurations in

accordance with the information in this manual

• Access control to the system, including password handling

• Analyzing all configuration settings and choosing the proper setting to

achieve the required safety rating

When applying functional safety, restrict access to qualified, authorized personnel who are trained and experienced.

ATTENTION: When designing your system, consider how personnel exit the machine if the door locks while they are in the machine. Additional safeguarding devices can be required for your specific application.

Safety Category 4 Performance Definition

To achieve Safety Category 4 according to EN ISO 13849-1:2006, the safetyrelated parts have to be designed such that:

• the safety-related parts of machine control systems and/or their protective equipment, as well as their components, shall be designed, constructed, selected, assembled, and combined in accordance with relevant standards so that they can withstand expected conditions.

• basic safety principles shall be applied.

• a single fault in any of its parts does not lead to a loss of safety function.

• a single fault is detected at or before the next demand of the safety

function, or, if this detection is not possible, then an accumulation of faults shall not lead to a loss of the safety function.

• the average diagnostic coverage of the safety-related parts of the control system shall be high, including the accumulation of faults.

• the mean time to dangerous failure of each of the redundant channels shall be high.

• measures against common cause failure shall be applied.

14 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

Safety Concept Chapter 1

IMPORTANT

TIP

Stop Category Definitions

The selection of a stop category for each stop function must be determined by a risk assessment.

• Stop Category 0 is achieved with immediate removal of power to the actuator, resulting in an uncontrolled coast to stop. Safe Torque Off accomplishes a Stop Category 0 stop.

• Stop Category 1 is achieved with power available to the machine actuators to achieve the stop. Power is removed from the actuators when the stop is achieved.

• Stop Category 2 is a controlled stop with power available to the machine actuators. The stop is followed by a holding position under power.

Refer to Safe Stop Mode

on page 55 for more information.

When designing the machine application, timing and distance must be considered for a coast to stop (Stop Category 0 or Safe Torque Off). For more information regarding stop categories, refer to EN 60204-1.

You can determine the drive/motor Stop Delay characteristics by using Motion Analyzer software, version 4.7 or later.

Performance Level and Safety Integrity Level (SIL) CL3

For safety-related control systems, Performance Level (PL), according to EN ISO 13849-1, and SIL levels, according to EN 61508 and EN 62061, include a rating of the system’s ability to perform its safety functions. All of the safety-related components of the control system must be included in both a risk assessment and the determination of the achieved levels.

Refer to the EN ISO 13849-1, EN 61508, and EN 62061 standards for complete information on requirements for PL and SIL determination.

Refer to Chapter and verification of a safety-related system containing the Kinetix 6200 and Kinetix 6500 drives.

10 for more information on the requirements for configuration

Rockwell Automation Publication 2094-RM001C-EN-P - May 2013 15

Chapter 1 Safety Concept

IMPORTANT

European Union Directives

If this product is installed within the European Union or EEC regions and has the CE mark, the following regulations apply.

CE Conformity

Conformity with the Low Voltage Directive and Electromagnetic Compatibility (EMC) Directive is demonstrated by using harmonized European Norm (EN) standards published in the Official Journal of the European Communities. The safe torque-off circuit complies with the EN standards when installed according instructions found in this manual.

EMC Directive

This unit is tested to meet Council Directive 2004/108/EC Electromagnetic Compatibility (EMC) by using these standards, in whole or in part:

• EN 61800-3 - Adjustable Speed Electrical Power Drive Systems, Part 3 - EMC Product Standard including specific test methods

• EN 61326-2-1 EMC - Immunity requirements for safety-related systems

The product described in this manual is intended for use in an industrial environment.

Functional Proof Tests

CE Declarations of Conformity are available online at go to http://www.rockwellautomation.com/rockwellautomation/certification/

overview.page and in EC Declaration of Conformity on page 178.

Low Voltage Directive

These units are tested to meet Council Directive 2006/95/EC Low Voltage Directive. The EN 60204-1 Safety of Machinery-Electrical Equipment of Machines, Part 1-Specification for General Requirements standard applies in whole or in part. Additionally, the standard EN 50178 Electronic Equipment for use in Power Installations apply in whole or in part.

Refer to the Kinetix Servo Drives Specifications Technical Data, publication

GMC-TD003

The functional safety standards require that functional proof tests be performed on the equipment used in the system. Proof tests are performed at user-defined intervals and are dependent upon PFD and PFH values.

, for environmental and mechanical specifications.

Your specific application determines the time frame for the proof test interval.

16 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

Safety Concept Chapter 1

PFD and PFH Definitions

PFD and PFH Data

Safety-related systems can be classified as operating in either a Low Demand mode, or in a High Demand/Continuous mode.

• Low Demand mode: where the frequency of demands for operation made on a safety-related system is no greater than one per year or no greater than twice the proof-test frequency.

• High Demand/Continuous mode: where the frequency of demands for operation made on a safety-related system is greater than once per year or greater than twice the proof test interval.

The SIL value for a low demand safety-related system is directly related to orderof-magnitude ranges of its average probability of failure to satisfactorily perform its safety function on demand or, simply, average probability of failure on demand (PFD). The SIL value for a High Demand/Continuous mode safety-related system is directly related to the probability of a dangerous failure occurring per hour (PFH).

These PFD and PFH calculations are based on the equations from IEC 61508 and show worst-case values.

This table provides test data for a 20-year proof test interval and demonstrates the worst-case effect of various configuration changes on the data.

Safe State

Table 1 - PFD and PFH for 20-year Proof Test Interval

Attribute Single Encoder Dual Encoder

PFH [1e-9] 5.88 2.37

PFD [1e-4] 10.3 4.15

SFF % 99.4% 99.5%

The Safe State encompasses all operation that occurs outside of the other monitoring and stopping behavior defined as part of the drive. In addition, configuration takes place in the Safe State. While the drive is in the Safe State, all safety control outputs, except the Door Control (DC_Out) output, are in their safe state (de-energized). The Door Control (DC_Out) output is in either the locked state or in the de-energized state depending upon the condition that resulted in the safe state.

When you cycle power, the drive enters the Safe State for self-testing. If the selftests pass and there is a valid configuration, the drive remains in the Safe State until a successful request for safe speed monitoring occurs.

If a Safe State fault is detected, the drive goes to the Safe State. This includes faults related to integrity of hardware or firmware.

For more information on faults, refer to Chapter

Rockwell Automation Publication 2094-RM001C-EN-P - May 2013 17

12.

Chapter 1 Safety Concept

IMPORTANT

Safety Reaction Time

Considerations for Safety Ratings

The safety reaction time is the amount of time from a safety-related event as input to the system until the system is in the Safe State.

The safety reaction time from an input signal condition that triggers a safe stop, to the initiation of the configured Stop Type, is 20 ms (maximum).

The safety reaction time from an overspeed event that triggers a safe stop, to the actual initiation of the configured Stop Type, is equal to the value of the [Overspeed Response Time] parameter.

For more information on overspeed response time, see Overspeed Response

Time on page 43.

The achievable safety rating of an application that uses safe speed monitoring is dependent upon many factors, including the encoder setup, drive options, and the type of motor.

When using two independent encoders to monitor motion and when installed in a manner to avoid any common cause dangerous failure, the Kinetix 6200 and Kinetix 6500 drives can be used in applications up to and including SIL CL3, PLe, and CAT 4.

For applications that rely on commutation to generate torque and motion, a safety rating up to and including SIL CL3, PLe, and CAT 4 can be achieved.

Some of the diagnostics performed on the encoder signals require motion to detect faults. You must make sure that motion occurs at least once every six months.

Considerations for Single-encoder Applications

When configured correctly, the Kinetix 6200 and Kinetix 6500 drive performs these diagnostics on the encoder:

• Sin

• Detection of open or short-circuit

• Encoder supply voltage monitoring

• Detection of illegal quadrature transitions of the sine and cosine signals

+ Cos2 diagnostic

18 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

Safety Concept Chapter 1

A safety rating up to and including SIL CL3, PLe, and CAT 4 can be achieved in a single-encoder application with these requirements:

• The motor is a permanent magnet (PM) brushless AC motor.

• The motor controller must be configured as a closed-loop application with

field-oriented control by using the single-encoder for commutation.

• The motor-to-encoder coupling is designed to exclude shaft slippage as a dangerous failure mechanism.

• The encoder is of the Sin/Cos type and is suitable for the desired safety rating of the application.

An encoder that is suitable for SIL CL3 applications must follow one of these two conventions:

– Use independent Sine/Cosine signals and be incapable of producing

simulated signals when under an error condition.

– Use simple or discreet circuitry with no complex or programmable

internal devices.

• Encoder voltage monitoring in Kinetix 6200 and Kinetix 6500 drives can be enabled, depending on the feedback configuration.

• The system design of the motor/encoder-to-load coupling excludes shaft slippage and breakage as a dangerous failure mechanism.

Understanding Commutation

Permanent magnet (PM), brushless AC motors are a class of synchronous motor that depends on electronic brushless commutation for their operation. In PM brushless motors, an electromagnetic field is created by the permanent magnets on the rotor. A rotating magnetic field is created by a number of electromagnets commutated electronically with IGBT’s at the right speed, order, and times. Movement of the electromagnetic field is achieved by switching the currents in the coils of the stator winding. This process is called commutation. Interaction of the two electromagnetic fields produces magnetic force or torque.

Rockwell Automation Publication 2094-RM001C-EN-P - May 2013 19

Chapter 1 Safety Concept

Notes:

20 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

Chapter 2

About the Kinetix 6200 and Kinetix 6500 Safe Speed Monitoring Features

This chapter describes the safe speed monitoring features of the Kinetix 6200 and Kinetix 6500 drives.

Top ic Pag e

Safety Functions 21

Hardware Features 24

Safety Functions

The Kinetix 6200 and Kinetix 6500 safe speed-monitoring servo drives feature five inputs, two sets of safety outputs, and one bipolar safety output. Each of the inputs and outputs support a specific safety function.

• Safe Stop (SS)

• Safe Limited Speed Monitoring (SLS)

• Door Monitoring (DM)

• Enabling Switch Monitoring (ESM)

• Lock Monitoring (LM)

• Door Control (DC)

An additional reset input provides for reset and monitoring of the safety circuit.

The drive can be used in single-axis or multi-axis applications, and can be configured as a master or slave based on its location in the system.

Rockwell Automation Publication 2094-RM001C-EN-P - May 2013 21

Chapter 2 About the Kinetix 6200 and Kinetix 6500 Safe Speed Monitoring Features

IMPORTANT

Operation Modes

You can configure the drive to operate in one of 11 user-selectable operation modes, based on combinations of the safety functions listed on the previous page.

Operation Mode Page

Disabled – In this mode, all safety functions are disabled. 22

Safe Stop – The drive activates the configured Stop Category upon deactivation of the S afe Stop input or the occurrence of a Stop Category fault.

Safe Stop with Door Monitoring – In addition to monitoring for Safe Stop, the drive monitors the status of the door.

Safe Limited Speed – In addition to monitoring for Safe Stop, the drive monitors the feedback velocity and compares it to a configurable Safe Speed Limit. If the velocity exceeds the limit, the drive initiates the configured Stop Category.

Safe Limited Speed with Door Monitoring – In addition to monitoring for Safe Stop and Safe Limited Speed, the drive monitors the status of the door.

Safe Limited Speed with Enabling Switch Control – In addition to monitoring for Safe Stop and Safe Limited Speed, the drive monitors the status of the Enabling Switch input.

Safe Limited Speed with Door Monitor and Enabling Switch – In addition to monitoring for Safe Stop and Safe Limited Speed, the drive monitors the status of the door and the Enabling Switch input.

Safe Limited Speed (status only) – In addition to monitoring for Safe Stop, the drive monitors the feedback velocity and compares it to a configurable Safe Speed Limit. If the velocity exceeds the limit, the system status is made available as a safe output intended for a safet y programmable logic controller. No stopping action takes place.

Slave, Safe Stop – The drive performs the same functions as Safe Stop. However, it regards the Door Monitor input as a Door Control output from an upstream axis, and performs a logical AND with its internal Door Control signal to form the cascaded Door Control output.

Slave, Safe Limited Speed – The drive performs the same functions as Safe Limited Speed mode. However, it regards the Door Monitor input as a Door Control output from an upstream axis, and performs a logical AND with its internal Door Control signal to form the cascaded Door Control output.

Slave, Safe Limited Speed (status only) – The drive performs the same functions as Safe Limited Speed Status Only mode. However, it regards the Door Monitor input as a Door Control output from an upstream axis, and performs a logical AND with its internal Door Control signal to form the cascaded Door Control output.

Disabled Mode

In Disabled mode, all safety functions are disabled. Input, output, or speed monitoring diagnostics do not take place and all outputs are in their safe state. Motion power is enabled for drive commissioning in this mode.

The drive monitors motion for Safe Stop in every mode except Disabled.

22 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

About the Kinetix 6200 and Kinetix 6500 Safe Speed Monitoring Features Chapter 2

Lock Monitoring

Lock monitoring helps prevent access to the hazard during motion. In many applications, it is not sufficient for the machine to initiate a stop command once the door has been opened, because a high inertia machine can take a long time to stop. Preventing access to the hazard until a safe speed has been detected can be the safest condition. The lock monitoring feature is used to verify the operation of the door locking mechanism.

Lock monitoring can be enabled on single units or on the first unit in a multi-axis system. If the Lock Monitor input (LM_In) indicates that the door is unlocked when the Door Control output (DC_Out) is in the locked state, or if the Lock Monitor input indicates locked when the Door Monitor input (DM_In) transitions from closed to open, the configured Stop Category is initiated.

Safe Maximum Speed, Safe Maximum Acceleration, and Safe Direction Monitoring

Three additional safety functions, Safe Maximum Speed (SMS), Safe Maximum Acceleration (SMA) and Safe Direction Monitoring (SDM), operate independent of the other modes, relying on the Safe Stop function. When you configure the drive for Safe Maximum Speed, the feedback velocity is monitored and compared against a user-configurable limit. If the measured velocity is greater than or equal to the limit, the configured Stop Category is executed.

When Safe Acceleration Monitoring is enabled, the option monitors the acceleration rate and compares it to a configured Safe Maximum Acceleration Limit. If acceleration is detected as greater than or equal to the Safe Maximum Acceleration Limit, an Acceleration fault occurs. If an Acceleration fault is detected while the option is actively monitoring motion, the configured Stop Category is initiated.

Safe Direction Monitoring is also activated via option configuration. The option monitors the feedback direction and executes the configured Stop Category when motion in the illegal direction is detected.

Refer to Chapter

9 for detailed information on these functions.

Rockwell Automation Publication 2094-RM001C-EN-P - May 2013 23

Chapter 2 About the Kinetix 6200 and Kinetix 6500 Safe Speed Monitoring Features

IMPORTANT

Kinetix 6200 and Kinetix 6500

IAM/AM Power Module

(IAM power module is shown)

Kinetix 6200 and Kinetix 6500 Control Module (2094-SE02F-M00-S1 is shown)

2090-K6CK-D44M

Low-profile Connector Kit

Auxiliary Feedback, I/O, and Safety Terminal Blocks

Hardware Features

The drive features five dual-channel inputs, two sets of sourcing safety outputs, and one bipolar safety output. You can configure dual-channel inputs to accept a following-contact configuration with two normally closed contacts, or one normally closed and one normally open contact. They can also be configured for single channel operation.

Single-channel operation does not meet SIL CL3, PLe, Cat 4 safety integrity.

These inputs also support output signal switching devices (OSSD). Each output has integral pulse-test checking circuitry.

The 2090-K6CK-D44M (44-pin) low-profile connector kit is designed specifically for use with the Kinetix 6200 and Kinetix 6500 modular drives. Safety connections are made by using this connector kit.

Figure 1 - 44-pin Low-profile Connector Kit

INPUTS

AUX FEEDBACK

0 11 10 9 8 7 6 5 4 3 2 1

0 39 41 40 39 42 40 39 43 40 39 44 40

0 38 37 36 35 34 33 32 31 30 29 28 27 28 27 28 27 28 27

Refer to Wiring the Safety Connections on page 26 for the connector pinouts.

24 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

28 27 26 25 24 23 22 21 20 19 18 17 15 14 0

S0&S1 W/S0 DISABLED

S1 ONLY

Chapter 3

Installation and Wiring

This chapter provides details on connecting devices and wiring the 2090-K6CKD44M Low-profile connector kit.

Top ic Pag e

General Safety Information 25

Power Supply Require ments 26

Wiring the Safety Connections 26

Terminal Connections 27

Compatible Encoders 28

General Safety Information

ATTENTION: The drive is intended to be part of the safety-related control

system of a machine. Before installation, a risk assessment must be performed to determine whether the specifications of this safety option are suitable for all foreseeable operational and environmental characteristics for the system being installed.

Observe all electrical safety regulations stipulated by the appropriate technical authorities.

ATTENTION: Make sure that the electrical power supplied to the drive is switched off before making connections.

Refer to the Kinetix 6200 and Kinetix 6500 Modular Multi-axis Servo Drive User Manual, publication 2094-UM002

, for more information.

Rockwell Automation Publication 2094-RM001C-EN-P - May 2013 25

Chapter 3 Installation and Wiring

28 27 26 25 24 23 22 21 20 19 18 17 15 14 0

AUX FEEDBACK

0 11 10 9 8 7 6 5 4 3 2 1

0 39 41 40 39 42 40 39 43 40 39 44 40

INPUTS

0 38 37 36 35 34 33 32 31 30 29 28 27 28 27 28 27 28 27

S1 ONLY

S0&S1 W/S0 DISABLED

28 27 26 25 24 23 22 21 20 19 18 17 15 14 0

AUX FEEDBACK

0 11 10 9 8 7 6 5 4 3 2 1

0 39 41 40 39 42 40 39 43 40 39 44 40

INPUTS

0 38 37 36 35 34 33 32 31 30 29

28 27 28 27 28 27 28 27

S1 ONLY

S0&S1 W/S0 DISABLED

Clamp

2090-K6CK-D44M Low-profile Connector Kit

Use tie wraps (4x)

for stress relief.

Turn clamps over for smaller

diameter cables.

Aux Feedback and I/O

Wires and Cables

Safety Wires

and Cables

Use shield clamps (3x) for

high-frequency bonding.

Kit pin numbering corresponds to the IOD

connector. Pins 27, 28, 39, and 40 are

given multiple terminals to

accommodate additional connections.

Power Supply Requirements

Wiring the Safety Connections

The external power supply must conform to the Directive 2006/95/EC Low Voltage, by applying the requirements of EN61131-2 Programmable Controllers, Part 2 - Equipment Requirements and Tests and one of the following:

• EN60950 - SELV (Safety Extra Low Voltage)

• EN60204 - PELV (Protective Extra Low Voltage)

• IEC 60536 Safety Class III (SELV or PELV)

• UL 508 Limited Voltage Circuit

• 21.6…28.8V DC must be supplied by a power supply that complies with

IEC/EN60204 and IEC/EN 61558-1.

For planning information, refer to the guidelines in Industrial Automation Wiring and Grounding Guidelines, Allen-Bradley publication 1770-4.1

Safety connections are made by using the 2090-K6CK-D44M low-profile connector kit.

Figure 2 - Making Safety Connections

Refer to the Kinetix 6200 and Kinetix 6500 Modular Multi-axis Servo Drive User Manual, publication 2094-UM002 signal descriptions and wiring examples when using the 2090-K6CK-D44M connector kit.

26 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

, for safety, auxiliary feedback, and I/O

Installation and Wiring Chapter 3

Terminal Connections

Prepare wires for termination on the IOD connector with a 5 mm (0.2 in.) strip length. Tighten all terminal screws firmly and recheck them after all connections have been made. Recommended terminal screw torque is 0.4 N•m (3.5 lb•in).

Refer to page 143

Table 2 - IOD Connector Pinouts

(1)

IOD Pin

0 Chassis Ground Shield

7 Clock Output + AUX_CLK+ 29 (68) Safe Limited Speed Output 0 SLS_OUT_CH0

8 Clock Output - AUX_CLK- 30 (78) Safe Limited Speed Output 1 SLS_OUT_CH1

9 Encoder 5V Power Output EPWR_5V 31 (S32) Door Monitor Input 0 DM_IN_CH0

10 Encoder Common ECOM 32 (S42) Door Monitor Input 1 DM_IN_CH1

11 Encoder 9V Power Output EPWR_9V 33 (X32) Lock Monitor Input 0 LM_IN_CH0

12 Reserved – 34 (X42) Lock Monitor Input 1 LM_IN_CH1

13 Reserved – 35 (51) Door Control Channel Output- DC_OUT_CH0

14 24V Power Out 24VPWR

15 24V Common 24VCOM 37 (S72) Enabling Sw. Mon. Input 0 ESM_IN_CH0

16 Reserved – 38 (S82) Enabling Sw. Mon. Input 1 ESM_IN_CH1

17 (A1) Safety 24V Power Input SPWR 39 24V Power Out 24VPWR

18 (A2) Safety 24V Common SCOM 40 24V Common 24VCOM

19 (S12) Safe Stop Input 0 SS_IN_CH0 41 Digital Input 1 INPUT1

20 (S22) Safe Stop Input 1 SS_IN_CH1 42 Digital Input 2 INPUT2

21 (34) Safe Stop Output 0 SS_OUT_CH0 43 Digital Input 3 INPUT3

22 (44) Safe Stop Output 1 SS_OUT_CH1 44 Digital Input 4 INPUT4

Description Signal IOD Pin

Sine Differential Input + A Differential Input +

Sine Differential Input A Differential Input -

Cosine Differential Input + B Differential Input +

Cosine Differential Input B Differential Input -

Data Differential Input + Index Differential Input +

Data Differential Input Index Differential Input -

AUX_S IN+ AUX_A +

AUX_S INAUX_A -

AUX_CO S+ AUX_B +

AUX_CO SAUX_B -

AUX_DATA+ AUX_I +

AUX_DATAAUX_I -

(2)

for the I/O signal electrical specifications.

(1)

Description Signal

23 (S52) Safe Limited Speed Input 0 SLS_IN_CH0

24 (S62) Safe Limited Speed Input 1 SLS_IN_CH1

25 Reset Reference RESET_REF

26 (S34) Reset Input RESET_IN

27 (S11) Pulse Test Output 0 TEST_OUT_0

28 (S21) Pulse Test Output 1 TEST_OUT_1

36 (52) Door Control Channel Output+ DC_OUT_CH1

(3)

(1) Designators in parenthe sis refer to the Guardmaster® MSR57P safety relay and PowerFlex® 750-Series safety option terminals. (2) Signals 24VPWR and 24VCOM (IOD-14 and IOD-15) do not apply to 2094-xx02x-M0x-S1 control modules.

(3) Use signals 24VPWR and 24VCOM (IOD-39 and IOD-40) as a 24V DC source to operate the digital inputs (50 mA maximum per input).

Rockwell Automation Publication 2094-RM001C-EN-P - May 2013 27

Chapter 3 Installation and Wiring

Compatible Encoders

Cat. No. and Description Additional Resources

Sin/Cos Encoders

Incremental Encoders

Rotary Motors

(1) Maximum cable length for sin/cos encoder s is 90 m (295 ft). (2) Maximum cable length for incremental encoders is 30.5 m (100 ft) when using 5V.

(1)

842HR-xJxxx15FWYx

845T-xx12xxx-x and 845T-xx13xxx-x 845T-xx42xxx and 845T-xx43xxx-x

(2)

845T-xx52xxx and 845T-xx53xxx-x

845H-SJxxx4xxYxx

1326AB-Bxxxx-M2L/S2L

MP-Series™ motors with embedded Sin/Cos or incremental encoders

Any motor with SRS-60 Stegmann encoder

Any motor with SRM -60 Stegmann encoder

These feedback devices are supported.

Refer to the Bulletin 842HR Sin/Cosine Encoders product profile, publication

842HR-PP001, for more information on these encoders.

Refer to the Sensors Reference Catalog, publication C116 number, dimensions, and specifications for Bulletin 845T and 845H Incremental Encoders.

Refer to the Kinetix Motion Control Select ion Guide, publication GMC-SG001 for more information on these motors.

Refer to the produ ct documentation for your s pecific motor to determine t he encoder type.

, for catalog

28 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

Chapter 4

IMPORTANT

Speed Monitoring I/O Signals

This chapter describes the safe-speed monitoring input and output signals of the Kinetix 6200 and Kinetix 6500 drives.

Top ic Pag e

Inputs 29

Outputs 35

Inputs

The Kinetix 6200 and Kinetix 6500 drives have five inputs capable of safetycertified dual-channel support. Each dual-channel input supports a specific safety function of the drive: Safe Stop, Safe Limited Speed, Door Monitoring, Enabling Switch Monitoring, and Lock Monitoring.

All five inputs are electrically identical and rely on the same pair of pulse test outputs, Test_Out_0 and Test_Out_1, when not using the OSSD configuration.

The inputs can be configured for one of the following settings:

• Not used

• Dual-channel equivalent

• Dual-channel equivalent 3 s

• Dual-channel complementary

• Dual-channel complementary 3 s

• Dual-channel SS equivalent 3 s

• Single channel

Single-channel configuration is not SIL CL3, PLe, Cat 4.

When configured for dual-channel operation, the consistency between the two channels is evaluated. For dual-channel equivalent configurations, the active state for both channel 0 and channel 1 is ON. For dual-channel complementary configurations, the active state for channel 0 is ON and the active state for channel 1 is OFF. Any time both channels are not active, the input pair is evaluated as OFF.

Rockwell Automation Publication 2094-RM001C-EN-P - May 2013 29

Chapter 4 Speed Monitoring I/O Signals

Channel 0

Active

Inactive

Channel 1

Active

Inactive

Evaluated Status

OFF

Cycle Inputs Required

When both channels are active, if one channel’s input terminal transitions from active to inactive and back to active, while the other channel’s input terminal remains active, both channels must go inactive at the same time before the evaluated status can return to ON. This condition is called ‘cycle inputs required’.

Figure 3 - Cycle Inputs Required

If inputs are configured with the following dual channel settings, an Input fault occurs if the inputs are discrepant for longer than 3 seconds or if a ‘cycle inputs required’ condition exists lor longer than 3 seconds.

• Dual-channel equivalent 3 s

• Dual-channel complementary 3 s

• Dual-channel SS equivalent 3 s

If inputs are configured with one of the following dual channel settings, which have no limit on the length of time that inputs can be discrepant, an Input fault does not occur for any discrepant condition or for any ‘cycle inputs required’ condition.

• Dual-channel equivalent

• Dual-channel complementary

For all input settings except Dual-channel SS equivalent 3 s, if one or two channels are connected to a 24V DC source other than terminals IOD-27 and IOD-28, a fault occurs.

I/O faults are Stop Category faults that initiate the configured Stop Category. I/O faults are latched until the drive is successfully reset.

For more information on I/O faults, refer to Troubleshooting the

Safe Speed

Monitoring Drive on page 133.

30 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

Speed Monitoring I/O Signals Chapter 4

Test_Out_0 (IOD-27) Test_Out_1 (IOD-28)

Dual-channel Equivalent Safety Device

Dual-channel Complementary Safety Device

Single Channel Safety Device

Solid State Safety Device

Drive

N/C N/C

Input 1 Input 0

GND

OSSD2

OSSD1

Drive

Input 1 Input 0

24V_COM (IOD-18) Input 1 Input 0

Test_Out_0 (IOD-27) Test_Out_1 (IOD-28)

IMPORTANT

When using a dual-channel complementary device, the normally-open input must be connected to the second input, as shown in the illustration. For example, if the door is open when the input is ON, the normally-open contact must be the second input (Input 1).

Figure 4 - Safety Input Wiring Examples

Cross wiring of Test Outputs to Inputs is not allowed. For example, do not connect TEST_OUT_0 to Input 1 or TEST_OUT_1 to Input 0.

Table 3 - IOD Connector Input Terminals

Function

Input 0 = Channel 0 IOD-19 IOD-23 IOD-31 IOD-37 IOD-33

Input 1 = Channel 1 IOD-20 IOD-24 IOD-32 IOD-38 IOD-34

Safe Stop (SS_In)

Safe Limited Speed (SLS_In)

Door Monitoring (DM_In)

Enabling Switch Monitoring (ESM_In)

Lock Monitoring (LM_In)

Short-circuits of the input loop to ground or 24V are detected. For dual-channel inputs, cross loops are also detected.

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Chapter 4 Speed Monitoring I/O Signals

Safe Stop Input (SS_In)

The SS_In input is intended for connection to an E-Stop device.

The SS_In input must be active to initiate Safe Stop monitoring. If the SS_In input is being monitored, a transition from ON to OFF (closed to open) is used to request the configured Stop Category.

In a cascaded configuration, the SS_In inputs of the middle and last drives are connected to the Safe Stop (SS_Out) output of an upstream drive.

Safe Limited Speed Input (SLS_In)

The SLS_In input is used to connect to a switch whose OFF state requests Safe Limited Speed monitoring.

If Safe Limited Speed monitoring is configured, the SLS_In input is monitored from the time of a successful Safe Stop Reset or Safe Limited Speed Reset, until the time that the configured Stop Category is initiated or the Safe State is entered.

If the SLS_In input is being monitored, the OFF state is used to request the Safe Limited Speed monitoring functionality of the drive.

In a cascaded configuration, the SLS_In inputs of the middle and last drives are connected to the Safe Limited Speed (SLS_Out) output of an upstream drive.

Door Monitor Input (DM_In)

This input monitors the status of the door to indicate if it is open or closed. The DM_In input can be connected to a non-guardlocking switch if the door does not need to be locked. The door status is monitored by the first unit in multi-axis systems.

The DM_In input is intended for connection to a guardlocking switch when the drive is configured as a master device with door monitoring. When the drive is configured as a slave in a cascaded system, its DM_In input is connected to the Door Control output (DC_Out) of the upstream drive.

Refer to Door Control Output (DC_Out)

on page 38 for more information.

32 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

Speed Monitoring I/O Signals Chapter 4

Enabling Switch Monitor Input (ESM_In)

The ESM_In input is intended to be connected to an enabling switch. The drive uses the ESM_In input only as a safety enable, not for control. The ESM_In inputs function and monitoring is performed by the first unit in multi-axis systems.

The ESM_In input ON state is used to enable motion under mode-specific conditions in the Safety Limited Speed with Enabling Switch and Safe Limited Speed with Door Monitoring and Enabling Switch Monitoring modes.

Refer to Safe Limited Speed with Door Monitoring Mode

Limited Speed with Enabling Switch Monitoring Mode on page 78 for the

conditions that must be true to start monitoring the ESM_In input.

If the ESM_In input is OFF while it is being monitored, an ESM Monitoring fault occurs and the drive initiates the configured Stop Category.

Refer to Chapter

12 for information on faults and how to recover from them.

on page 75 and Safe

Lock Monitor Input (LM_In)

The LM_In input verifies that the guardlocking solenoid switch is locked. It is intended to confirm the door control function.

The LM_In input is monitored by the first unit in multi-axis systems.

Rockwell Automation Publication 2094-RM001C-EN-P - May 2013 33

Chapter 4 Speed Monitoring I/O Signals

Manual

Monitored

Reset

RESET_IN

IOD-25

IOD-26

IOD-25

IOD-26

IMPORTANT

Reset Input (Reset_In)

The Reset input is for reset and monitoring of the safety circuit. The reset input can be configured for automatic, manual, or manual monitored reset types.

Wire the reset input terminal (IOD-26) to the 24V DC input terminal, (IOD-25), depending on the configured reset type, as shown.

Figure 5 - Reset Input Configurations

If you configure the drive for automatic reset, wiring of the reset input terminal (IOD-26) is not required.

34 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

Speed Monitoring I/O Signals Chapter 4

Drive (Master)

SS_OUT_CH0

SS_OUT_CH1

Drive (Slave)

SS_IN_CH0

SS_IN_CH1

IOD-19 and IOD-20 are configured as 2 OSSD 3s inputs.

IOD-21

IOD-19

IOD-22

IOD-20

Outputs

The drive has three safety control outputs. The outputs have various output current capabilities, depending on function.

See the specifications in Appendix

A to verify your power requirements.

Safe Stop Output (SS_Out)

The safe state for this signal is OFF.

These outputs are typically used in multi-axis applications. In multi-axis applications, you can use these outputs to daisy-chain the master drive to a slave.

For SS_Out to SS_In cascaded signals, the interface is a dual-channel sourcing solid-state safety output connected to a dual-channel safety input configured as OSSD. The outputs are pulse-tested.

Figure 6 - SS_Out to SS_In Connections for Multi-axis Applications

For more information on multi-axis configurations, see Cascaded Configurations starting on page 89

Rockwell Automation Publication 2094-RM001C-EN-P - May 2013 35

Chapter 4 Speed Monitoring I/O Signals

Alternately, the first SS_Out output can be used to signal a programmable logic controller (PLC) that a Safe Stop has been requested.

If the SS_In is ON (closed) and a successful Safe Stop Reset is performed, the SS_Out output is turned ON. If Lock Monitoring is not enabled or the door control logic state is Unlock, the SS_Out signal turns ON immediately when the SS_In turns ON. If Lock Monitoring is enabled, and the door control logic state is Lock, the SS_Out signal is not turned ON until the door has been locked by using the DC_Out signal and the LM_In input has been verified as ON.

If the Stop Category is initiated or if a Safe Stop is initiated due to a fault, the SS_Out output is turned OFF.

If an error is detected on either channel of the dual-channel output, a fault occurs. I/O faults are Stop Category faults that initiate the configured Stop Category. The fault is latched until the drive is successfully reset.

For more information on faults, refer to Chapter

12.

Safe Limited Speed Output (SLS_Out)

The safe state for this signal in all cases is OFF.

The SLS_Out output functionality is determined by the configured Operation mode. If the SLS_In is ON and a successful Safe Stop or Safe Limited Speed reset is performed, the SLS_Out turns ON in all Safe Limited Speed modes except Safe Limited Speed Status Only.

For the Safe Limited Speed modes (SLS), the SLS_Out is used to interconnect speed monitoring drives in multi-axis applications. For SLS_Out to SLS_In cascaded signals, the interface is a dual-channel sourcing solid state safety output connected to a dual-channel safety input configured as OSSD.

36 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

Speed Monitoring I/O Signals Chapter 4

Drive (Master)

SLS_OUT_CH0

SLS_OUT_CH1

Drive (Slave)

SLS_IN_CH0

SLS_IN_CH1

IOD-29

IOD-30

IOD-24

IOD-23

For a single unit system or the last unit in a cascaded system, the SLS_Out is intended to be connected to an input of a safety programmable logic controller (PLC). The same PLC could also control the Safe Stop function with a safe PLC output connected to the Safe Stop input (SS_In).

For the first or middle units in a cascaded system, the SLS_Out is intended to be connected to the Safe Limited Speed input (SLS_In) of the next drive in the cascaded system. This lets one SLS switch enable Safe Limited Speed on all axes at the same time.

Figure 7 - SLS_Out to SLS_In Connections for Multi-axis Applications

For more information on multi-axis configurations, see Cascaded Configurations starting on page 89

For Safe Limited Speed Status Only modes, the SLS_Out output is used as an indication that the Safe Limited Speed monitoring is active and the monitored speed is less than the configured Safe Speed Limit. If the speed is greater than or equal to the Safe Speed Limit, the SLS_Out is turned OFF. When Safe Limited Speed monitoring is not active or the drive is in a SLS Monitoring Delay, the SLS_Out output is OFF. The SLS_Out output is turned OFF when a Safe Stop has been initiated, a fault has occurred, or the drive is in the safe state.

See Safe Limited Speed Status Only Mode

on page 84 for more information.

For more information on faults, refer to Chapter

12.

Rockwell Automation Publication 2094-RM001C-EN-P - May 2013 37

Chapter 4 Speed Monitoring I/O Signals

TEST_OUT_CH0

DM_IN_CH0

DM_IN_CH1

LM_IN_CH0

LM_IN_CH1

DC_OUT_CH1

DC_OUT_CH0

Door Status Locking Mechanism Status

TEST_OUT_CH1 TEST_OUT_CH0 TEST_OUT_CH1

IOD-27 IOD-28

IOD-27

IOD-28

IOD-31

IOD-32

IOD-33

IOD-34

IOD-36

IOD-35

TIP

Door Control Output (DC_Out)

You can use this output for door control in single-axis and multi-axis systems. This output attempts to maintain last state when a fault occurs.

The DC_Out output is updated based on door control logic status, the [Door Control Output] parameter setting, and any Safe State faults that can be detected.

This output is Unlocked only when motion is verified to be at Standstill Speed or Safe Limited Speed.

Figure 8 - Door Control and Lock Monitoring

Check your interlock switch for internal jumpers before installation.

For more information on faults, refer to Chapter

The DC_Out output can be used as a bipolar output in Power to Release or Power to Lock configurations, or it can be configured as Cascading (2Ch Sourcing).

12.

38 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

Speed Monitoring I/O Signals Chapter 4

DM_IN_CH0 DM_IN_CH1

DC_OUT_CH0

DC_OUT_CH1

Drive (Master)

Drive (Slave)

IOD-36

IOD-35

IOD-31

IOD-32

Load

Bi-polar

Load

Single-ended

Load

Door Status 2-Channel

Source

(1)

+24V DC

Door Control

Sourcing Output

Door Control

Sinking Output

+24V DC Common

Load

Input Circuit

IOD-35

IOD-36

IOD-35

IOD-36

(2)

When the Door Control output is configured as cascading (2Ch Sourcing), the dual-channel bipolar output acts as two sourcing outputs capable of driving the OSSD Door Monitor input (DM_In) of the next speed monitoring drive in the cascaded chain. The DC_out output can also be used as a source for general purpose inputs. In this configuration, the current is limited to 20 mA.

Figure 9 - Door Control Cascading Outputs

Only the wiring configurations shown below are supported for the Door Control output.

Figure 10 - Door Control Output Wiring

(1) When wired as a source for a safety input, current is limited to 20 mA per output. (2) For example, SmartGuard 600 controller, Guard I/O module.

Short-circuits of the output loop to ground or 24V are detected. For cascaded outputs, cross loops are also detected.

Rockwell Automation Publication 2094-RM001C-EN-P - May 2013 39

Chapter 4 Speed Monitoring I/O Signals

Notes:

40 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

Chapter 5

General Device and Feedback Monitoring Configuration

This chapter describes the general and feedback configuration settings that must be configured to operate the safe speed monitoring features.

Top ic Pag e

Cascaded Configuration 41

Operation Mode 42

Reset Type 42

Overspeed Response Time 43

General Parameter List 48

Feedback Monitoring 49

Feedback Parameter List 54

Cascaded Configuration

The drive can be used in single-axis or multi-axis applications. The [System Configuration] parameter indicates the drive’s location in the system: Single Unit (Single), Cascaded First Unit (Multi First), Cascaded Middle Unit (Multi Mid), or Cascaded Last Unit (Multi Last). Single unit and cascaded first options are system masters.

Refer to Chapter

8 for more information on cascaded configurations.

Rockwell Automation Publication 2094-RM001C-EN-P - May 2013 41

Chapter 5 General Device and Feedback Monitoring Configuration

TIP

Operation Mode

Reset Type

You can configure the drive to operate in one of 11 user-selectable Operation modes, based on combinations of the safety functions the drive supports. The modes, except for Disabled, are described in detail in subsequent chapters of this manual.

Table 4 - Safety Function Combinations

For these modes See

Master, Safe Stop Chapter

Master, Safe Stop - Door Monitor

Master, Safe Stop - Safe Limited Speed Chapter 7

Master, Safe Stop - Safe Limited Speed - Door Monitor

Master, Safe Stop - Safe Limited Speed - Enable Switch

Master, Safe Stop - Safe Limited Speed - Door Monitor - Enable Switch

Master, Safe Stop - Safe Limited Speed Status Only

Slave, Safe Stop Chapter

Slave, Safe Limited Speed

Slave, Safe Limited Speed Status Only

You can configure the [Reset Type] parameter as automatic, manual, or manual monitored. The default is manual monitored. The configured Reset Type applies to both Safe Stop and Safe Limited Speed Resets.

The Reset input does not require wiring for automatic reset configurations.

See Safe Stop Reset

page 73

, page 76, and page 78 for details on how the [Reset Type] parameter

on page 63 and page 69, and Safe Limited Speed Reset on

affects Safe Stop and Safe Limited Speed operation.

ATTENTION: For all types of reset (automatic, manual, or manual monitored), if a reset of the Safe Stop or Safe Limited Speed functions can result in machine operation, the other speed monitoring functions must be configured to detect and prevent dangerous motion.

ATTENTION: The Safe Stop Reset does not provide safety-related restart according to EN 60204-1. Restart must be performed by external measures if automatic restart could result in a hazardous situation. You are responsible for determining whether automatic restart could pose a hazard.

42 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

General Device and Feedback Monitoring Configuration Chapter 5

Overspeed Response Time

The [Overspeed Response Time] parameter setting determines the maximum reaction time from an overspeed event to the initiation of the configured [Stop Category]. The safety reaction time from an overspeed event that triggers a Stop Category, to the actual initiation of that Stop Category, is equal to the value of the [Overspeed Response Time] parameter. The configurable options are 42, 48, 60, 84, 132, 228, and 420 ms.

The [Overspeed Response Time] parameter setting also determines the speed resolution that can be achieved. The Overspeed Response Time and the encoder resolution affect the speed resolution accuracy as shown in the tables on the following pages.

Speed Resolution Accuracy for Rotary Systems

Table 5 - En coder Res olution 16 lines/rev

Overspeed Response Time Setting

42 156.253 156.283 156.583 159.583 189.583 489.583

48 78.127 78.142 78.292 79.792 94.792 244.792

60 39.063 39.071 39.146 39.896 47.396 122.396

84 19.532 19.535 19.573 19.948 23.698 61.198

132 9.766 9.768 9.786 9.974 11.849 30.599

228 4.883 4.884 4.893 4.987 5.924 15.299

420 2.441 2.442 2.447 2.493 2.962 7.650

1 10 100 1000 10,000 100,000

Speed (RPM)

Table 6 - Encoder Resolution 128 lines/rev

Overspeed Response Time Setting

42 19.535 19.565 19.865 22.865 52.865 332.031

48 9.767 9.782 9.932 11.432 26.432 166.016

60 4.884 4.891 4.966 5.716 13.216 83.008

84 2.442 2.446 2.483 2.858 6.608 41.504

132 1.221 1.223 1.242 1.429 3.304 20.752

228 0.610 0.611 0.621 0.715 1.652 10.376

420 0.305 0.306 0.310 0.357 0.826 5.188

1 10 100 1000 10,000 93,750

Speed (RPM)

Rockwell Automation Publication 2094-RM001C-EN-P - May 2013 43

Chapter 5 General Device and Feedback Monitoring Configuration

Table 7 - Encoder Resolution 1000 lines/rev

Overspeed Response Time Setting

42 2.503 2.533 2.833 5.833 35.833 42.500

48 1.252 1.267 1.417 2.917 17.917 21.250

60 0.626 0.633 0.708 1.458 8.958 10.625

84 0.313 0.317 0.354 0.729 4.479 5.313

132 0.156 0.158 0.177 0.365 2.240 2.656

228 0.078 0.079 0.089 0.182 1.120 1.328

420 0.039 0.040 0.044 0.091 0.560 0.664

1 10 100 1000 10,000 12,000

Speed (RPM)

Table 8 - Encoder Resolution 1024 lines/rev

Overspeed Response Time Setting

42 2.445 2.475 2.775 5.775 35.775 41.504

48 1.222 1.237 1.387 2.887 17.887 20.752

60 0.611 0.619 0.694 1.444 8.944 10.376

84 0.306 0.309 0.347 0.722 4.472 5.188

132 0.153 0.155 0.173 0.361 2.236 2.594

228 0.076 0.077 0.087 0.180 1.118 1.297

420 0.038 0.039 0.043 0.090 0.559 0.648

1 10 100 1000 10,000 11,718.75

Speed (RPM)

Table 9 - Encoder Resolution 3000 lines/rev

Overspeed Response Time Setting

42 0.837 0.867 1.167 4.167 14.167

48 0.418 0.433 0.583 2.083 7.083

60 0.209 0.217 0.292 1.042 3.542

84 0.105 0.108 0.146 0.521 1.771

132 0.052 0.054 0.073 0.260 0.885

228 0.026 0.027 0.036 0.130 0.443

420 0.013 0.014 0.018 0.065 0.221

1 10 100 1000 4000

Speed (RPM)

44 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

General Device and Feedback Monitoring Configuration Chapter 5

Table 10 - Encoder Resolution 5000 lines/rev

Overspeed Response Time Setting

42 0.503 0.533 0.833 3.833 8.500

48 0.252 0.267 0.417 1.917 4.250

60 0.126 0.133 0.208 0.958 2.125

84 0.063 0.067 0.104 0.479 1.063

132 0.031 0.033 0.052 0.240 0.531

228 0.016 0.017 0.026 0.120 0.266

420 0.008 0.008 0.013 0.060 0.133

1 10 100 1000 2400

Speed (RPM)

Speed Resolution Accuracy for Linear Systems

Table 11 - Encoder Resolution 500 lines/mm

Overspeed Response Time Setting

42 0.083 0.084 0.087 0.117 0.417 1.417

48 0.042 0.042 0.043 0.058 0.208 0.708

60 0.021 0.021 0.022 0.029 0.104 0.354

84 0.010 0.010 0.011 0.015 0.052 0.177

132 0.005 0.005 0.005 0.007 0.026 0.089

228 0.003 0.003 0.003 0.004 0.013 0.044

420 0.001 0.001 0.001 0.002 0.007 0.022

0.01 0.1 1 10 100 400

Speed (mm/s)

Table 12 - Encoder Resolution 1000 lines/mm

Overspeed Response Time Setting

42 0.042 0.042 0.045 0.075 0.375 0.708

48 0.021 0.021 0.023 0.038 0.188 0.354

60 0.010 0.011 0.011 0.019 0.094 0.177

84 0.005 0.005 0.006 0.009 0.047 0.089

132 0.003 0.003 0.003 0.005 0.023 0.044

228 0.001 0.001 0.001 0.002 0.012 0.022

420 0.001 0.001 0.001 0.001 0.006 0.011

0.01 0.1 1 10 100 200

Speed (mm/s)

Rockwell Automation Publication 2094-RM001C-EN-P - May 2013 45

Chapter 5 General Device and Feedback Monitoring Configuration

Tri p Zo ne

Can Trip

No Trip

Table 13 - Encoder Resolution 5000 lines/mm

Overspeed Response Time Setting

42 0.008367 0.008667 0.011667 0.041667 0.141667

48 0.004183 0.004333 0.005833 0.020833 0.070833

60 0.002092 0.002167 0.002917 0.010417 0.035417

84 0.001046 0.001083 0.001458 0.005208 0.017708

132 0.000523 0.000542 0.000729 0.002604 0.008854

228 0.000261 0.000271 0.000365 0.001302 0.004427

420 0.000131 0.000135 0.000182 0.000651 0.002214

0.01 0.1 1 10 40

Speed (mm/s)

Table 14 - Encoder Resolution 20,000 lines/mm

Overspeed Response Time Setting

42 0.002117 0.002417 0.005417 0.035417

48 0.001058 0.011208 0.002708 0.017708

60 0.000529 0.000604 0.001354 0.008854

84 0.000265 0.000302 0.000677 0.004427

132 0.000132 0.000151 0.000339 0.002214

228 0.000066 0.000076 0.000169 0.001107

420 0.000033 0.000038 0.000085 0.000553

0.01 0.1 1 10

Speed (mm/s)

For example, an encoder resolution of 128 and Overspeed Response Time of 42 ms results in a speed resolution accuracy of ±19.865 RPM if your Safe Maximum Speed is configured for 100.0 RPM. An SMS Speed fault can occur when encoder 1 is at 80.135 RPM. However, the SMS Speed fault cannot occur until encoder 1 reaches 119.865 RPM.

Figure 11 - Need Figure Title Here

80.135

100

119.865

RPM

46 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

General Device and Feedback Monitoring Configuration Chapter 5

Speed Resolution =

(RPM)

15000

(Overspeed Response Time - 36) x Feedback Resolution

Speed (RPM) x 0.02

(Overspeed Response Time - 36)

Speed Resolution =

(mm/s)

250

(Overspeed Response Time - 36) x Feedback Resolution

Speed (RPM) x 0.02

(Overspeed Response Time - 36)

IMPORTANT

If your encoder resolution is not listed in the tables, use these equations.

For rotary systems, the conversion from [Overspeed Response Time] to Speed Resolution in revolutions per minute is:

For linear systems, the conversion from [Overspeed Response Time] to mm/s is:

To avoid nuisance FEEDBACK 1 faults, do not configure Overspeed Response Time in the shaded area of Tab le 15

Table 15 - Allowable Overspeed Response/Encoder Resolution Setting

Encoder Resolution

Lines/Rev

16 156.250 78.125 39.063 19.531 9.766 4.883 2.441

32 78.125 39.063 19.531 9.766 4.883 2.441 1.221

128 19.531 9.766 4.883 2.441 1.221 0.610 0.305

256 9.766 4.883 2.441 1.221 0.610 0.305 0.153

512 4.883 2.441 1.221 0.610 0.305 0.153 0.076

1024 2.441 1.221 0.610 0.305 0.153 0.076 0.038

2048 1.221 0.610 0.305 0.153 0.076 0.038 0.019

4096 0.610 0.305 0.153 0.076 0.038 0.019 0.010

8192 0.305 0.153 0.076 0.038 0.019 0.010 0.005

16,384 0.153 0.076 0.038 0.019 0.010 0.005 0.002

32,768 0.076 0.038 0.019 0.010 0.005 0.002 0.001

42 48 60 84 132 228 420

39.063 19.531 9.766 4.883 2.441 1.221 0.610

Overspeed Response Time (ms)

Rockwell Automation Publication 2094-RM001C-EN-P - May 2013 47

Chapter 5 General Device and Feedback Monitoring Configuration

General Parameter List

Tab Parameter Name Description

Safety Change System

Configurat ion

System Configuration Defines whether the drive is a single unit or if it occupies

Operation Mode Defines the primary operating mode of the speed

Reset Type Defines the type of reset used by the drive. Default: Manual Monitored

Overspeed Response Time

a first, middle, or last position in a multi-axis cascaded system.

monitoring safety functions.

Configuration for the feedback interface sampling rate. Default: 42 ms

Set these parameters to configure general operation of the drive.

Table 16 - General Parameters

Value s

(Safety Configuration Tool)

Default: Single Unit

Options: Single Unit

Cascaded First Unit Cascaded Middle Unit Cascaded Last Unit

Default: SafeStop

Options: Disabled

SafeStop SafeStop-DoorMonitor SafeStop-SafeLimitedSpeed SafeStop-SafeL imitedSpeed-DoorMonitor SafeStop-SafeLimitedSpeed-EnableSwitch SafeStop-SafeLimitedSpeed-DoorMonitor-EnableSwitch SafeStop-SafeLimitedSpeedStatusOnly

Options: Au tomatic

Manual Manual Monitored

Options: 42 ms

48 ms 60 ms 84 ms 132 ms 228 ms 420 ms

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General Device and Feedback Monitoring Configuration Chapter 5

IMPORTANT

Feedback Monitoring

The [Feedback Mode] parameter defines whether the feedback monitoring devices are configured as a single encoder or as dual encoders. When two encoders are used, the [Feedback Mode] parameter also defines the type of discrepancy checking that is performed between the two encoders.

Feedback devices can be a Sin/Cos or incremental feedback device.

You choose the type of feedback device, either sine/cosine or incremental for encoder 1 by using the [Primary Feedback Type] parameter. You also choose the feedback type, resolution, and polarity of both encoders.

Configure the feedback type as rotary or linear by using the [Primary Feedback Units] parameter. Configure the resolution in lines per revolution or lines per millimeter by using the [Primary Feedback Cycles] parameter.

For dual encoder configurations, the resolution of the first encoder can be different than the resolution of the second encoder. After discrepancy testing has passed, the speed, relative position, and direction used by the drive are based on encoder 1.

For dual-encoder configurations, the resolution of the first encoder can be different than the resolution of the second encoder, but it must be equal to or higher than the resolution of the second encoder.

Feedback Polarity

Configure the direction of polarity to be the same as the encoder or reversed by using the [Primary Feedback Polarity] parameter. The drive defines the normal positive direction for encoders as A leading B. To use encoders where B leads A, you must choose Negative for the [Primary Feedback Polarity] parameter. Set the [Secondary Feedback Polarity] parameter so that the resulting speed direction is of the same polarity as encoder 1.

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Chapter 5 General Device and Feedback Monitoring Configuration

TIP

IMPORTANT

Single Encoder

If the [Feedback Mode] parameter is set to Single Encoder, the single encoder input is processed redundantly and cross-checked in a 1oo2 architecture. The speed, direction, and stopped status are derived from the single encoder by the 1oo2 architecture.

If the [Feedback Mode] parameter is set to Single Encoder, the single encoder input corresponds to the Kinetix 6200 motor feedback (MF connector) connections.

Refer to Considerations for Safety Ratings

, on page 18, for more information.

Dual Encoders

If the [Feedback Mode] parameter is set to Dual Encoders, each encoder input is processed by a single channel and cross-checked in a 1oo2 architecture. Discrepancy checking is performed between the two encoders. After the discrepancy checks have passed, the speed, direction, and stopped status are derived from encoder 1.

If the [Feedback Mode] parameter is set to Dual Encoders, the encoder 1 input corresponds to the Kinetix 6200 motor feedback (MF) connector and the encoder 2 input corresponds to Kinetix 6200 auxiliary feedback (IOD) connector.

All monitoring functions are based on the speed of encoder 1. The encoder 2 signal is used for fault diagnostics.

Speed and direction checks are affected by these parameters:

• Dual Feedback Speed Ratio, [Velocity Ratio]

• Dual Feedback Position Tolerance, [Position Discrepancy Tolerance]

• Dual Feedback Speed Discrepancy Tolerance, [Velocity Discrepancy

Tolerance]

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General Device and Feedback Monitoring Configuration Chapter 5

IMPORTANT

Expected Speed of Encoder 2 Expected Speed of Encoder 1

Dual Feedback Speed Ratio

[Velocity Ratio] Parameter

Dual Feedback Speed Ratio

The Dual Feedback Speed Ratio, [Velocity Ratio] parameter, is defined as the ratio of the expected speed of encoder 2 divided by the expected speed of encoder

1. This parameter configures the anticipated gearing between encoder 1 and encoder 2.

If [Feedback Mode] equals Single Encoder, the only legal value for [Velocity Ratio] parameter is 0.0.

If [Feedback Mode] is any Dual Encoder configuration, the range of legal values for [Velocity Ratio] is from 0.0001…10,000.0.

For example, if encoder 2’s speed is expected to be 1000 revolutions per second while encoder 1’s speed is expected to be 100 revolutions per second, then configure the [Velocity Ratio] as 10.0.

The units used to measure encoder speed are configurable as either rotary (rev) or linear (mm) units. Any combination of rotary and linear units for the two encoders is allowed.

Dual Feedback Position Discrepancy Tolerance

The Dual Feedback Position Discrepancy Tolerance, [Position Discrepancy Tolerance] parameter, defines the cumulative position discrepancy that is tolerated between encoder 1 and encoder 2. The position discrepancy is defined as position change relative to encoder 1.

The relative position discrepancy difference is reset to zero at each Safe Stop Reset.

This discrepancy checking is performed only while the [Feedback Mode] parameter is equal to one of these values.

[Feedback Mode] Parameter Settings

Dual encoder with speed and position discrepancy checking

Dual encoder with position discrepancy checking

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Chapter 5 General Device and Feedback Monitoring Configuration

IMPORTANT

This table defines the legal values for each Feedback mode value.

[Feedback Mode] Parameter Settings

One encoder 0

Dual encoder with speed and position discrepancy 1…65,535 in degrees (rotary encoders) or mm (linear encoders)

Dual encoder with speed discrepancy checking 0

Dual encoder with position discrepancy checking 1…65,535 in degrees (rotary encoders) or mm (linear encoders)

Dual Feedback Position Discrepancy Tolerance, [Position Discrepancy Tolerance] Legal Values

relative to the resolution of encoder 1

If an illegal value is detected, an Invalid Configuration fault occurs and the drive remains in the Safe State.

When setting discrepancy tolerances, consider that configuring a high gear ratio between encoder 1 and encoder 2 can lead to unexpected dual feedback position faults. This is because a very large encoder 1 movement translates into a very small encoder 2 movement.

Dual Feedback Speed Discrepancy Tolerance

The Dual Feedback Speed Discrepancy Tolerance [Velocity Discrepancy Tolerance] parameter, defines the discrepancy that is tolerated for a difference in speed between encoder 1 and encoder 2. This speed is relative to encoder 1. This discrepancy checking is performed only while the Feedback mode is equal to one of these values.

[Feedback Mode] Parameter Settings

Dual encoder with speed and position discrepancy checking

Dual encoder with speed discrepancy checking

For rotary systems, the value is specified in revolutions per minute. For linear systems, the value is specified in mm per second.

[Feedback Mode] Parameter Settings

One encoder 0

Dual encoder with speed and position discrepancy checking

Dual encoder with speed discrepancy checking 0.1…6553.5 in rev/min (rotary encoders) or mm/s (linear

Dual encoder with position discrepancy checking 0

Dual Feedback Speed Discrepancy Tolerance, [Velocity Discrepancy Tolerance] Values

0.1…6553.5 in rev/min (rotary encoders) or mm/s (linear encoders)

encoders)

If an illegal value is detected, an Invalid Configuration fault occurs and the drive remains in the Safe State.

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General Device and Feedback Monitoring Configuration Chapter 5

Feedback Voltage Monitoring Range

Use the [5V Monitoring] and [9V Monitoring] parameters to set the feedback voltage monitoring range. The monitoring ranges help define the trip zone for encoder 1 and encoder 2, respectively.

Table 17 - Feedback Voltage Monitoring Range

5/9V Monitoring Setting

Range 4.5…5.5V 7…12V

Tri p Zo ne < 4.5V < 7V

The encoder must be specified Can Trip 4.5…4.62V 7…7.4V

to operate across this complete No Trip 4.62…5.38V 7.4…11.4V

range or larger. Can Trip 5.38…5.5V 11.4…12.0V

Tri p Zo ne >5.5V > 12.0V

Your power supply must stay within the No Trip range.

Feedback Fault

The allowable frequency of feedback input signals is limited. The drive monitors feedback signals whenever its configuration is valid and the Operation mode is not configured as Disabled.

Table 18 - Maximum Encoder Frequency

Encoder Type Frequency, max

Sine/cosine ≤ 100 kHz

Incremental ≤ 200 kHz

If the feedback signals indicate greater-than or equal-to the maximum value, a Feedback_x fault (Safe State fault) occurs (x equals 1 or 2 depending upon the encoder that has the fault).

Diagnostics are performed on the encoder input signals. If the encoder diagnostic tests fail, a Feedback_x fault (Safe State fault) occurs.

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Chapter 5 General Device and Feedback Monitoring Configuration

TIP

Feedback Parameter List

Tab Parameter Name Description

Feedba ck Change Feedback

Configurat ion

Feedba ck Primary Feedback

Feedba ck Secondary Feedback

Feedba ck Dual Feedback

Feedback Mode Selects the number of feedback devices and the type of

5V Monitoring Enable 5V monitoring. Default: Voltage not monitored

9V Monitoring Enable 9V monitoring. Default: Voltage not monitored

Type Selects the type of feedback for encoder 1. Default: Sin/Cos

Cycles Defines counts (linear) or revolutions (rotary) for

Units Selects millimeters or revolutions for encoder 1. Default: Revolutions (per Rev)

Feedback Polarity Defines the direction polarity for encoder 1. Default: Positive

Cycles Defines counts (linear) or revolutions (rotary) for

Units Selects millimeters or revolutions for encoder 2. Options: Revolutions (per Rev)

Feedback Polarity Defines the direction polarity for encoder 2. Options: Positive

Velocity Ratio Defines the ratio of the expected speed of encoder 2

Vel ocit y Di scre panc y Tol e ra nc e

Posit ion Discre pancy Tol e ra nc e

discrepancy checking.

encoder 1.

encoder 2.

divided by the expected speed of encoder 1. Not valid when Feedback Mode = Single Encoder.

Dual Feedback Speed Discrepancy Tolerance. Range: 0…6553.5 rpm or mm/s

Acceptable difference in position between encoder 1 and encoder 2.

To define the type of feedback used by the drive, set these parameters.

Secondary feedback parameter settings are not required when the [Feedback Mode] parameter setting is single encoder.

Table 19 - Feedback Parameters

Value s

(Safety Configuration Tool)

Default: Single Encoder

Options: Single Encoder

Dual Encoders w/speed and position discrepancy Dual Encoders w/speed discrepancy Dual Encoders w/position discrepancy

Options: Voltage not monitored

Voltage monitored

Options: Voltage not monitored

Voltage monitored

Options: Sin/Cos

TTL (incremental)

Default: 1024

Range: 1…65,535 pulses/revolution or pulses/mm based on the

[Primary Feedback Units] parameter

Options: Revolutions (per Rev)

Millimeters (per mm)

Options: Positive

Negative

Range: 1…65,535 pulses/revolution or pulses/mm based on the

[Secondary Feedback Units] parameter

Millimeters (per mm)

Negative

Range: 0.0001…10,000.0

ratio based on revolutions or millimeters configuration defined by the [Primary Feedback Units] parameter

Range: 0…65,535 deg or mm

ratio based on revolutions or millimeters configuration defined by the [Primary Feedback Units] parameter

54 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

Chapter 6

Safe Stop and Safe Stop with Door Monitoring Modes

This chapter describes the Safe Stop modes of safety operation and provides a list of configuration parameters as well as wiring examples for each Safe Stop mode.

Top ic Pag e

Safe Stop Mode 55

Safe Stop Parameter List 66

Safe Stop Wiring Example 68

Safe Stop with Door Monitoring Mode 68

Safe Stop with Door Monitoring Parameter List 69

Safe Stop with Door Monitoring Wiring Example 69

Safe Stop Mode

When properly configured for Safe Stop, the drive monitors the Safe Stop input (SS_In) and initiates the configured Stop Category upon deactivation of the input. The Stop Category is configurable as either Safe Torque Off with or without Standstill Checking, Safe Stop 1, or Safe Stop 2. The drive recognizes motion as stopped when encoder 1 feedback signals indicate the system has reached the configured Standstill Speed. Once Standstill Speed has been reached, the Door Control output (DC_Out) is set to Unlock.

In addition to setting the Standstill Speed, you configure the Stop Delay [Maximum Stop Time], the period where deceleration occurs after a Safe Stop is initiated, and an optional Stop Monitoring Delay [Safe Stop Monitor Delay] that is a delay between the action that requests the Safe Stop and the initiation of the configured Stop Category. A [Safe Stop Monitor Delay] can be configured only for Safe Stop 1 or Safe Stop 2.

When properly configured for Safe Stop mode, the drive also monitors for faults and initiates the appropriate reaction. If the fault is a Safe State fault, the drive enters the Safe State. If the fault is a Stop Category fault, the drive initiates the configured Stop Category.

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Chapter 6 Safe Stop and Safe Stop with Door Monitoring Modes

IMPORTANT

Stop Request

Stop Delay

Safe Torque-off

Active

Door Control Output Unlock

Standstill Speed

SS_Out Output

Motion Power

(1)

DC_Out Output

(2)

Speed

Time

SS_In Input

Stop Categories

Use the [Stop Category] parameter to configure the type of stop that the system executes when a Safe Stop is initiated. A Safe Stop can be initiated by a transition of the SS_In input from ON to OFF or by the occurrence of a Stop Category fault.

While the drive executes the configured Stop Category, it continues to monitor the system. If a Stop Category fault is detected, the drive sets the outputs to a faulted state, but allows for the door control logic to be set to Unlock if the feedback signals indicate Standstill Speed has been reached.

Safe torque-off, with or without standstill checking, opens the Guard Gate drive output (status = 0) when the Safe Stop is executed. This is commonly known as coast-to-stop.

Safe Torque Off with Standstill Checking

This Stop Category lets you access the hazard area immediately after motion is detected as stopped rather than waiting until a specific time has elapsed.

When Safe Torque Off with Standstill Checking is initiated, motion power is removed immediately and the configured Stop Delay [Maximum Stop Time] begins. If the configured Standstill Speed is detected any time after the Safe Stop has been initiated and before the end of the configured Stop Delay, door control logic is set to Unlock.

If the Standstill Speed is not detected by the end of the configured Stop Delay, a Stop Speed fault occurs and the door control logic remains set to Lock until Standstill Speed is detected.

After successful SS_Reset, the Logix Designer application must issue an MSF instruction prior to restarting the machine.

Figure 12 - Timing Diagram for Safe Torque-off with Standstill Checking

56 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

(1) This signal is internal to the drive. (2) DC_Out output shown configured as Power to Release. See Door Control

on page 64 for more information.

Safe Stop and Safe Stop with Door Monitoring Modes Chapter 6

IMPORTANT

EXAMPLE

Safe Decel Rate, rev/s 2=

(Decel Ref Speed, rpm)/60, s

Max Stop Time, s

Stop Time, s =

Actual Speed, rev/s

Safe Decel Rate, rev/s

Safe Decel Rate =

2400/60

Deceleration Reference Speed = 2400 rpm Maximum Stop Time = 10 seconds Actual Speed (when stop occurs) = 1200 rpm

4 rev/s

Stop Time =

1200/60

5 s

Safe Stop 1 and 2

When Safe Stop 1 or 2 is initiated by a transition of the SS_In input from ON to OFF, the drive does not initiate the configured Stop Delay [Maximum Stop Time] until after the optional Stop Monitoring Delay [Safe Stop Monitor Delay] expires, unless a Stop Category fault occurs during the Stop Monitoring Delay.

When Safe Stop 1 or 2 is initiated by a Stop Category fault, the Stop Delay [Maximum Stop Time] begins immediately, regardless of whether a Stop Monitoring Delay [Safe Stop Monitor Delay] is configured.

During a Safe Stop 1 and 2, the drive decelerates at a rate calculated by using the [Deceleration Reference Speed] and [Maximum Stop Time] parameters. When Safe Stop 1 or 2 is initiated, the drive decelerates at the calculated rate. Follow these calculations, depending on the conditions of your application.

Use these formulas if the actual speed of the drive is ≤ the Decel Reference Speed.

Deceleration Reference Speed must be the application’s actual maximum motor speed. If the actual motor speed is greater than the Deceleration Reference Speed, then the Actual Stop Time equals the Maximum Stop Time.

Use this formula if the actual speed of the drive is ≥ the Decel Reference Speed.

Max Stop Time, sStop Time, s =

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Chapter 6 Safe Stop and Safe Stop with Door Monitoring Modes

TIP

IMPORTANT

Stop Request

Stop Delay

Safe Torque-off

Active

Deceleration Tol e ra nc e

Standstill Speed

Speed

Stop Monitoring

Delay

SS_Out Signal

SS_In Signal

Time

Motion Power

(1)

DC_Out Output

(2)

Deceleration monitoring takes place during the Stop Delay [Maximum Stop Time]. These three configurable parameters define the deceleration profile that is used:

If Standstill Speed is detected any time after the Safe Stop has been initiated and before the Stop Delay [Maximum Stop Time] expires, door control logic is set to Unlock. If the Standstill Speed is not detected by the end of the configured Stop Delay [Maximum Stop Time], a Stop Speed fault occurs.

When Safe Stop 1 is executed, the Guard Gate drive output is on (status = 1) until standstill speed is reached or a fault occurs. This safe stop is commonly known as a controlled, monitor stop.

• [Deceleration Reference Speed]

• [Deceleration Tolerance]

• Stop Delay, [Maximum Stop Time]

You can determine the drive/motor Stop Delay characteristics by using Motion Analyzer software, version 4.7 or later.

Do not use Safe Stop 1 for vertical axis applications because the Guard Gate output is off (status = 0) when below standstill speed.

For Safe Stop 1, motion power is removed when Standstill Speed is reached.

For Safe Stop 1, after a successful SS_Reset, the Logix Designer application must issue an MSF instruction prior to restarting the machine.

Figure 13 - Timing Diagram for Safe Stop 1

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(1) This signal is internal to the drive. (2) DC_Out output shown configured as Power to Release. See Door Control

on page 64 for more information.

Safe Stop and Safe Stop with Door Monitoring Modes Chapter 6

IMPORTANT

SS_Out Output

SS_In Input

Stop Request

Stop Delay

Standstill Position and Standstill

Speed Monitoring

(drive remains enabled)

Deceleration Tol e ra nc e

Standstill Speed

Speed

Stop Monitoring

Delay

Time

Motion Power

(1)

DC_Out Output

(2)

When Safe Stop 2 is executed, the Guard Gate drive output is on (status = 1) until after standstill speed is reached or a fault occurs. Use this safe stop for vertical load applications. The IGBT remains active, therefore follow the examples on page 57

to MAS before SS_Reset.

For Safe Stop 2, motion power is not removed when Standstill Speed is reached.

For Safe Stop 2, the Logix Designer application must monitor the state of the Axis.GuardStopRequestStatus tag. After the tag becomes active and stop monitoring expires, the program must issue an MAS instruction. Successful SS_Reset is required prior to restarting the machine.

Figure 14 - Timing Diagram for Safe Stop 2

(1) This signal is internal to the drive. (2) DC_Out output shown configured as Power to Release. See Door Control

on page 64 for more information.

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Chapter 6 Safe Stop and Safe Stop with Door Monitoring Modes

Stop Request

Stop Delay

Safe Torque-off

Active

Door Control Output Unlock

Time

SS_Out Output

SS_In Input

Speed

Motion Power

(1)

DC_Out Output

(2)

TIP

Safe Torque Off without Standstill Checking

When Safe Torque Off without Standstill Checking is initiated, motion power is removed immediately and the configured Stop Delay [Maximum Stop Time] begins. Door control logic is set to Unlock when the Stop Delay [Maximum Stop Time] expires, regardless of speed.

Figure 15 - Timing Diagram for Safe Torque Off without Standstill Checking

(1) This signal is internal to the drive. (2) DC_Out output shown configured as Power to Release. See Door Control

All Stop Types require an encoder to be connected.

on page 64 for more information.

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Safe Stop and Safe Stop with Door Monitoring Modes Chapter 6

IMPORTANT

Standstill Speed and Position Tolerance

For Stop Categories that include Standstill Checking, you set the Standstill Speed and Standstill Position Tolerance.

The [Standstill Speed] and [Standstill Position Window] parameters are not used for Safe Torque Off without Standstill Checking configurations. Set these parameters to zero.

Standstill Speed is used to declare motion as stopped. The system is at standstill when the speed detected is less than or equal to the configured Standstill Speed. The [Standstill Speed] parameter defines the speed limit before the drive determines standstill has been reached and the door control logic is set to Unlo ck .

Standstill detection relies on the encoder 1 signal. The encoder 2 signal is used for fault diagnostics.

The [Standstill Position Window] parameter defines the position limit in encoder 1 units that is tolerated after standstill has been reached. If the position changes by more than the amount specified by the Standstill Position Tolerance, after standstill has been reached and the door is unlocked, a Motion After Stopped fault occurs. This type of fault results in the drive entering the safe state.

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Chapter 6 Safe Stop and Safe Stop with Door Monitoring Modes

Standstill Speed

Time

Stop Delay

(∆v) = Deceleration Tolerance %

x Deceleration Reference Speed

Actual speed measured at the start of the Stop

Delay [Maximum Stop Time].

Stop Request

Speed

TIP

The time required to verify that the Standstill Speed has been reached can be considerable when a very small Standstill Speed is configured and the encoder resolution of encoder 1 is very low.

Deceleration Monitoring

Deceleration monitoring takes place during the configured Stop Delay [Maximum Stop Time], when the Stop Category is configured as Safe Stop 1 or Safe Stop 2. The deceleration start speed is captured at the beginning of the Stop Delay [Maximum Stop Time] and used to calculate the deceleration profile.

These parameters define the deceleration profile:

• For rotary systems, the time (in seconds) exceeds 15 / [Standstill Speed (RPM) x Encoder 1 Resolution].

• For linear systems, the time (in seconds) exceeds

0.25 / [Standstill Speed (mm/s) x Encoder 1 Resolution].

• Deceleration Reference Speed, [Deceleration Reference Speed]

• Deceleration Tolerance, [Deceleration Tolerance]

• Stop Delay, [Maximum Stop Time]

The Deceleration Reference Speed is relative to encoder 1. The [Deceleration Tolerance] parameter defines the percentage of the Deceleration Reference Speed that is tolerated above the calculated deceleration profile.

Figure 16 - Deceleration Monitoring

When deceleration monitoring is being performed, the speed limit monitored during the Stop Delay [Maximum Stop Time] must be less than the Deceleration Monitoring Value or a Deceleration fault occurs. A Deceleration fault places outputs in the faulted state, but allows the door to be unlocked when the feedback signals indicate Standstill Speed has been reached.

To account for system overshoot and drive delay, choose ∆v and set [Deceleration Reference Speed] to the highest normal operating speed to calculate the Deceleration Tolerance. Remember that [Deceleration Tolerance] parameter is a percentage.

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Safe Stop and Safe Stop with Door Monitoring Modes Chapter 6

IMPORTANT

Safe Stop Reset

The Safe Stop Reset (SS Reset) is a reset from the Safe State or from a stopping condition to actively monitoring motion. The reset is successful if the SS_In input is ON and no faults are present.

When an SS Reset is requested, all diagnostic tests that can be performed prior to outputs being energized are performed prior to a successful SS Reset. If a diagnostic test can be performed only when outputs are energized, the test is performed immediately following the SS Reset.

An SS Reset is not attempted if the GuardStopInputCycleRequiredStatus attribute is set (1), indicating that an error, other than an invalid configuration fault or ESM_In input fault, occurred.

The GuardStopInputCycleRequiredStatus attribute is bit 25 of the [Guard Status] parameter.

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Chapter 6 Safe Stop and Safe Stop with Door Monitoring Modes

Automatic

If the SS Reset is configured as automatic, the drive always attempts a reset if it is in the Safe State or has initiated a Stop Category. The reset is attempted when the SS_In input transitions from OFF to ON or if SS_In is ON at powerup.

Manual

If the SS Reset is configured as manual, the reset is attempted when the SS_In input is ON and the Reset_In input is ON.

Manual Monitored

A manual monitored reset requires an OFF to ON to OFF transition of the Reset_In input.

If at any time before the closing and opening of the Reset_In input, the SS_In input transitions from ON to OFF, the reset is aborted.

Faults

If a fault occurs, other than an Invalid Configuration fault or an ESM Monitoring fault, the SS_In input must turn OFF and ON again to reset the GuardStopInputCycleRequiredStatus bit before a successful SS Reset can occur.

Door Control

The status of door control logic (Lock or Unlock) and the Door Monitor Input (DM_In), along with the drive’s location in the system [System Configuration] and Door Control Output Type [Door Control Output] determine whether the Door Control output (DC_Out) is locked or unlocked during normal operation.

When the DC_Out output has no faults, the drive is configured for Safe Stop, and the drive is monitoring motion, the door control logic state is Locked. It remains locked while a Safe Stop is being executed. For all Stop Categories except Safe Torque Off without Standstill Checking, door control logic is set to Unlock only when Standstill Speed has been reached. If the Stop Category is Safe Torque Off without Standstill Checking, door control logic is set to Unlock when the Stop Delay [Maximum Stop Time] has elapsed, regardless of speed.

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Safe Stop and Safe Stop with Door Monitoring Modes Chapter 6

Configuration

You configure the type of door control for each Safe Speed Monitor Option module in the system.

[Door Control Output] Settings

Single and Last Units First and Middle Units

Power to Release Not valid ON = Door is unlocked.

Power to Lock Not valid ON = Door is locked.

Cascadi ng (2 Ch Sourcing)

Cascading (2 Ch Sourcing)

DC_Out Status and Lock State

OFF = Door is locked.

OFF = Door is unlocked.

ON = Door is unlocked. OFF = Door is locked.

A single or last drive in a cascaded system can be configured for any Door Output Type setting. For example, choose 2 Ch Sourcing to connect to a safety programmable controller input. The first or middle drive in a cascaded system must be configured as 2 Ch Sourcing.

ATTENTION: When the DC_Out output is configured as Power to Lock, the safe state and faulted state is Unlocked. Make sure that this possibility does not create a hazard.

Effect of Faults

These fault conditions affect the integrity of the DC_Out output and force the DC_Out output to its safe state (OFF) regardless of the status of door control logic:

• DC Out fault

• Invalid Configuration fault

• Internal Power Supply or MPU faults

ATTENTION: If a fault occurs after Standstill Speed has been reached, door control remains unlocked.

For fault conditions where the DC_Out output can maintain its integrity, both door control logic and the DC_Out output hold last state. If hold last state cannot be maintained, faults can turn the DC_Out output OFF.

ATTENTION: If a fault occurs while the door is unlocked, it can remain unlocked. Make sure that this possibility does not create a hazard.

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Chapter 6 Safe Stop and Safe Stop with Door Monitoring Modes

TIP

Lock Monitoring

If Lock Monitoring is enabled, the Lock Monitoring input (LM_In) must be in the ON state any time the Door Control output (DC_Out) is in the Lock state, except for the 5 seconds following the DC_Out output’s transition from the Unlocked state to the Locked state. If the LM_In input is not ON during this time, a Lock Monitoring fault occurs. The LM_In input must be OFF when the DM_In input transitions from ON to OFF (the door opens).

A Lock Monitoring fault is a Stop Category fault that initiates the configured Stop Category.

Safe Stop Parameter List

Table 20 - Safe Stop Parameters

Tab Parameter Name Description

Safety Change System

Configurat ion

Input Change Input

Configuration Type

Operation Mode Defines the primary operating mode of the speed

monitoring safety functions.

Safe Stop Configuration for Safe Stop input (SS_In). Default: Dual Channel Equivalent

To configure the drive for Safe Stop mode, set these parameters in addition to the General and Feedback parameters listed on page 48

and page 54.

Not all Safe Stop configuration parameters require configuring for each Safe Stop category.

Value s

(Safety Configuration Tool)

Setting: SafeStop

Options: Not Used

Dual Channel Equivalent Dual Channel Equivalent 3 s Dual Channel Complementary Dual Channel Complementary 3 s Solid State Device Equivalent 3 s Single Channel

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Table 20 - Safe Stop Parameters (continued)

Safe Stop and Safe Stop with Door Monitoring Modes Chapter 6

Tab Parameter Name Description

Safe Stop Change Safe Stop

Configurat ion

Safe Stop Change Safe Stop

Configurat ion

Safety Change System

Configurat ion

Input Change Input

Configuration Type

Stop Category Safe operating stop type se lection. This defines the type

Safe Stop Monitor Delay

Deceleration Reference Speed

Maximum Stop Time Defines the maximum stop dela y time that is us ed wh en

Deceleration Tol e ra nc e

Standstill Speed Defines the speed limit that is used to declare motion as

Standstill Position Wind ow

Door Control Output Defines the lock and unlock state for door control output

Enable Lock Monitoring

Lock Monitor Configuration for the Lock Monitor input (LM_In). Default: Not Used

of Safe Stop that is performed if the Safe Stop function is initiated by a stop type condition.

Enable Standstill Checking. Automatically enabled for Safe Stop 1 and Safe Stop 2.

Defines the monitoring delay between the request and the Maximum Stop Time when the request for a Safe Stop 1 or a Safe Stop 2 is initiated by an SS_In input ON to OFF transition. If the Stop Category is Safe Torque-Off with or without Standstill Speed Checking, the Safe Stop Monitor Delay must be 0 or an Invalid Configuration fault occurs.

Determines deceleration rate to monitor for Safe Stop 1 or Safe Stop 2.

the Safe Stop function is initiated by a stop type condition.

This is the acceptable tolerance above the deceleration rate set by the [Deceleration Reference Speed] parameter.

stopped. Not valid for Safe Torque-Off without Standstill

Checking.

Defines the position limit window in encoder 1 degrees or mm that are tolerated after a safe stop condition has been detected.

Not valid for Safe Torque-Off without Standstill Checking.

(DC_Out). Any Door Control Output option can be used for a

single-axis system or for the last unit in a multi-axis system. The first and middle units of a mult i-axis system must be configured as 2 Channel Sourcing.

Lock Monitoring can be enabled only when the drive is a single unit or the first unit in a multi-axis system as set in [System Configuration].

Value s

(Safety Configuration Tool)

Default: Safe Torque-Off

Options: Safe Torque-Off

Safe Stop 1 Safe Stop 2

Default: Standstill Checking Enabled

Options: Standstill Checking Enabled

Standstill Checking Not Enabled

Default: 0

Range: 0…6553.5 s

Default: 0

Range: 0…65,535 rpm or mm/s

ratio based on revolutions or millimeters configuration defined by the [Primary Feedback Units] parameter

Default: 0

Range: 0…6553.5 s

Default: 0

Range: 0…100% of Deceleration Reference Speed

Default: 0.001

Range: 0.001…65.535 rpm or mm/s

ratio based on revolutions or millimeters configuration defined by the [Primary Feedback Units] parameter

Default: 10

Range: 0…65,535 degrees (360° = 1 revolution) or mm

ratio based on revolutions or millimeters configuration defined by the [Primary Feedback Units] parameter

Default: Power to Release

Options: Power to Release

Power to Lock 2 Channel Sourcing

Default: Lock Monitoring Not Enabled

Options: Lock Monitoring Not Enabled

Lock Monitoring Enabled

Options: Not Used

Dual Channel Equivalent Dual Channel Equivalent 3 s Dual Channel Complementary Dual Channel Complementary 3 s Solid State Device Equivalent 3 s Single Channel

Rockwell Automation Publication 2094-RM001C-EN-P - May 2013 67

Chapter 6 Safe Stop and Safe Stop with Door Monitoring Modes

GND

+24V DC

IOD Connector

TEST_OUT_1 TEST_OUT_0

RESET_IN

RESET_REF

28 27 26 25 24 23 22 21 20 19 18 17

SLS_IN_CH1

SLS_IN_CH0 SS_OUT_CH1 SS_OUT_CH0

SS_IN_CH1 SS_IN_CH0

SCOM SPWR

(1)

Kinetix 6200 and Kinetix 6500 Control Module Safety Connections IOD (44-pin) Connector

Request

Reset

Safe Stop to Next Axis (option al)

IMPORTANT

Safe Stop Wiring Example

Safe Stop with Door Monitoring Mode

This example illustrates safe stop wiring.

Figure 17 - Master, Safe Stop (First or Single Unit)

(1) SCOM must be at the same potential as the drive common because of the encoder signal.

When properly configured for Safe Stop with Door Monitoring, the drive monitors the Safe Stop input (SS_In) and initiates the configured Stop Category upon deactivation of the input as described in Safe Stop Mode

on page 55.

In addition, the drive verifies through monitoring the Door Monitor input (DM_In) that the door interlock solenoid controlled by the Door Control output (DC_Out) is in an expected state. The DM_In input is ON when the door is closed and OFF when the door is open. If the door is monitored as opened during Safe Stop monitoring, a Door Monitoring fault occurs and the drive initiates the configured Stop Category.

You can monitor the door’s status with or without using the Door Control (lock/ unlock) function. When door control logic is set to Lock, the drive puts the solenoid into the locked state when the machine is not at a safe speed or at Standstill Speed.

Lock Monitoring

If an Operaton mode that includes Door Monitoring is selected and Lock Monitoring is enabled, the Lock Monitor input (LM_In) signal must be OFF

68 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

any time that the Door Monitor input (DM_In) transitions from ON to OFF.

If your application uses Lock Monitoring without Door Monitoring, you must use some means to make sure that the Lock Monitor is not stuck at Lock indication.

Safe Stop and Safe Stop with Door Monitoring Modes Chapter 6

GND

+24V DC

424152

IOD Connector

TEST_OUT_0 TEST_OUT_1

SLS_OUT_CH0 SLS_OUT_CH1

DM_IN_CH0 DM_IN_CH1 LM_IN_CH0

LM_IN_CH1 DC_OUT_CH0 DC_OUT_CH1 ESM_IN_CH0 ESM_IN_CH1

29 30 31 32 33 34 35 36 37 38

IOD Connector

TEST_OUT_1 TEST_OUT_0

RESET_IN

RESET_REF

28 27 26 25 24 23 22 21 20 19 18 17

SLS_IN_CH1 SLS_IN_CH0 SS_OUT_CH1 SS_OUT_CH0

SS_IN_CH1 SS_IN_CH0

SCOM

SPWR

(2)

Kinetix 6200 and Kinetix 6500 Control Module Safety Connections IOD (44-pin) Connector

Request

Reset

Remove (2)

Internal

Jumpers

TLS3 GD2 440G-T27260 Safety Switch

(1)

Safe Stop to Next Axis (optional)

SS Reset

If the Door Monitor input (DM_In) is OFF when a Safe Stop (SS) Reset is attempted in any state other than actively monitoring Safe Limited Speed, a Door Monitoring fault occurs and the drive initiates the configured Stop Category.

Safe Stop with Door Monitoring Parameter List

To configure the drive for Safe Stop with Door Monitoring, set the DM Input parameter in addition to the Safe Stop parameters listed on page 66

Table 21 - Safe Stop with Door Monitoring Parameters

Tab Parameter Name Description

Safety Change System

Configuration

Input Change Input

Configuration Type

(1) You must configure this parameter with a non-zero value in this mode.

Safe Stop with Door Monitoring Wiring Example

Operation Mode Defines the primary operating mode of the speed monitoring

Door Monitor Configuration for the Door Monitor input (DM_In). Default: Not Used

safety functions.

This example illustrates wiring for safe stop with door monitoring.

Figure 18 - Master, Safe Stop with Door Monitoring (First or Single Unit)

Values

(Safety Configuration Tool)

Setting: SafeStop-Door Monitor

(1)

Options: Not Used

Dual Channel Equivalent Dual Channel Equivalent 3 s Dual Channel Complementary Dual Channel Complementary 3 s Solid State Device Equivalent 3 s Single Channel

Rockwell Automation Publication 2094-RM001C-EN-P - May 2013 69

(1) Lock monitoring connections are not required for Safe Limited Speed with Door Monitoring mode operation. (2) SCOM must be at the same potential as the drive common because of the encoder signal.

Chapter 6 Safe Stop and Safe Stop with Door Monitoring Modes

Notes:

70 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

Chapter 7

Safe Limited Speed (SLS) Modes

This chapter describes the Safe Limited Speed (SLS) modes of safety operation and provides a list of configuration parameters along with wiring examples for each mode.

Top ic Pag e

Safe Limited Speed (SLS) Mode 71

Safe Limited Speed Parameter List 74

Safe Limited Speed Wiring Example 75

Safe Limited Speed with Door Monitoring Mode 75

SLS with Door Monitoring Parameter List 77

SLS with Door Monitoring Wiring Example 77

Safe Limited Speed with Enabling Switch Monitoring Mode 78

SLS with Enabling Switch Monitoring Parameter List 79

SLS with Enabling Switch Monitoring Wiring Example 79

Safe Limited Speed with Door Monitoring and Enabling Switch Monitoring Mode 80

SLS with Door Monitoring and Enabling Switch Monitoring Parameter List 82

SLS with Door Monitoring and Enabling Switch Monitoring Wiring Example 83

Safe Limited Speed Status Only Mode 84

SLS Status Only Parameter List 85

SLS Status Only Wiring Examples 86

Safe Limited Speed (SLS) Mode

When properly configured for Safe Limited Speed, the drive performs Safe Limited Speed (SLS) monitoring functions in addition to the Safe Stop function described in Safe Stop Mode

on page 55. When the Safe Limited Speed input (SLS_In) is OFF, feedback velocity is monitored and compared against a configurable Safe Speed Limit.

Rockwell Automation Publication 2094-RM001C-EN-P - May 2013 71

Chapter 7 Safe Limited Speed (SLS) Modes

SLS

Request

Safe Speed Limit

Speed

Time

SLS Monitoring

Delay

Safe Limited Speed

Active

SLS Fault

Acceptable Speed Range

SLS Request

Removed

If the feedback velocity is below the Safe Speed Limit during Safe Limited Speed monitoring, the Door Control output (DC_Out) is unlocked after the [Safe Limited Speed Monitor Delay], if configured, has expired.

ATTENTION: Make sure that an unlocked door does not result in a hazardous situation.

If a Stop Category is initiated or a fault occurs while the drive is actively monitoring Safe Limited Speed, door control remains unlocked. The safe state of the SLS_In input can result in the door being unlocked.

If the measured velocity exceeds the Safe Speed Limit, an SLS fault occurs and the configured [Stop Category] is initiated. An optional [Safe Limited Speed Monitor Delay] can be configured to delay the start of Safe Limited Speed monitoring.

Safe Limited Speed monitoring is requested by a transition of the Safe Limited Speed input (SLS_In) from ON to OFF. When the SLS_In input is ON, the drive does not monitor for Safe Limited Speed and the measured velocity can be above or below the Safe Speed Limit.

If the Reset Type is configured as Automatic, Safe Limited Speed monitoring is disabled when the SLS_In input is turned ON and the machine operates at its normal run speed. Make sure that the SLS_In input cannot transition to ON while someone is in the hazardous area.

If you configure a [Safe Limited Speed Monitor Delay], the delay begins when Safe Limited Speed monitoring is requested by the SLS_In transition from ON to OFF. The drive begins monitoring for Safe Limited Speed when the delay times out. If system speed is greater than or equal to the configured Safe Speed Limit during Safe Limited Speed monitoring, an SLS fault occurs and the drive initiates the configured Stop Category.

Figure 19 - Timing Diagram for Safe Limited Speed (SLS)

72 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

Safe Limited Speed (SLS) Modes Chapter 7

Safe Limited Speed Reset

A Safe Limited Speed (SLS) Reset is a transition out of actively monitoring safe limited speed. It can also occur during a [Safe Limited Speed Monitor Delay], if one is configured. When an SLS Reset occurs, the drive no longer monitors for safe limited speed and the door is locked. Speed is no longer restricted to the configured Safe Speed Limit.

The SLS Reset function monitors the SLS_In input. If an SLS Reset is requested, the drive checks that no faults are present and verifies that the SLS_In input is ON (closed circuit) before the reset is performed.

When the input is OFF, Safe Limited Speed monitoring takes place, after the [Safe Limited Speed Monitor Delay], if one is configured. An SLS Reset can be requested during active Safe Limited Speed monitoring or during a Safe Limited Speed Monitoring Delay. If a reset is requested during a Safe Limited Speed Monitoring Delay, the reset does not wait for the delay to time out.

Automatic

Once the SLS_In input is ON (closed), the drive lets the drive resume normal operating speed. No reset button is required to re-enter the normal run state.

Manual

When the SLS_In input transitions from OFF to ON and the Reset_In input is ON, an SLS_Reset is attempted.

If the SLS_In transitions from OFF to ON and the Reset_In input is OFF, the drive stays in its current state, whether it is actively monitoring Safe Limited Speed or is in a Safe Limited Speed Monitoring Delay, and waits for the Reset_In input to transition to ON, before attempting the SLS_Reset. If at any time, the SLS_In input transitions back to OFF, the SLS_Reset is aborted.

Manual Monitored

When the SLS_In input transitions from OFF to ON, the drive waits for an OFF to ON to OFF transition of the Reset_In input before an SLS_Reset is attempted. If at any time during this period, the SLS_In input transitions back to OFF, the SLS_Reset is aborted.

Rockwell Automation Publication 2094-RM001C-EN-P - May 2013 73

Chapter 7 Safe Limited Speed (SLS) Modes

Safe Limited Speed Parameter List

To configure the drive for Safe Limited Speed monitoring, set these parameters in addition to the Safe Stop parameters listed beginning on page 66

Table 22 - Safe Limited Speed Parameters

Tab Parameter Name Description

Safety Change System

Configurat ion

Input Change Input

Configuration Type

Safe Limited Speed Change Safe Limited

Speed Configuration

(1) You must configure this parameter with a non-zero value in this mode.

Operation Mode Defines the primary operating mode of the speed

Safe Limited Speed Configuration for the Safe Limited Speed input

Safe Limited Speed Monitor Delay

Safe Speed Limit Defines the speed limit that is monitored in Safe Limited

monitoring safety functions.

(SLS_In).

Defines the Safe Limited Speed Monitoring Delay between the SLS_In ON to OFF transition and the initiation of the Safe Limited Speed (SLS) monitoring.

Speed (SLS) mode.

Value s

(Safety Configuration Tool)

Setting: SafeStop-Safe Limited Speed

Default: Not Used

Options: Not Used

Default: 0

Range: 0…6553.5 s

Default: 0

Range: 0…65,535 rpm or mm/s

(1)

Dual Channel Equivalent Dual Channel Equivalent 3 s Dual Channel Complementary Dual Channel Complementary 3 s Solid State Device Equivalent 3 s Single Channel

(1)

ratio based on revolutions or millimeters configuration defined by the [Primary Feedback Units] parameter

74 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

Safe Limited Speed (SLS) Modes Chapter 7

GND

+24V DC

IOD Connector

27 28 27 28 27 28 27 28

TEST_OUT_0 TEST_OUT_1 TEST_OUT_0 TEST_OUT_1 TEST_OUT_0 TEST_OUT_1 TEST_OUT_0 TEST_OUT_1

SLS_OUT_CH0 SLS_OUT_CH1

DM_IN_CH0 DM_IN_CH1 LM_IN_CH0

LM_IN_CH1 DC_OUT_CH0 DC_OUT_CH1 ESM_IN_CH0 ESM_IN_CH1

29 30 31 32 33 34 35 36 37 38

IOD Connector

TEST_OUT_1 TEST_OUT_0

RESET_IN

RESET_REF

28 27 26 25 24 23 22 21 20 19 18 17

SLS_IN_CH1

SLS_IN_CH0 SS_OUT_CH1 SS_OUT_CH0

SS_IN_CH1 SS_IN_CH0

SCOM SPWR

Kinetix 6200 and Kinetix 6500 Control Module Safety Connections IOD (44-pin) Connector

SLS

Request

Reset

Safe Stop to Next Axis (optional)

Safe Limited Speed Wiring Example

This example illustrates wiring for safe limited speed.

Figure 20 - Master, Safe Limited Speed (First or Single Unit)

Safe Limited Speed with Door Monitoring Mode

When properly configured for Safe Limited Speed with Door Monitoring, the drive performs Safe Limited Speed (SLS) monitoring functions as described in

Safe Limited Speed (SLS) Mode

functions as described in Safe Stop Mode

on page 71 in addition to the Safe Stop

on page 55.

In addition, the drive verifies through monitoring the Door Monitor input (DM_In) that the drive controlled by the Door Control output (DC_Out) is in the expected state. If the door is monitored as opened when it should be closed, the drive initiates the configured Stop Category.

The Door Monitor input (DM_In) is ON when the door is closed and OFF when the door is open. The DM_In input must be ON (door closed) whenever Safe Limited Speed monitoring is inactive (SLS_In is ON, meaning the circuit is closed). The DM_In input must also be ON (door closed) during a Safe Limited Speed Monitor Delay. A Door Monitor fault is a Stop Category fault that initiates the configured Stop Category.

Rockwell Automation Publication 2094-RM001C-EN-P - May 2013 75

Chapter 7 Safe Limited Speed (SLS) Modes

If Safe Limited Speed Monitoring is active (SLS_In input is OFF) and the drive has verified a safe speed condition, the door can be unlocked and opened.

ATTENTION: Make sure that an open door does not result in a hazardous situation.

You can monitor the door’s status with or without the door control (lock/ unlock) function. When door control logic is set to lock, it prevents personnel from entering the hazardous area when the machine is not at a safe speed or at Standstill Speed.

Safe Limited Speed Reset

When properly configured for Safe Limited Speed with Door Monitoring, the drive must be monitoring motion (SLS_In input is OFF) if the door is open (DM_In is OFF). Make sure the door is closed before requesting an SLS Reset.

A Safe Limited Speed Reset results in a Door Monitoring fault if the door is open (DM_In is OFF) when the reset is requested by a transition of the SLS_In input from OFF to ON. A Door Monitor fault is a Stop Category fault that initiates the configured Stop Category.

76 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

Safe Limited Speed (SLS) Modes Chapter 7

424152

GND

+24V DC

IOD Connector

27 28 27 28 27 28 27 28

TEST_OUT_0 TEST_OUT_1 TEST_OUT_0 TEST_OUT_1 TEST_OUT_0 TEST_OUT_1 TEST_OUT_0 TEST_OUT_1

SLS_OUT_CH0 SLS_OUT_CH1

DM_IN_CH0 DM_IN_CH1 LM_IN_CH0

LM_IN_CH1 DC_OUT_CH0 DC_OUT_CH1 ESM_IN_CH0 ESM_IN_CH1

29 30 31 32 33 34 35 36 37 38

IOD Connector

TEST_OUT_1 TEST_OUT_0

RESET_IN

RESET_REF

28 27 26 25 24 23 22 21 20 19 18 17

SLS_IN_CH1

SLS_IN_CH0 SS_OUT_CH1 SS_OUT_CH0

SS_IN_CH1 SS_IN_CH0

SCOM SPWR

Kinetix 6200 and Kinetix 6500 Control Module Safety Connections IOD (44-pin) Connector

SLS

Request

Reset

Safe Stop to Next Axis (option al)

Remove (2) Internal Jumpers

TLS3 GD2 440G-T27260 Safety Switch

(1)

SLS with Door Monitoring Parameter List

To configure the drive for Safe Limited Speed with Door Monitoring, set the DM Input parameter in addition to the Safe Stop parameters listed on page 66 and the Safe Limited Speed parameters listed on page 74

Table 23 - SLS with Door Monitoring Parameters

Tab Parameter Name Description

Safety Change System

Configurat ion

Input Change Input

Configuration Type

(1) You must configure this parameter with a non-zero value in this mode.

SLS with Door Monitoring Wiring Example

Operation Mode Defines the primary operating mode of the speed

monitoring safety functions.

Door Monitor Configuration for the Door Monitor input (DM_In). Default: Not Used

This example illustrates wiring for SLS with door monitoring.

Figure 21 - Master, Safe Limited Speed with Door Monitoring (First or Single Unit)

Value s

(Safety Configuration Tool)

Setting: SafeStop-Safe Limited Speed with Door Monitoring

(1)

Options: Not Used

Dual Channel Equivalent Dual Channel Equivalent 3 s Dual Channel Complementary Dual Channel Complementary 3 s Solid State Device Equivalent 3 s Single Channel

(1) Lock monitoring connections are not required for Safe Limited Speed with Door Monitoring mode operation.

Rockwell Automation Publication 2094-RM001C-EN-P - May 2013 77

Chapter 7 Safe Limited Speed (SLS) Modes

IMPORTANT

Safe Limited Speed with Enabling Switch Monitoring Mode

When properly configured for Safe Limited Speed with Enabling Switch Monitoring, the drive performs Safe Limited Speed (SLS) monitoring functions as described in Safe Limited Speed (SLS) Mode Safe Stop functions as described in Safe Stop Mode

In addition, the drive monitors the Enabling Switch Monitor input (ESM_In) after the Safe Limited Speed Monitoring Delay times out. Once the enabling switch is activated, the ESM_In input must remain ON while Safe Limited Speed monitoring is active or an ESM Monitoring fault occurs. An ESM Monitoring fault is a Stop Category fault that initiates the configured Stop Category.

When Safe Limited Speed Monitoring is inactive, the ESM_In input is not monitored.

on page 71 in addition to the

on page 55.

Safe Stop Reset (SS Reset) and Safe Limited Speed Reset (SLS Reset)

If an ESM Monitoring Fault occurs due to the ESM_In input turning OFF (enabling switch is released), the drive can be reset without cycling the SS_In input. To perform an SLS Reset, first return the ESM_In input to ON (grip the enabling switch in the middle position). Then, press and release the reset button. In this case, only the SS_In input does not need to be cycled to reset the drive following a fault.

While Safe Limited Speed is being monitored after the [Safe Limited Speed Monitor Delay] times out, if the SLS_In input is ON and an SLS Reset occurs, the ESM_In is not monitored.

ATTENTION: Make sure that the SLS_In input cannot transition to ON while someone is in the hazard area.

Use appropriate procedures when selecting safe limited speed to prevent other users from changing the mode while personnel are in the machine area.

If you attempt an SS Reset when the SLS_In input is OFF and the ESM_In input is OFF, an ESM Monitoring fault occurs. An ESM Monitoring fault is a Stop Category fault that initiates the configured Stop Category.

78 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

Safe Limited Speed (SLS) Modes Chapter 7

Kinetix 6200 and Kinetix 6500 Control Module

Safety Connections

IOD (44-pin) Connector

SLS

Request

Reset

Safe Stop to Next Axis (option al)

Remove (2) Internal Jumpers

440J-N21TNPM Enabling Switch

TLS3 GD2 440G-T27260 Safety Switch

SLS with Enabling Switch Monitoring Parameter List

To configure the drive for Safe Limited Speed with Enabling Switch Monitoring, set the [Enabling Switch Monitor] parameter in addition to the Safe Stop parameters listed on page 66

page 74

Table 24 - SLS with Enabling Switch Monitoring Parameters

Tab Parameter Name Description

Safety Change System

Configurat ion

Input Change Input

Configuration Type

(1) You must configure this parameter with a non-zero value in this mode.

SLS with Enabling Switch Monitoring Wiring Example

Operation Mode Defines the primary operating mode of the speed

Enabling Switch Monitor

monitoring safety functions.

Configuration for the Enabling Switch input (ESM_In). Default: Not Used

This example illustrates wiring for SLS with enabling switch monitoring.

Figure 22 - Master, Safe Limited Speed with Enabling Switch Monitoring (First or Single Unit)

and the Safe Limited Speed parameters listed on

Value s

(Safety Configuration Tool)

Setting: SafeStop-Safe Limited Speed with Enabling Switch Control

(1)

Options: Not Used

Dual Channel Equivalent Dual Channel Equivalent 3 s Dual Channel Complementary Dual Channel Complementary 3 s Solid State Device Equivalent 3 s Single Channel

424152

IOD Connector

TEST_OUT_0

TEST_OUT_1

TEST_OUT_0

TEST_OUT_1

TEST_OUT_0

27 28 27 28

29 30 31 32 33 34 35 36 37 38

TEST_OUT_1 TEST_OUT_0 TEST_OUT_1

SLS_OUT_CH0 SLS_OUT_CH1

DM_IN_CH0 DM_IN_CH1

LM_IN_CH0

LM_IN_CH1 DC_OUT_CH0 DC_OUT_CH1

ESM_IN_CH0 ESM_IN_CH1

(1)

27 28 27 28 27 28 27 28

29 30 31 32 33 34 35 36 37 38

IOD Connector

28 27 26 25 24 23 22 21 20 19 18 17

TEST_OUT_1 TEST_OUT_0

RESET_IN

RESET_REF SLS_IN_CH1 SLS_IN_CH0

SS_OUT_CH1 SS_OUT_CH0

SS_IN_CH1

SS_IN_CH0

SCOM SPWR

28 27 26 25 24 23 22 21 20 19 18 17

GND

+24V DC

(1) Lock monitoring connections are not required for Safe Limited Speed with Enabling Switch Monitoring mode operation.

Rockwell Automation Publication 2094-RM001C-EN-P - May 2013 79

Chapter 7 Safe Limited Speed (SLS) Modes

Safe Limited Speed with Door Monitoring and Enabling Switch Monitoring Mode

When properly configured for Safe Limited Speed with Door Monitoring and Enabling Switch Monitoring, the drive performs Safe Limited Speed (SLS) monitoring functions as described on page 71 functions as described in Safe Stop Mode

The drive also monitors both the Enabling Switch Monitor input (ESM_In) and the Door Monitor input (DM_In). This mode lets you access the hazardous area when the machine is under a Safe Limited Speed condition. The following is a typical procedure for accessing the hazardous area by using this mode.

1. Set the SLS_In input to OFF.

The Safe Speed Limit must not be exceeded after the [Safe Limited Speed Monitor Delay], if configured, times out.

2. After the Safe Limited Speed Monitoring Delay has timed out, hold the enabling switch in the middle position

Once a safe speed is detected and the enabling switch is in the middle position, the drive unlocks the door.

3. Continue to hold the enabling switch while you open the door, enter the hazard area, and perform the required maintenance.

, in addition to the Safe Stop

on page 55.

Follow these steps to remove the safe speed condition and resume normal run operation.

1. Leave the hazard area while holding the enabling switch.

2. Hold the enabling switch until the door is closed and you have disabled the

SLS_In input by setting it to the ON or closed position.

3. Press the reset button, if manual reset is configured.

4. Release the enabling switch.

The machine resumes normal run operation.

ATTENTION: Make sure that the SLS_In input cannot transition to ON while someone is in the hazard area.

Use appropriate procedures when selecting safe limited speed to prevent other users from changing the mode while personnel are in the machine area.

80 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

Safe Limited Speed (SLS) Modes Chapter 7

Behavior During SLS Monitoring

When Safe Limited Speed monitoring is active, door control logic is set to Unlock if the ESM_In input is ON and the speed is detected at below the Safe Speed Limit.

If the ESM_In input is ON, the door can be opened (DM_In transitions from ON to OFF). However, if the ESM_In input transitions to OFF after the door has been opened, an ESM Monitoring fault occurs. An ESM Monitoring fault is a Stop Category fault that initiates the configured [Stop Category].

If the DM_In input transitions from ON to OFF (door is opened), while the ESM_In input is OFF, a Door Monitoring fault occurs. A Door Monitoring fault is a Stop Category fault that initiates the configured [Stop Category].

ATTENTION: While Safe Limited Speed Monitoring is active, the ESM_In input is not monitored until the DM_In input is detected as OFF.

Make sure that the ESM_In input is not relied upon for safety until the DM_In input has transitioned to OFF.

After the DM_In input turns OFF, it could turn back ON again if the door is closed behind the operator but the ESM_In input is still monitored.

Behavior While SLS Monitoring is Inactive

If Safe Limited Speed monitoring is inactive, the DM_In input must be ON (door closed) or a Door Monitoring fault occurs and the drive initiates the configured [Stop Category]. The ESM_In input can be ON or OFF.

Behavior During SLS Monitoring Delay

The status of the ESM_In input does not affect the operation of the system during a [Safe Limited Speed Monitor Delay]. However, the DM_In input must be ON (door closed) during the delay or a Door Monitoring fault occurs and the drive initiates the configured [Stop Category].

Rockwell Automation Publication 2094-RM001C-EN-P - May 2013 81

Chapter 7 Safe Limited Speed (SLS) Modes

Safe Stop Reset (SS Reset) and Safe Limited Speed Reset (SLS Reset)

The door must be closed when an SS Reset or SLS Reset is requested. An SS Reset results in a Door Monitoring fault if the door is open when the reset is requested by a transition of the SS_In input from OFF to ON. An SLS Reset also results in a Door Monitoring fault if the door is open when the reset is requested by a transition of the SLS_In input from OFF to ON. A Door Monitor fault is a Stop Category fault that initiates the configured [Stop Category].

If an SS Reset is attempted while the SLS_In input is OFF, an ESM Monitoring fault occurs. An ESM Monitoring fault is a Stop Category fault that initiates the configured [Stop Category].

SLS with Door Monitoring and Enabling Switch Monitoring Parameter List

Tab Parameter Name Description

Safety Change System

Configurat ion

Input Change Input

Configuration Type

Operation Mode Defines the primary operating mode of the speed

Door Monitor Configuration for the Door Monitor input (DM_In). Default: Not Used

Enabling Switch Monitor

monitoring safety functions.

Configuration for the Enabling Switch input (ESM_In). Default: Not Used

To configure the drive for Safe Limited Speed with Door Monitoring and Enabling Switch Monitoring, set the [Door Monitor] and [Enable Switch Monitor] parameters in addition to the Safe Stop parameters listed on page 66 and the Safe Limited Speed parameters listed on page 74

Table 25 - SLS with Door Monitoring and Enabling Switch Monitoring Parameters

Value s

(Safety Configuration Tool)

Setting: SafeSto p-Safe Limited Speed with Door Monitor and

Enabling Switch

(1)

Options: Not Used

Dual Channel Equivalent Dual Channel Equivalent 3 s Dual Channel Complementary Dual Channel Complementary 3 s Solid State Device Equivalent 3 s Single Channel

(1)

Options: Not Used

Dual Channel Equivalent Dual Channel Equivalent 3 s Dual Channel Complementary Dual Channel Complementary 3 s Solid State Device Equivalent 3 s Single Channel

(1) You must configure this parameter with a non-zero value in this mode.

82 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

Safe Limited Speed (SLS) Modes Chapter 7

424152

GND

+24V DC

IOD Connector

27 28 27 28 27 28 27 28

TEST_OUT_0 TEST_OUT_1 TEST_OUT_0 TEST_OUT_1 TEST_OUT_0 TEST_OUT_1 TEST_OUT_0 TEST_OUT_1

SLS_OUT_CH0 SLS_OUT_CH1

DM_IN_CH0 DM_IN_CH1 LM_IN_CH0

LM_IN_CH1 DC_OUT_CH0 DC_OUT_CH1 ESM_IN_CH0 ESM_IN_CH1

29 30 31 32 33 34 35 36 37 38

IOD Connector

TEST_OUT_1 TEST_OUT_0

RESET_IN

RESET_REF

28 27 26 25 24 23 22 21 20 19 18 17

SLS_IN_CH1

SLS_IN_CH0 SS_OUT_CH1 SS_OUT_CH0

SS_IN_CH1 SS_IN_CH0

SCOM SPWR

(1)

Kinetix 6200 and Kinetix 6500 Control Module

Safety Connections

IOD (44-pin) Connector

SLS

Request

Reset

Safe Stop to Next Axis (option al)

Remove (2) Internal Jumpers

440J-N21TNPM

Enabling Switch

TLS3 GD2 440G-T27260 Safety Switch

SLS with Door Monitoring and Enabling Switch Monitoring Wiring Example

This example illustrates wiring for SLS with door monitoring and enabling switch monitoring.

Figure 23 - Master, Safe Limited Speed with Door Monitoring and Enabling Switch Monitoring (First or Single Unit)

(1) Lock monitoring connections are not required for Safe Limited Speed with Door Monitoring and Enabling Switch Monitoring mode operation.

Rockwell Automation Publication 2094-RM001C-EN-P - May 2013 83

Chapter 7 Safe Limited Speed (SLS) Modes

TIP

Low Threshol d

(1)

SLS_In

SLS_Out

SLS

Request

Safe Speed

Limit

Speed

Time

SLS Monitoring Delay

Safe Limited Speed

Active

SLS Request

Removed

(1) Low Threshold = (Speed Hysteresis/100) x Safe Speed Limit

Safe Limited Speed Status Only Mode

When properly configured for Safe Limited Speed Status Only, the drive provides Safe Limited Speed status information in addition to the Safe Stop functions as described in Safe Stop Mode

on page 55.

When the Safe Limited Speed input (SLS_In) is OFF, the feedback velocity is monitored and compared against a configurable Safe Speed Limit. If the measured velocity exceeds the limit, no stopping action takes place. Instead, the system status is made available as a safe output intended for a safety programmable logic controller (PLC). You can program an optional [Safe Limited Speed Monitor Delay] to delay the start of Safe Limited Speed monitoring.

In Safe Limited Speed Status Only mode, Door Monitoring and Enabling Switch Monitoring are not available.

ATTENTION: When the drive is properly configured for Safe Limited Speed Status Only mode, it does not automatically initiate a Safe Stop in the event of an overspeed condition.

Safe Limited Speed monitoring is requested by a transition of the SLS_In input from ON to OFF. If you configure a [Safe Limited Speed Monitor Delay], the delay begins when Safe Limited Speed monitoring is requested by the SLS_In input transition from ON to OFF. The drive begins monitoring for Safe Limited Speed when the delay times out. The SLS_Out output is ON if Safe Limited Speed monitoring is active and the speed is below the configured Safe Speed Limit, considering hysteresis.

Figure 24 - Timing Diagram for Safe Limited Speed Status Only

84 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

Safe Limited Speed (SLS) Modes Chapter 7

Speed Hysteresis

The [Safe Limited Speed Hysteresis] parameter provides hysteresis for the SLS_Out output when the drive is configured for SLS Status Only and Safe Limited Speed monitoring is active. The SLS_Out output is turned ON if the speed is less than the Low Threshold [(Speed Hysteresis/100) x Safe Speed Limit]. The SLS_Out output is turned OFF when the speed is greater than or equal to the configured [Safe Speed Limit].

The SLS_Out output remains OFF if Safe Limited Speed monitoring begins when the detected speed is less than the configured Safe Speed Limit but greater than or equal to the Low Threshold [(Speed Hysteresis/100) x Safe Speed Limit].

The SLS_Out output is held in its last state when the speed is less than the configured Safe Speed Limit and the speed is greater than or equal to the Low Threshold [(Speed Hysteresis/100) x Safe Speed Limit].

SLS Status Only Parameter List

Tab Parameter Name Description

Safety Change System

Configurat ion

Input Change Input

Configuration Type

Safe Limited Speed Change Safe Limited

Speed Configuration

Operation Mode Defines the primary operating mode of the speed

Safe Limited Speed Configuration for the Safe Limited Speed input

Safe Limited Speed Monitor Delay

Safe Speed Limit Defines the speed limit that is monitored in Safe Limited

Safe Limited Speed Hysteresis

monitoring safety functions.

(SLS_In).

Defines the Safe Limited Speed Monitoring Delay between the SLS_In ON to OFF transition and the initiation of the Safe Limited Speed (SLS) monitoring.

Speed (SLS) mode.

Provides hysteresis for SLS_Out output when Safe Limited Speed monitoring is active.

To configure the drive for Safe Limited Speed Status Only monitoring, set these parameters in addition to the Safe Stop parameters listed on page 66

Table 26 - SLS Status Only Parameters

Value s

(Safety Configuration Tool)

Setting: SafeStop-Safe Limited Speed Status Only

Default: Not Used

Options: Not Used

Default: 0

Range: 0…6553.5 s

Default: 0

Range: 0…65,535 rpm or mm/s

Default: 0

Range: 10…100% when [Operation Mode] =

(1)

Dual Channel Equivalent Dual Channel Equivalent 3 s Dual Channel Complementary Dual Channel Complementary 3 s Solid State Device Equivalent 3 s Single Channel

ratio based on revolutions or millimeters configuration defined by the [Primary Feedback Units] parameter

SafeStop-SafeLimitedSpeedStatusOnly

(1) You must configure this parameter with a non-zero value in this mode.

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Chapter 7 Safe Limited Speed (SLS) Modes

GND

+24V DC

IOD Connector

27 28 27 28 27 28 27 28

TEST_OUT_0 TEST_OUT_1 TEST_OUT_0 TEST_OUT_1 TEST_OUT_0 TEST_OUT_1 TEST_OUT_0 TEST_OUT_1

SLS_OUT_CH0 SLS_OUT_CH1

DM_IN_CH0 DM_IN_CH1

LM_IN_CH0

LM_IN_CH1 DC_OUT_CH0 DC_OUT_CH1 ESM_IN_CH0 ESM_IN_CH1

29 30 31 32 33 34 35 36 37 38

IOD Connector

TEST_OUT_1 TEST_OUT_0

RESET_IN

RESET_REF

28 27 26 25 24 23 22 21 20 19 18 17

SLS_IN_CH1

SLS_IN_CH0 SS_OUT_CH1 SS_OUT_CH0

SS_IN_CH1 SS_IN_CH0

SCOM SPWR

In 7

In 6

In 5

In 4

In 3

In 2

In 1

In 0

Out 0

Out 1

Out 2

Out 3

Out 4

Out 5

Out 6

Out 7

1791DS-IB8XOB8

GND

SLS

Request

Reset

Kinetix 6200 and Kinetix 6500 Control Module Safety Connections IOD (44-pin) Connector

SLS Status Only Wiring Examples

These examples illustrate wiring for SLS status only operation.

Figure 25 - Master, Safe Limited Speed Status Only (Single Unit)

86 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

GND

+24V DC

IOD Connector

27 28 27 28 27 28 27 28

TEST_OUT_0 TEST_OUT_1 TEST_OUT_0 TEST_OUT_1 TEST_OUT_0 TEST_OUT_1 TEST_OUT_0 TEST_OUT_1

In 7 In 6 In 5 In 4 In 3 In 2 In 1 In 0

V0 V1

G0 G1

Out 0 Out 1 Out 2 Out 3 Out 4 Out 5 Out 6 Out 7

1791DS-IB8XOB8

GND

SLS_OUT_CH0 SLS_OUT_CH1

DM_IN_CH0 DM_IN_CH1 LM_IN_CH0

LM_IN_CH1 DC_OUT_CH0 DC_OUT_CH1 ESM_IN_CH0 ESM_IN_CH1

29 30 31 32 33 34 35 36 37 38

IOD Connector

TEST_OUT_1 TEST_OUT_0

RESET_IN

RST_REF

28 27 26 25 24 23 22 21 20 19 18 17

SLS_IN_CH1

SLS_IN_CH0

SS_OUT_CH1 SS_OUT_CH0

SS_IN_CH1 SS_IN_CH0

SCOM

SPWR

IOD Connector

TEST_OUT_1 TEST_OUT_0

RESET_IN

RESET_REF

28 27 26 25 24 23 22 21 20 19 18 17

SLS_IN_CH1

SLS_IN_CH0 SS_OUT_CH1 SS_OUT_CH0

SS_IN_CH1 SS_IN_CH0

SCOM SPWR

First Axis

Safety Option Terminals

SLS

Request

Reset

Next Downstream Axis

Safety Option Terminals

Kinetix 6200 and Kinetix 6500 Control Module Safety Connections IOD (44-pin) Connector

Figure 26 - Master, Safe Limited Speed Status Only (First Unit)

Safe Limited Speed (SLS) Modes Chapter 7

Rockwell Automation Publication 2094-RM001C-EN-P - May 2013 87

Chapter 7 Safe Limited Speed (SLS) Modes

Reset

Kinetix 6200 and Kinetix 6500

Control Module

Safety Connections

IOD (44-pin) Connector

This example assumes that a programmable safety controller is monitoring all drive functions and controlling the drive. The SS_In and SLS_In inputs are connected to the I/O module; however, standard safety component inputs could also be used.

These functions are not performed by the drive in this scenario:

• Guardlocking switch inputs

• Door locking

• Door status (open or closed)

• Enabling switch

Figure 27 - Safe Limited Speed Status Only with Programmable Controller Monitoring

In 7

In 6

In 5

In 4

IOD Connector

TEST_OUT_0

TEST_OUT_1

TEST_OUT_0

TEST_OUT_1

TEST_OUT_0

TEST_OUT_1

28 27 28

SLS_OUT_CH0

SLS_OUT_CH1

30 31 32 33 34

DC_OUT_CH0

DC_OUT_CH1

ESM_IN_CH0

ESM_IN_CH1

TEST_OUT_0 TEST_OUT_1

DM_IN_CH0 DM_IN_CH1 LM_IN_CH0 LM_IN_CH1

In 3

27 28 27 28 27 28 27 28

29 30 31 32 33 34 35 36 37 38

GND

+24V DC

28 27 26 25 24 23 22 21 20 19 18 17

IOD Connector

TEST_OUT_1 TEST_OUT_0

RESET_IN

RESET_REF SLS_IN_CH1 SLS_IN_CH0

SS_OUT_CH1 SS_OUT_CH0

SS_IN_CH1

SS_IN_CH0

SCOM SPWR

28 27 26 25 24 23 22 21 20 19 18 17

In 2

In 1

In 0

1791DS-IB8XOB8

Out 0

Out 1

Out 2

Out 3

Out 4

Out 5

Out 6

Out 7

GND

88 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

Chapter 8

Slave Modes for Multi-axis Cascaded Systems

This chapter describes the slave modes of safety operation and wiring examples of cascaded multi-axis configurations.

Top ic Pag e

Cascaded Configurations 89

Slave, Safe Stop Mode 91

Slave, Safe Stop Parameter List 91

Slave, Safe Stop Wiring Examples 93

Slave, Safe Limited Speed Mode 96

Slave, Safe Limited Speed Parameters 96

Slave, Safe Limited Speed Wiring Examples 97

Slave, Safe Limited Speed Status Only Mode 99

Slave, Safe Limited Speed Status Only Parameter List 99

Slave, Safe Limited Speed Status Only Wiring Examples 100

Multi-axis Connections 101

Cascaded Configurations

Use the [System Configuration] parameter to define the drive’s position in the system as Single Unit, Cascaded First Unit, Cascaded Middle Unit, or Cascaded Last Unit. Only the middle or last drive in a multi-axis system can be configured for slave modes.

For cascaded drives, connect the safety switches to the safety inputs (SS_In, SLS_In, DM_In, ESM_In, and LM_In) of only the first (master) axis. Each feedback for Safe Stop functions are connected to their respective axis. The inputs are cascaded from one drive to the next by connecting the outputs from the previous drive to the inputs of the next drive.

Rockwell Automation Publication 2094-RM001C-EN-P - May 2013 89

Chapter 8 Slave Modes for Multi-axis Cascaded Systems

SLS_OUT_CH1 IOD-30 SLS_OUT_CH0 IOD-29

SS_OUT_CH1 IOD-22 SS_OUT_CH0 IOD-21

SLS_OUT_CH1 IOD-30 SLS_OUT_CH0 IOD-29

SS_OUT_CH1 IOD-22 SS_OUT_CH0 IOD-21

SLS_OUT_CH1 IOD-30 SLS_OUT_CH0 IOD-29

SS_OUT_CH1 IOD-22 SS_OUT_CH0 IOD-21

IOD-20 SS_IN_CH1 IOD-19 SS_IN_CH0

IOD-24 SLS_IN_CH1 IOD-23 SLS_IN_CH0

IOD-38 ESM_IN_CH1 IOD-37 ESM_IN_CH0

IOD-28 TEST_OUT_CH1 IOD-27 TEST_OUT_CH0

IOD-32 DM_IN_CH1 IOD-31 DM_IN_CH0

DM_OUT_CH1 IOD-36 DM_OUT_CH0 IOD-35

IOD-34 LM_IN_CH1 IOD-33 LM_IN_CH0

IOD-25 RESET_REF

IOD-26 RESET_IN IOD-26 RESET_IN

IOD-26 RESET_IN

IOD-18

IOD-17 IOD-17

IOD-17

Safe Stop Input

Safe Limited Speed Input

Enabling Switch Monitor Input

Manual Reset

First Axis

Feedba ck

Second Axis

Feedba ck

Third Axis Feedback

Middle Axis

(Slave)

Axis 2

First Axis (Master)

Axis 1

To D oo r Control Solenoid

(3)

Auto Reset

(1)

Last Axis

(Slave)

Axis 3

Lock Monitor Input

(2)

Door Monitor Input

TLS3-GD2

440G-T27260

Power to Release

24V DC Common

24V DC

(1) Automatic reset is selected for middle and last cascaded units if a single reset input to the master unit is used. A single reset by the first unit resets all following units in the cascaded system. If a

fault occurs after the first axis in the cascaded chain, only the subsequent axes enter the safe state. Reset is accomplished either manual or manual monitored by applying IOD-25 RESET_Ref to

IOD-26 RESET_In. To reset all axes, you must c ycle the SS_Input on the first axis. (2) The Enabling Switch Monitor Input and Lock Monitor Input are connected to only the master axis. (3) The Cascaded Last Unit DC output is conected to the door control solenoid to indicate that the door monitor output is terminated and encompasses the master, middle, and last units in the chain.

Auto Reset

(1)

IMPORTANT

Figure 28 - Cascaded Connections

The inputs from the safety switches are monitored by the first (master) drive. A Safe Limited Speed Reset detected by the first drive is cascaded to the subsequent drives via the SLS_Out to SLS_In chain. Although all units can be configured for any reset type, we recommend using automatic reset in all slave units to follow the master units reset type.

90 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

Any fault or transition of the SS_In input to OFF is detected by the first drive and initiates the configured [Stop Category] to all of the drives via the SS_Out to SS_In chain.

Any fault in a slave drive initiates the configured [Stop Category] only to that drive and to slave drives further down the chain.

Safe Stop monitoring is not initiated for non-faulted units earlier in the cascaded chain.

The safety reaction time for a cascaded system includes the sum of the reaction times of each drive in the chain.

Slave Modes for Multi-axis Cascaded Systems Chapter 8

Slave, Safe Stop Mode

Slave, Safe Stop Parameter List

Table 27 - Slave, Safe Stop Parameters

Tab Parameter Name Description

Safety Change System

Configurat ion

Input Change Input

Configuration Type

System Configuration Defines whether the drive is a single unit or if it occupies

a first, middle, or last position in a multi-axis cascaded system.

Operation Mode Defines the primary operating mode of the speed

monitoring safety functions.

Safe Stop Configuration for Safe Stop input (SS_In). Option: Solid State Device Equivalent 3 s

When properly configured for Slave, Safe Stop mode, the drive performs the same functions as Safe Stop except that the drive regards the Door Monitor input as a Door Control output from an upstream axis, and performs a logical AND with its internal Door Control signal to form the cascaded Door Control output. This makes sure that the Door Control output commands the door to unlock only if all units command the door to unlock.

To configure the drive for a Slave, Safe Stop mode, set these parameters. See

Multi-axis Connections

on page 101 for details on configuring slave drives.

Value s

(Safety Configuration Tool)

Options: Cascaded Middle Unit

Cascaded Last Unit

Default: SafeStop

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Chapter 8 Slave Modes for Multi-axis Cascaded Systems

Table 27 - Slave, Safe Stop Parameters (continued)

Tab Parameter Name Description

Safe Stop Change Safe Stop

Configurat ion

Safety

Change System Configurat ion

Input

Stop Category Safe operating stop type selec tion. This defines the type

Safe Stop Monitor Delay

Deceleration Reference Speed

Maximum Stop Time Defines the maximum stop delay time that is used when

Deceleration Tol e ra nc e

Standstill Speed De fines the speed limit that is used to declare motion as

Standstill Position Wind ow

Door Control Output Defines the lock and unlock state for door control output

Door Monitor Configuration for the Door Monitor input (DM_In). Option: Solid State Device Equivalent 3 s

of Safe Stop that is performed if the Safe Stop function is initiated by a stop type condition.

Enable Standstill Checking Automatically enabled for Safe Stop 1 and Safe Stop 2.

Defines the monitoring delay between the request and the Maximum Stop Time when the request for a Safe Stop 1 or a Safe Stop 2 is initiated by an SS_In input ON to OFF transitio n.

If the Stop Category is Safe Torque-Off with or without Standstill Speed Checking, the Safe Stop Monitor Delay must be 0 or an Invalid Configuration fault occurs.

Determines deceleration rate to monitor for Safe Stop 1 or Safe Stop 2.

the Safe Stop function is initiated by a stop type condition.

This is the acceptable tolerance above the deceleration rate set by the [Deceleration Reference Speed] parameter.

stopped. Not valid for Safe Torque-Off without Standstill

Checking.

Defines the position limit window in encoder 1 degrees or mm that is tolerated after a safe stop condition has been detected.

Not valid for Safe Torque-Off without Standstill Checking.

(DC_Out). Any Door Control Output option can be used for a

single-axis system or for the last unit in a multi-axis system. The first and middle units of a multi-axis system must be configured as 2 Channel Sourcing.

Value s

(Safety Configuration Tool)

Default: Safe Torque-Off

Options: Safe Torque-Off

Safe Stop 1 Safe Stop 2

Default: Standstill Checking Enabled

Options: Standstill Checking Enabled

Standstill Checking Not Enabled

Default: 0

Range: 0…6553.5 s

Default: 0

Range: 0…65,535 rpm or mm/s

ratio based on revolutions or millimeters configuration defined by the [Primary Feedback Units] parameter

Default: 0

Range: 0…6553.5 s

Default: 0

Range: 0…100% of Deceleration Reference Speed

Default: 0.001

Range: 0.001…65.535 rpm or mm/s

ratio based on revolutions or millimeters configuration defined by the [Primary Feedback Units] parameter

Default: 10

Range: 0…65,535 degrees (360° = 1 revolution) or mm

ratio based on revolutions or millimeters configuration defined by the [Primary Feedback Units] parameter

Default: Power to Release

Options: Power to Release

Power to Lock 2 Channel Sourcing

Change Input Configuration Type

92 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

Slave Modes for Multi-axis Cascaded Systems Chapter 8

+24V DC

GND

SLS_OUT_CH0 SLS_OUT_CH1

DM_IN_CH0 DM_IN_CH1 LM_IN_CH0

LM_IN_CH1 DC_OUT_CH0 DC_OUT_CH1 ESM_IN_CH0 ESM_IN_CH1

29 30 31 32 33 34 35 36 37 38

IOD Connector

TEST_OUT_1 TEST_OUT_0

RESET_IN

RESET_REF

28 27 26 25 24 23 22 21 20 19 18 17

SLS_IN_CH1

SLS_IN_CH0

SS_OUT_CH1 SS_OUT_CH0

SS_IN_CH1 SS_IN_CH0

SCOM SPWR

SLS_OUT_CH0 SLS_OUT_CH1

DM_IN_CH0 DM_IN_CH1

LM_IN_CH0

LM_IN_CH1 DC_OUT_CH0 DC_OUT_CH1 ESM_IN_CH0 ESM_IN_CH1

29 30 31 32 33 34 35 36 37 38

IOD Connector

TEST_OUT_1 TEST_OUT_0

RESET_IN

RESET_REF

28 27 26 25 24 23 22 21 20 19 18 17

SLS_IN_CH1

SLS_IN_CH0

SS_OUT_CH1 SS_OUT_CH0

SS_IN_CH1 SS_IN_CH0

SCOM

SPWR

SLS_OUT_CH0 SLS_OUT_CH1

DM_IN_CH0 DM_IN_CH1

LM_IN_CH0

LM_IN_CH1 DC_OUT_CH0 DC_OUT_CH1

ESM_IN_CH0 ESM_IN_CH1

29 30 31 32 33 34 35 36 37 38

IOD Connector

TEST_OUT_1 TEST_OUT_0

RESET_IN

RESET_REF

28 27 26 25 24 23 22 21 20 19 18 17

SLS_IN_CH1

SLS_IN_CH0

SS_OUT_CH1 SS_OUT_CH0

SS_IN_CH1 SS_IN_CH0

SCOM SPWR

Previous Upstream Axis

IOD Connector Terminals

Next Downstream Axis

IOD Connector Terminals

Middle Axis

IOD Connector Terminals

Slave, Safe Stop Wiring Examples

These examples show two different Slave, Safe Stop configurations.

The first example shows the drive configured as a cascaded middle unit via the [System Configuration] parameter. It has SS_In and DM_In input connections from the previous upstream drive, as well as SS_Out and DC_Out output connections to the next downstream drive. This unit is configured with automatic reset so it follows the function of the previous axis.

See Safe Stop with Door Monitoring Wiring Example

on page 69 for an example

of a first (master) unit.

Figure 29 - Slave, Safe Stop, Middle Unit

Rockwell Automation Publication 2094-RM001C-EN-P - May 2013 93

Chapter 8 Slave Modes for Multi-axis Cascaded Systems

+24V DC

GND

424152

IOD

27 28

IOD

34 33

IOD

32 31

SLS_OUT_CH0 SLS_OUT_CH1

DM_IN_CH0 DM_IN_CH1 LM_IN_CH0

LM_IN_CH1 DC_OUT_CH0 DC_OUT_CH1 ESM_IN_CH0 ESM_IN_CH1

29 30 31 32 33 34 35 36 37 38

IOD Connector

TEST_OUT_1 TEST_OUT_0

RESET_IN

RESET_REF

28 27 26 25 24 23 22 21 20 19 18 17

SLS_IN_CH1

SLS_IN_CH0 SS_OUT_CH1 SS_OUT_CH0

SS_IN_CH1 SS_IN_CH0

SCOM SPWR

SLS_OUT_CH0 SLS_OUT_CH1

DM_IN_CH0 DM_IN_CH1 LM_IN_CH0

LM_IN_CH1 DC_OUT_CH0 DC_OUT_CH1

ESM_IN_CH0 ESM_IN_CH1

29 30 31 32 33 34 35 36 37 38

IOD Connector

TEST_OUT_1 TEST_OUT_0

RESET_IN

RESET_REF

28 27 26 25 24 23 22 21 20 19 18 17

SLS_IN_CH1

SLS_IN_CH0 SS_OUT_CH1 SS_OUT_CH0

SS_IN_CH1 SS_IN_CH0

SCOM SPWR

Previous Upstream Axis

IOD Connector Terminals

Last Axis

IOD Connector Terminals

First Axis

IOD Connector Terminals

TLS3 GD2

440G-T27260

Safety Switch

This example shows the last cascaded slave drive in the system. It has SS_In and DM_In inputs from the previous upstream drive, but its DC_Out output is connected to a guardlocking interlock switch. This unit is configured with automatic reset so it follows the function of the previous axis.

Figure 30 - Slave, Safe Stop, Last Unit

94 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

Slave Modes for Multi-axis Cascaded Systems Chapter 8

IMPORTANT

424152

+24V DC

GND

SLS_OUT_CH0 SLS_OUT_CH1

DM_IN_CH0 DM_IN_CH1

LM_IN_CH0

LM_IN_CH1 DC_OUT_CH0 DC_OUT_CH1

ESM_IN_CH0 ESM_IN_CH1

29 30 31 32 33 34 35 36 37 38

IOD Connector

TEST_OUT_1 TEST_OUT_0

RESET_IN

RESET_REF

28 27 26 25 24 23 22 21 20 19 18 17

SLS_IN_CH1

SLS_IN_CH0

SS_OUT_CH1 SS_OUT_CH0

SS_IN_CH1 SS_IN_CH0

SCOM SPWR

SLS_OUT_CH0 SLS_OUT_CH1

DM_IN_CH0 DM_IN_CH1 LM_IN_CH0

LM_IN_CH1 DC_OUT_CH0 DC_OUT_CH1 ESM_IN_CH0 ESM_IN_CH1

29 30 31 32 33 34 35 36 37 38

IOD Connector

TEST_OUT_1 TEST_OUT_0

RESET_IN

RESET_REF

28 27 26 25 24 23 22 21 20 19 18 17

SLS_IN_CH1

SLS_IN_CH0

SS_OUT_CH1 SS_OUT_CH0

SS_IN_CH1 SS_IN_CH0

SCOM

SPWR

SLS_OUT_CH0 SLS_OUT_CH1

DM_IN_CH0 DM_IN_CH1 LM_IN_CH0

LM_IN_CH1 DC_OUT_CH0 DC_OUT_CH1 ESM_IN_CH0 ESM_IN_CH1

29 30 31 32 33 34 35 36 37 38

IOD Connector

TEST_OUT_1 TEST_OUT_0

RESET_IN

RESET_REF

28 27 26 25 24 23 22 21 20 19 18 17

SLS_IN_CH1

SLS_IN_CH0

SS_OUT_CH1 SS_OUT_CH0

SS_IN_CH1 SS_IN_CH0

SCOM

SPWR

Middle Axis

Safety Option Terminals

Last Axis

Safety Option Terminals

First Axis

Safety Option Terminals

TLS3 GD2 440G-T27260 Safety Switch

This example shows three drives connected together in a cascaded system.

All drive modules must share a common ground.

Figure 31 - First, Middle, and Last Drives in a Cascaded System with Door Control and Lock Monitoring

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Chapter 8 Slave Modes for Multi-axis Cascaded Systems

TIP

Slave, Safe Limited Speed Mode

Slave, Safe Limited Speed Parameters

Tab Parameter Name Description

Safety Change System

Configurat ion

Input Change Input

Configuration Type

Safe Limited Speed Change Safe Limited

Speed Configuration

System Configuration Defines whether the drive is a single unit or if it occupies

Operation Mode Defines the primary operating mode of the speed

Safe Limited Speed Configuration for the Safe Limited Speed input

Safe Limited Speed Monitor Delay

Safe Speed Limit Defines the speed limit that is monitored in Safe Limited

a first, middle, or last position in a multi-axis cascaded system.

monitoring safety functions.

(SLS_In).

Defines the Safe Limited Speed Monitoring Delay between the SLS_In ON to OFF transition and the initiation of the Safe Limited Speed (SLS) monitoring.

Speed (SLS) mode.

When properly configured for Slave, Safe Limited Speed mode, the drive performs the same functions as Safe Limited Speed mode as described on

page 71

However, the drive regards the Door Monitor input as a Door Control output from an upstream axis, and performs a logical AND with its internal Door Control signal to form the cascaded Door Control output. Door Monitoring, Enabling Switch Monitoring, and Lock Monitoring functions are not allowed in this mode.

For the door to unlock, all axes must be below safe limited speed.

Only the middle and last drive in a multi-axis system can be configured for slave modes.

To configure the drive for Slave, Safe Limited Speed monitoring, set these parameters in addition to the Slave, Safe Stop parameters listed on page 91

Multi-axis Connections

on page 101 for details on configuring slave drives.

Value s

(Safety Configuration Tool)

Options: Cascaded Middle Unit

Default: SafeStop-Safe Limited Speed

Default: Solid State Device Equivalent 3 s

Default: 0

Range: 0…6553.5 s

Default: 0

Range: 0…65,535 rpm or mm/s

Cascaded Last Unit

(1)

ratio based on revolutions or millimeters configuration defined by the [Primary Feedback Units] parameter

. See

(1) You must configure this parameter with a non-zero value in this mode.

96 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

Slave Modes for Multi-axis Cascaded Systems Chapter 8

+24V DC

GND

SLS_OUT_CH0 SLS_OUT_CH1

DM_IN_CH0 DM_IN_CH1 LM_IN_CH0

LM_IN_CH1 DC_OUT_CH0 DC_OUT_CH1 ESM_IN_CH0 ESM_IN_CH1

29 30 31 32 33 34 35 36 37 38

IOD Connector

TEST_OUT_1 TEST_OUT_0

RESET_IN

RESET_REF

28 27 26 25 24 23 22 21 20 19 18 17

SLS_IN_CH1

SLS_IN_CH0

SS_OUT_CH1 SS_OUT_CH0

SS_IN_CH1 SS_IN_CH0

SCOM SPWR

SLS_OUT_CH0 SLS_OUT_CH1

DM_IN_CH0 DM_IN_CH1 LM_IN_CH0

LM_IN_CH1 DC_OUT_CH0 DC_OUT_CH1 ESM_IN_CH0 ESM_IN_CH1

29 30 31 32 33 34 35 36 37 38

IOD Connector

TEST_OUT_1 TEST_OUT_0

RESET_IN

RESET_REF

28 27 26 25 24 23 22 21 20 19 18 17

SLS_IN_CH1

SLS_IN_CH0

SS_OUT_CH1 SS_OUT_CH0

SS_IN_CH1 SS_IN_CH0

SCOM SPWR

SLS_OUT_CH0 SLS_OUT_CH1

DM_IN_CH0 DM_IN_CH1 LM_IN_CH0

LM_IN_CH1 DC_OUT_CH0 DC_OUT_CH1 ESM_IN_CH0 ESM_IN_CH1

29 30 31 32 33 34 35 36 37 38

IOD Connector

TEST_OUT_1 TEST_OUT_0

RESET_IN

RESET_REF

28 27 26 25 24 23 22 21 20 19 18 17

SLS_IN_CH1

SLS_IN_CH0

SS_OUT_CH1 SS_OUT_CH0

SS_IN_CH1 SS_IN_CH0

SCOM SPWR

Middle Axis

IOD Connector Terminals

Next Downstream Axis

IOD Connector Terminals

Previous Upstream Axis

IOD Connector Terminals

Slave, Safe Limited Speed Wiring Examples

These examples show two different Slave, Safe Limited Speed configurations.

The first example is configured as a cascaded middle unit via the [System Configuration] parameter. It has SS_In, SLS_In, and DM_In input connections from the previous upstream drive, as well as SS_Out, SLS_Out, and DC_Out output connections to the next downstream drive.

See SLS with Door Monitoring Wiring Example

on page 77 for an example of a

first (master) unit.

Figure 32 - Slave, Safe Limited Speed, Middle Unit

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Chapter 8 Slave Modes for Multi-axis Cascaded Systems

424152

IOD

27 28

IOD

34 33

IOD

32 31

+24V DC

GND

SLS_OUT_CH0 SLS_OUT_CH1

DM_IN_CH0 DM_IN_CH1 LM_IN_CH0

LM_IN_CH1 DC_OUT_CH0 DC_OUT_CH1 ESM_IN_CH0 ESM_IN_CH1

29 30 31 32 33 34 35 36 37 38

IOD Connector

TEST_OUT_1 TEST_OUT_0

RESET_IN

RESET_REF

28 27 26 25 24 23 22 21 20 19 18 17

SLS_IN_CH1

SLS_IN_CH0

SS_OUT_CH1 SS_OUT_CH0

SS_IN_CH1 SS_IN_CH0

SCOM SPWR

SLS_OUT_CH0 SLS_OUT_CH1

DM_IN_CH0 DM_IN_CH1

LM_IN_CH0

LM_IN_CH1 DC_OUT_CH0 DC_OUT_CH1

ESM_IN_CH0 ESM_IN_CH1

29 30 31 32 33 34 35 36 37 38

IOD Connector

TEST_OUT_1 TEST_OUT_0

RESET_IN

RESET_REF

28 27 26 25 24 23 22 21 20 19 18 17

SLS_IN_CH1

SLS_IN_CH0

SS_OUT_CH1 SS_OUT_CH0

SS_IN_CH1 SS_IN_CH0

SCOM

SPWR

Previous Upstream Axis

IOD Connector Terminals

Last Axis

IOD Connector Terminals

First Axis

IOD Connector Terminals

TLS3 GD2 440G-T27260 Safety Switch

This second example is configured as a cascaded last unit via the [System Configuration] parameter. It has SS_In, SLS_In, and DM_In input connections from the previous upstream drive, but its DC_Out output is connected to a guardlocking interlock switch.

Figure 33 - Slave, Safe Limited Speed, Last Unit

98 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

Slave Modes for Multi-axis Cascaded Systems Chapter 8

TIP

Slave, Safe Limited Speed Status Only Mode

Slave, Safe Limited Speed Status Only Parameter List

When properly configured for Slave, Safe Limited Speed Status Only mode, the Safe Speed Monitor Option module performs the same functions as Safe Limited Speed Status Only mode as described on page 84

. However, the drive regards the Door Monitor input as a Door Control output from an upstream axis, and performs a logical AND with its internal Door Control signal to form the cascaded Door Control output.

The SLS_Out output of the last drive in a cascaded chain goes high only when all axes are below the Safe Speed Limit. In Safe Limited Speed Status Only mode, each subsequent unit does not enable Safe Limited Speed until the previous unit has reached the Safe Speed Limit.

Door Monitoring and Enabling Switch Monitoring functions are not allowed in this mode.

Only the middle and last drive in a multi-axis system can be configured for slave modes.

To configure the drive for Slave, Safe Limited Speed Status Only monitoring, set these parameters in addition to the Slave, Safe Stop parameters listed on page 91 and the Slave, Safe Limited Speed parameters listed on page 96

. See Multi-axis

Connections on page 101 for details on configuring slave drives.

Tab Parameter Name Description

Safety Change System

Configurat ion

Safe Limited Speed Change Safe Limited

Speed Configuration

System Configuration Defines whether the drive is a single unit or if it occupies

Operation Mode Defines the primary operating mode of the speed

Safe Limited Speed Hysteresis

a first, middle, or last position in a multi-axis cascaded system.

monitoring safety functions.

Provides hysteresis for SLS_Out output when Safe Limited Speed monitoring is active.

Table 28 - Slave, Safe Limited Speed Status Only Parameters

Value s

(Safety Configuration Tool)

Options: Cascaded Middle Unit

Cascaded Last Unit

Option: S afeStop-Safe Limited Speed Status O nly

Default: 0

Range: 10…100% when [Operation Mode] =

SafeStop-SafeLimitedSpeedStatusOnly

Rockwell Automation Publication 2094-RM001C-EN-P - May 2013 99

Chapter 8 Slave Modes for Multi-axis Cascaded Systems

IMPORTANT

+24V DC

GND

SLS_OUT_CH0 SLS_OUT_CH1

DM_IN_CH0 DM_IN_CH1

LM_IN_CH0

LM_IN_CH1 DC_OUT_CH0 DC_OUT_CH1

ESM_IN_CH0 ESM_IN_CH1

29 30 31 32 33 34 35 36 37 38

IOD Connector

TEST_OUT_1 TEST_OUT_0

RESET_IN

RESET_REF

28 27 26 25 24 23 22 21 20 19 18 17

SLS_IN_CH1

SLS_IN_CH0 SS_OUT_CH1 SS_OUT_CH0

SS_IN_CH1 SS_IN_CH0

SCOM

SPWR

SLS_OUT_CH0 SLS_OUT_CH1

DM_IN_CH0 DM_IN_CH1 LM_IN_CH0

LM_IN_CH1 DC_OUT_CH0 DC_OUT_CH1

ESM_IN_CH0 ESM_IN_CH1

29 30 31 32 33 34 35 36 37 38

IOD Connector

TEST_OUT_1 TEST_OUT_0

RESET_IN

RESET_REF

28 27 26 25 24 23 22 21 20 19 18 17

SLS_IN_CH1

SLS_IN_CH0

SS_OUT_CH1 SS_OUT_CH0

SS_IN_CH1 SS_IN_CH0

SCOM SPWR

Previous Upstream Axis

IOD Connector Terminals

Next Downstream Axis

IOD Connector Terminals

Safe Stop to Next Axis

SLS to Next Axis

Slave, Safe Limited Speed Status Only Wiring Examples

These examples show two different Slave, Safe Limited Speed Status Only configurations.

The SLS_Out signals change state immediately based on the speed relative to the Safe Speed Limit if the Safe Limited Speed Monitoring Delay is set to zero.

See SLS Status Only Wiring Examples

starting on page 86 for an example of a

first (master) unit.

Figure 34 - Slave, Safe Limited Speed Status Only, Middle Drive

100 Rockwell Automation Publication 2094-RM001C-EN-P - May 2013

Rockwell Automation 2094-EN02D-M01-S1 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Important User Information

Summary of Changes

New and Updated Information

Table of Contents

Preface

About This Publication

Audience

Conventions

Terminology

Studio 5000 Environment

Additional Resources

Safety Certification

Important Safety Considerations

Safety Category 4 Performance Definition

Stop Category Definitions

Performance Level and Safety Integrity Level (SIL) CL3

European Union Directives

CE Conformity

EMC Directive

Functional Proof Tests

Low Voltage Directive

PFD and PFH Definitions

PFD and PFH Data

Safe State

Safety Reaction Time

Considerations for Safety Ratings

Considerations for Single-encoder Applications

Understanding Commutation

Safety Functions

Operation Modes

Disabled Mode

Lock Monitoring

Safe Maximum Speed, Safe Maximum Acceleration, and Safe Direction Monitoring

Hardware Features

General Safety Information

Power Supply Requirements

Wiring the Safety Connections

Terminal Connections

Compatible Encoders

Inputs

Safe Stop Input (SS_In)

Safe Limited Speed Input (SLS_In)

Door Monitor Input (DM_In)

Enabling Switch Monitor Input (ESM_In)

Lock Monitor Input (LM_In)

Reset Input (Reset_In)

Outputs

Safe Stop Output (SS_Out)

Safe Limited Speed Output (SLS_Out)

Door Control Output (DC_Out)

Cascaded Configuration

Operation Mode

Reset Type

Overspeed Response Time

Speed Resolution Accuracy for Rotary Systems

Speed Resolution Accuracy for Linear Systems

General Parameter List

Feedback Monitoring

Feedback Polarity

Single Encoder

Dual Encoders

Dual Feedback Speed Ratio

Dual Feedback Position Discrepancy Tolerance

Dual Feedback Speed Discrepancy Tolerance

Feedback Voltage Monitoring Range

Feedback Fault

Feedback Parameter List

Safe Stop Mode

Stop Categories

Safe Torque Off with Standstill Checking

Safe Stop 1 and 2

Safe Torque Off without Standstill Checking

Standstill Speed and Position Tolerance

Deceleration Monitoring

Safe Stop Reset

Automatic