Rockwell Automation 2094-EN02D-M01-S1 User Manual
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
12
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
Table of Contents
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:
2
• 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.
55
68
71
75
78
79
84
91
96
99
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
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
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
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
1
2
3
4
5
6
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
ON
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
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