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750-RM001 - Rockwell Automation

1. Previous Upstream Axis Last Axis Safety Option Terminals Safety Option Terminals 1 1 S11 511 TEST OUT 0 S11 TEST OUT 0 511 S11 511 521 521 TEST OUT 1 521 TEST OUT 1 521 521 21 TB2 TB2 RESET IN 534 RESET IN 534 52 52 DC OUT CHx DC OUT CHx 51 51 515 OUT CHx 8 515 OUT CHx 68 68 5 OUT M ss our 34 3 LM IN CHx i LM IN CHx AM X32 X32 DM_IN_CHx 2 DM_IN_CHx 2 532 32 S62 S62 5 5 IN CHx SLS IN CHx 52 52 582 582 ESM IN CH ESM IN CHx Sp LIN CHx SS CHx 2 SS_IN_CHx 2 uii 512 512 GND ine 24V 2 24 COM A2 as M ew Power to Release TLS3 GD2 4406 27260 First Axis Safety Option Terminals TBI TB2 511 521 X42 X32 Rockwell Automation Publication 750 February 2012 Slave Safe Limited Speed Status Only Mode Slave Safe Limited Speed Status Only Parameter List E HOST GROUPS Group General Limited Speed 21 56 Display Name Full Name Description Cascaded Config Cascaded Configuration Defines whether the speed monitoring safety option is a single unit or if it occupies a first middle or last position in a multi axis cascaded system Safety Mode Safety Mode Defines the primary operating mode ofthe speed monit
2. Example 2 Limited Speed Group Example 2 Door Control Group Settings Example 2 Max Speed se stad re Uo eod dax utes Example 2 Final Security Group Rockwell Automation Publication 750 February 2012 Troubleshooting the PowerFlex Safety Option Module Specifications Parameter Data Index Table of Contents Chapter 12 A irte ter 151 Status Indic eb utu DIM RUN derit a aU ESOS 151 INontecoverdble Faults 9 es ER 152 Fault Recovery esce eade e RI RE 152 Input and Output 5 poete reve tu eus 152 Fault Codes and Descriptions e Met Ett 152 155 Site State 155 Stop Category Faults and Fault While Stopping Faults 155 Status Attributes e panem pe o 156 Guard Status A ttr bUtes Corsi pre M tee rr PEE es 156 I O Diagnostic Status AttrIDutes eic epe ge 158 Configuration Fault Codes cce eee hie PRSE 159 Appendix A Introductio saxo 161 General Specifications ui Tcl eee ee Et eig 161 Environmental Specifications cocos eov Lecta ro ex mU 162 Certificatios i o ceca php Es UE DE e 163 CE Conformity sern 163 Machinery Directive 2006 42 163 EMC Direct
3. This example shows the last cascaded slave safety option in the system It has SS_In and DM In inputs from the previous upstream safety option 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 31 Slave Safe Stop Last Unit Last Axis Safety Option Terminals First Axis Safety Option Terminals TB2 TB2 TEST OUT 0 511521 X42Y32 42 32 ST 521 Power to 521 TEST OUT 1 Release 521 Safety Option Terminals TB1 S11 S11 11 TEST 0470 511 S11 S11 521 521 21 TEST OUT 1 21 521 521 2 534 RESET 534 22 DC OUT CHx 51 51 i 515 OUT CHx i 68 68 ss Cx 1 4 34 34 i LM_IN_CHx A X32 X32 uL DM IN CHx 20 32 32 302 5 5 CHx 200 52 52 812 ESM_IN_CHx 582 572 572 ou SS_IN_CHx x 512 512 2 24V COM A2 M 24V Al TB2 534 RESET_IN 34 52 52 DC OUT CHx 51 51 78 78 TLS3 GD2 SLS OUT CHx 440G 127260 68 68 Safety Switch y M ss QUT 4 m m X42 X42 LM_IN_CHx x2 x2 542 542 DM IN CHx 532 32 62 Qs IN 262 go
4. Commissioning the System Specifying the Safety Configure the Safe Speed Monitor Option Module Project Verification ER tempe ei Confirm the etes Sopa Safety Validation cs hance aae bo cue pto Al aa cf Verifying the Signature and Lock in the Safe Speed Monitor Option Module Configure ADC and the Safe Speed Monitor Option Module Editing the Configuration vecors rette et RR aa Chapter 11 D edu eoe qu DER Ra utis Example Application 1 5 Example 1 Initial Security Group Example 1 General Group Example 1 Feedback Group Example 1 Stop Group Example 1 Limited Speed Group Settings Example 1 Door Control Group Settings Example 1 Max Speed Group d e teo Treue Example 1 Final Security Group Example Application Example 2 Initial Security Group Example 2 General Group Example 2 Feedback Group Example 2 Stop Group
5. A 61 Safe Stop d cete ac a eeu 62 Standstill Speed and Position 65 Deceleration Monitoring uuo xoa ties a To pF RH Pd 65 Sale Stop Reset screen iyu MO HARE I E EE 66 IDGor Control x05 uoo e SER 67 Lock Monitoring suo 5 codex Ati RR NE ge EIOS 69 Sate Stop Parameter ahve E PEE 69 Safe Stop Wiring Example cedex dada eee RENE ha eR aded teg 71 Safe Stop with Door Monitoring Mode 72 Lock Monitoring dura van tod oet Spera tid 72 SS RESET ded 72 Safe Stop with Door Monitoring Parameter 180 72 Safe Stop with Door Monitoring Wiring Example 74 Rockwell Automation Publication 750 February 2012 Safe Limited Speed 515 Modes Slave Modes for Multi axis Cascaded Systems Table of Contents Chapter 7 ee ou EL D DTE Ie d RETO Safe Limited Speed SES Mode e cis FEE Eo D RU RO Safe Limited 0 055452 Sate Limited Speed Parameter Visti trece eee modis Configuring the PowerFlex 750 Series Drive SLS Operation Safe Limited Speed Wiring Safe Limited Speed with Door Monitoring Sate Li
6. s 144 E Devices EtherNet IP Direct Node 1 PowerFlex 755 1 Fbk Mode Single Fbk 9 0 PowerFlex 755 480 224 1 4 28 Fbk 1 Type Incremental 5 1 oHm LcD HI Us BS M H E 4 rity lori ni METTI 1 4 31 Fbk Resolution 1024 Device Parameters 1 4 32 Fbk 1 Volt Mon D El Parameter Groups 1 4 33 Fbk 1 Speed 0 0 Security 1 4 34 Fbk 2 Units Rev General 1 4 35 Fbk 2 Polarity Normal 1 4 36 Fbk 2 Resolution 0 Stop 1 4 37 2 Volt nn yn 1 4 38 Fbk 2 Spee 0 0 Linked 1 4 89 Fbk Speed Ratio 0 00000 Door Control 1 4 40 Fbk Speed Tol 0 0 Max Speed 1 4 41 Fbk Pos Tol 0 Faults 1 4 42 Direction Mon Disable 9 5 Dual Encoder DENC 1 1 4 43 Direction Tol 10 9 13 EtherNet IP Embedded Follow these steps to configure the type of feedback used by the safety option 1 From the Feedback group choose the P27 Fbk Mode parameter 2 Set the P27 Fbk Mode parameter value to 0 default for redundant processing and cross checking of the single encoder input in a 1002 architecture 3 Choose the P28 Fbk 1 Type parameter The default value is 1 for incremental encoder input 4 Setthe P28 Fbk 1 Type parameter value to 0 for Sine Cosine and internal monitoring of the single encoder input 5 Choose the P29 Fbk 1 Units parameter 6 Set the P29 Fbk 1 Units parameter to 0 default which equals Rotary feedback 7 Choose the P30 Fbk 1 Polarity parameter 8
7. Display Name Values E 2 Full Name 8 Description s 0 ea Password Default N A 32 bit Password Min Max 0 4294967295 Integer Password for Lock and Unlock function 5 Lock State Default 0 Unlock RW 8 bit Lock State Options 0 Integer Command to lock or unlock the safety option configuration 1 Loc 6 Operating Mode Default 0 Program RW 8 bit Operating Mode Options 0 Program Integer Command to place the system in Program or Run mode 1 Run 2 Config Fault 7 Reset Defaults Default 0 No Action RW 8 bit Reset Defaults Options 0 No Action Integer 5 Resets safety option to factory defaults Reset Fac Reset to factory defaults M 10 Signature ID Default RO 32bit 5 Signature Identifier Min Max 0 4294967295 Integer amp a Safety configuration identifier L3 1 New Password Default RW 32 bit New Password Min Max 0 4294967295 Integer 32 bit configuration password 17 Password Command Default 0 No Action RW 8 bit Password Command Options 0 Action Integer Save new password command 1 Change PW Change Password 2 Reset PW Reset Password 18 Security Code Default RO 32 bit Security Code Min Max 0 65535 Integer Used for Reset Password command 19 Vendor Password Default N A RW 16 bit Vendor Password Min Max 0 65535 Integer Vendor password for Reset Password command 1
8. Noise Management DVD publication GMC SP004 Information examples and techniques designed to minimize system failures caused by electrical noise Safety Guidelines for the Application Installation and Maintenance of Solid State Control publication SGI 1 1 Describes important differences between solid state control and hardwired electromechanical devices You can view or download publications at http www rockwellautomation com literature To order paper copies of technical documentation contact your local Rockwell Automation distributor or sales representative Rockwell Automation Publication 750 February 2012 13 Preface Notes 14 Rockwell Automation Publication 750 February 2012 Introduction Safety Certification Chapter 1 Safety Concept This chapter describes the safety performance level concept and how the PowerFlex 750 Series drives can meet the requirements for SIL CL3 CAT 4 or PL e applications Topic Page Safety Certification 15 Functional Proof Tests 18 PFD and PFH Definitions 18 Safe State 19 Safety Reaction Time 20 Considerations for Safety Ratings 20 Contact Information if Safety Option Failure Occurs 22 The PowerFlex 750 Series safety option is certified for use in safety applications up to and including SIL CL3 according to EN 61800 5 2 EN 61508 and EN 62061 Performance Level PL e and CAT 4 accor
9. February 2012 Configuration Fault Codes Troubleshooting the PowerFlex Safety Option Module Chapter 12 Use these fault codes stored in the P70 Config Flt Code parameter to identify the reason for an Invalid Configuration fault Value Description Display 0 No fault No Fault 1 Password Required Password Req 2 P21 Safety Mode value not legal based on P20 Cascaded Config value P21 P20 3 P57 Door Out Type value not legal based on P20 Cascaded Config value P57 P20 4 P46 Stop Mon Delay value not legal based on P45 Safe Stop Type value P46 P45 5 P50 Decel Ref Spd value not legal based on P31 1 Resolution value P50 P31 6 P48 Standstill Speed value not legal based on P20 Cascaded Config value P48 P20 7 P53 LimSpd MonDelay value not legal based on P21 Safety Mode value P53 P21 8 P55 Safe Speed Limit value not legal based on P21 Safety Mode or P31 Fbk 1 Resolution value P55 P21 P31 9 P56 Speed Hysteresis value not legal based on P21 Safety Mode value P56 P21 10 P62 Safe Max Speed value not legal based on P31 Fbk 1 Resolution value P62 P31 11 P42 Direction Mon value not legal based on P21 Safety Mode value P42 21 12 P59 Lock Mon Enable value not legal based on P21 Safety Mode value P59 P21 13 P36 Fbk 2 Resolution value not legal based on
10. Previous Upstream Axis Next Downstream Axis Safety Option Terminals Safety Option Terminals TB1 1 11 S11 S11 S11 11 TEST OUT 0 511 11 TEST OUT 0 511 11 11 S11 511 521 521 521 521 521 TEST OUT 1 51 521 TEST OUT 1 51 521 521 521 521 2 TB2 34 RESET IN 34 34 RESET 34 52 5 52 t DC OUT CHx DC OUT CHx 5 51 51 78 78 78 gt Safety Stop 68 5 5 SLS OUT CHx to Next Axis 44 55 QUT CHx 4 Sisto 34 34 34 gt Next Axis Eid LM IN CHx m LM IN CHx 0 32 32 32 DM IN CHx 20 DM IN CHx w 32 32 32 562 562 SLS_IN_CHx 8 55 52 552 552 582 582 ESM IN CH ESM IN CHx 97 _IN_Crix S2 Z SS_IN_CHx 25 SS 22 S12 512 512 GND TIS 24 COM 241 A2 us Al 24V Al Al 24 Al 108 Rockwell Automation Publication 750 February 2012 GND 24V DC Previous Upstream Axis Safety Option Terminals Slave Modes for Multi axis Cascaded Systems Chapter 8 This second example is configured as a cascaded last unit via the P20 Cascaded Config parameter Multi Last Ithas 55 In SLS In and DM In input connections from the previous upstream safety option but its 55 Out SLS Out and out outputs are connected to a Bulletin 179105 module Figure 36 Slave Safe Limited Speed Status Only Last Safety Option Last Axis Safe
11. 1 Thissignal is internal between the safety option and drive 2 DC Outoutput shown configured as Power to Release See Door Control on page 67 for more information Rockwell Automation Publication 750 February 2012 63 Chapter6 Safe Stop and Safe Stop with Door Monitoring Modes Figure 13 Timing Diagram for Safe Stop 2 Stop Request Stop Monitoring Delay A P46 Stop Delay P47 A A P51 Stop Decel Tol Speed Standstill Position and Standstill Speed Monitoring drive remains enabled P48 Standstill Speed SS InInput SS Out Output Motion Power Stop Command 0 DC Out Output 0 1 Thissignal is internal between the safety option and drive 2 DC Outoutput shown configured as Power to Release See Door Control on page 67 for more information 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 P47 Max Stop Time begins Door control logic is set to Unlock when the Stop Delay P47 Max Stop Time expires regardless of speed Figure 14 Timing Diagram for Safe Torque Off without Standstill Checking Stop Request A A Stop Delay P47 A gt Safe Torque off Active Speed Door Control Output Unlock p gt Time SS InInput i 55 Out Output Moti
12. res T IE TRUCOS UST 1 4 56 Speed Hysteresis 0 Device Parameters E Parameter Groups Security General Feedback Door Control Max Speed Faults 5 Dual Encoder DENC 1 13 EtherNet IP Embedded 14 DeviceLogix Embedded Custom Views E Follow these steps to configure the Safe Limited Speed operation 1 From the Limited Speed group choose the P52 Lim Speed Input parameter The default value is 0 Disabled for applications without Safe Limited Speed control Set the P52 Lim Speed Input parameter value to 1 for 2NC dual channel equivalent operation In this example application the Safe Limited Speed input 51 5 In monitors a switch with two normally closed 2NC contacts If the NC contacts are open and speed exceeds the configured Safe Limited Speed the safety option initiates the configured Safe Stop Type When the safety option is actively monitoring Safe Limited Speed and the machine s speed is at or below the configured Safe Speed Limit the gate interlock is released and the door can be opened Choose the P53 LimSpd Mon Delay parameter The default value is 0 s The valid range is from 0 6553 5 s a value to define the desired delay between the SLS In input ON to OFF transition and the start of Safe Limited Speed monitoring Choose the P54 Enable SW Input parameter The default value is 0 Not Used for applications without an enabling switch Set the P54
13. Rockwell Automation Publication 750 February 2012 85 Chapter7 Safe Limited Speed SLS Modes Safe Limited Speed with din di uA A a for i 2 Speed is 2 gu Door Monitoring and nabling Switcl onitoring the sa ety option per orms Sate imited Spee D SLS monitoring functions as described on page 75 in addition to the Safe Stop Enabling Switch Monitoring functions as described in Safe Stop Mode on page 61 Mode The safety option also monitors both the Enabling Switch Monitor input ESM_In and the Door Monitor input DM 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 P53 LimSpd Mon 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 safety option unlocks the door 3 Continue to hold the enabling switch while you open the door enter the hazard area and perform the required maintenance 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 enabli
14. Test Out 1 521 Single Channel 7 i 1 END 24 COM 2 Safety Device i Solid State OSSD1 1 Input 1 Safety Device T o nput Input 1 05502 1 Inputo 1 Input 0 bi Le IMPORTANT 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 4 Safety Option Input Terminals Function SafeStop Safe Door Enabling Lock SS In Limited Monitoring Switch Monitoring Speed DM In Monitoring LM In SLS In ESM In Input 0 Channel 0 512 552 532 572 x2 Input 1 Channel 1 52 562 42 82 X42 Short circuits of the input loop to ground or 24V will be detected For dual channel inputs cross loops will also be detected Rockwell Automation Publication 750 February 2012 37 Chapter 4 38 Speed Monitoring 1 0 Signals Safe Stop Input 55 In The 55 In input is intended for connection to E Stop device The SS In input must be active to initiate Safe Stop monitoring If the 55 In input is being monitored a transition from ON to OFF closed to open is used to request the configured Safe Stop Type In a cascaded configuration the 55 In inputs of the middle and last drives connected to the Safe Stop 55 Out output of an upstream safety option Safe Limited Speed Input SLS In The SLS In input is used to connect to a switch whose OFF state requests Safe Limited
15. 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 safety option initiates the configured Safe Stop Type Rockwell Automation Publication 750 February 2012 Safe Stop and Safe Stop with Door Monitoring Modes Chapter 6 Safe Stop with Door To configure the safety option for Safe Stop with Door Monitoring set the DM Monitoring Parameter List Input parameter in addition to the Safe Stop parameters listed on page 69 Display Name Full Name Description Read Write File Group 121 Safety Mode Setting 2 Safe Stop DM 8 bit Safety Mode Integer 5 Defines the primary operating mode ofthe speed monitoring safety functions 58 DM Input Default 0 Not used 7 RW 8 bit Door Monitor Input Options 0 Not used Integer Configuration for the Door Monitor input DM 1 2 5 2NC 1 Dual channel equivalent 2 2 35 S 2NC 3s 2 Dual channel equivalent 3 s 3 1NC 1N0 E 1NC 1NO 3 Dual channel complementary 4 1NC 1N0 35 1NC 1NO 35 4 Dual channel complementary 3 s 5 2 0590 35 2 OSSD 3s 5 Dual channel SS equivalent 3 5 6 6 Single channel equivalent 1 You must configure this parameter with a non zero value in this
16. or 6 PM FV Set P125 Pri Vel Fdbk Sel any available feedback device Set P635 Spd Options Ctrl bit 7 Auto Tach SW 0 Contact Inform ation if Safety If you experience a failure with any safety certified device contact your local Option Failure Occurs 22 Rockwell Automation distributor With this contact you can return the device to Rockwell Automation so the failure is appropriately logged for the catalog number affected and a record is made of the failure request a failure analysis if necessary to determine the probable cause of the failure Rockwell Automation Publication 750 February 2012 Introduction Safety Functions Chapter 2 About the PowerFlex Safe Speed Monitor Option Module This chapter describes the safety option features of the PowerFlex 750 Series drives Topic Page Safety Functions 2 Hardware Features 26 Configuration 27 The PowerFlex 750 Series speed monitoring safety option features five inputs three sets of safety outputs and one bipolar safety output Each of the inputs support a specific safety function Safe Stop SS Safe Limited Speed Monitoring 51 5 Door Monitoring DM Enabling Switch Monitoring ESM Lock Monitoring LM An additional reset input provides for reset and monitoring of the safety circuit The safety option can be used in single axis or multi axis applications and can be configured a
17. 3 Dual channel complementary 1NC 1NO 3s 4 Dual channel complementary 3 s 2 OSSD 3s 5 Dual channel SS equivalent 3 s 6 Single channel equivalent LimSpd Mon Delay Limited Speed Monitoring Delay Defines the Safe Limited Speed Monitoring Delay between the 515 In ON to OFF transition and the initiation of the Safe Limited Speed SLS or Safe Maximum Speed SMS monitoring Enable SW Input Enable Switch Input Configuration for the Enabling Switch input ESM 1 Dual channel equivalent 2NC 3s 2 Dual channel equivalent 3 s 1NC 1NO 3 Dual channel complementary 1NC 1N0 35 4 Dual channel complementary 3 s 2 OSSD 3s 5 Dual channel SS equivalent 3 s 6 Single channel equivalent Safe Speed Limit Safe Speed Limit Defines the speed limit that will be monitored in Safe Limited Speed SLS mode Units are based on rotary or linear configuration defined by P29 Fbk 1 Units Speed Hysteresis Speed Hysteresis Provides hysteresis for 515 Out output when Safe Limited Speed monitoring is active 0 when P21 Safety Mode 1 2 3 4 5 6 8 or 9 10 100 when P21 Safety Mode 7 or 10 Values Default Options Units Default Min Max Default Options Units Default Min Max Units Default Min Max 0 Not Used 0 Not Used 1 2NC 2 2NC 3s 3 1NC 1N
18. RPM mm s 0 0 65535 RPM 0 65535 mm s 0 Torque Off 0 Torque Off 1 Safe Stp Typ 0 Disable 0 Disable 1 Enable Rev s mm s 0 0 65535 52 0 65535 mm s 0 Torque Off 0 Torque Off 1 Safe Stp Typ Rockwell Automation Publication 750 RM001F EN P February 2012 Read Write RW RW RW RW RW 8 bit Integer 16 bit Integer 8 bit Integer 8 bit Integer 16 bit Integer 8 bit Integer File Parameter Data Appendix B Display Name Full Name Description Read Write Data Type RO 32 bit 67 Fault Status Fault Status Bit encoded faults Options Door DM In Fit Dir Flt Mov in Stop gt Spd Fit gt Lock Mon Reserved Reserved gt Reserved S Fbk 2 V Fit Fbk 1 V Fit ESM Mon ESM In Flt LM In Flt DC Out Fit gt SMS Spd 515 Spd Fit 515 Out Fit ISLS In Fit Decel Fit SS Out Fit JSS In Fit gt IAccel Fit Default 0 0 Bit 9 28 3 22 21 20 19 18 17 16 15 14 13 12 11 Bit 0 Combined Flt Combined Fault Status Bit 1 Critical Flt Critical Fault Bit 2 Invalid Cfg Invalid Configuration Fault Bit 3 MP Out Flt MP Out Fault Bit 4 Reset PwrUp Reset On at PwrUp Fault Bit 5 Fbk 1 Flt Feedback 1 Fault Bit 6 Fbk 2 Flt Feedback 2 Fault Bit 7 Dual Fbk Spd Dual FB Speed Fa
19. 1 Reversed 0 Normal 0 Normal Same as encoder 1 Reversed 0 Disabled 0 Disabled 1 Pos Always 2 Neg Always 3 Pos in SLS 4 Neg in SLS Deg mm 10 0 65 535 deg 0 65 535 mm 0 Disable 0 Disable 1 Enable RPM mm s 0 0 65 535 RPM 0 65 535 mm s 0 Torque Off 0 Torque Off 1 Safe Stp Typ 0 Disable 0 Disable 1 Enable Rev s mm s 0 0 65 535 rev s 0 65 535 mm s 0 Torque Off 0 Torque Off 1 Safe Stp Typ Rockwell Automation Publication 750 RM001F EN P February 2012 Set these parameters to configure Safe Maximum Speed Safe Maximum Acceleration and Safe Direction Monitoring Read Write RW RW RW RW RW RW RW RW RW Data Type 8 bit Integer 8 bit Integer 8 bit Integer 16 bit Integer 8 bit Integer 16 bit Integer 8 bit Integer 8 bit Integer 16 bit Integer 8 bit Integer Introduction Safety Configuration Chapter 10 Safety Configuration and Verification This chapter provides guidelines for configuring your safe speed monitor option module Topic Page Safety Configuration 121 Basics of Application Development and Testing 123 Commissioning the System 124 Editing the Configuration 130 When you configure a speed monitoring safety system you must record and verify the configuration signature and set the safet
20. Enable SW Input parameter value to 1 for 2NC dual channel equivalent operation In this example application ESM In input monitors an enabling switch with two normally closed 2NC contacts As long as the enabling Rockwell Automation Publication 750 February 2012 17 11 Configuration Examples switch is held in the middle position the safety gate can be opened during Safe Limited Speed monitoring 6 Choose the P55 Safe Speed Limit parameter The default value is 0 rpm or mm s Enter a value from 0 6553 5 7 Type the maximum allowable rpm value for safe reduced velocity The speed is calculated in rpm based on the P29 Fbk 1 Units parameter setting 0 Rotary feedback entered previously 8 Go to the next section to set the parameters that configure Door Control operation Example 2 Door Control Group Settings Figure 58 Door Control Group Parameters HIM Screen Software Screen Mot Enable AUTO 0 000 Hz FU File Edit Explore Actions Help OSH 6 E Devices EtherNet IP Direct Port 04 Param File Group FILE Parameter Groups A GROUP Door Control Node 1 PowerFlex 755 Door Out Type Pwr to Rel DM Input 9 0 PowerFlex 755 480 22A 1 4 58 DM Input Not Used Lock Mon Enable Y 1 20 HIM x6 LCD HIM t 2 icd EM Sir EE 4 ock Mon Inpul lot User lt xs nec Mont 1 4 74 Door Out Mode Pulse Test
21. IMPORTANT Donotover tighten retaining screws PowerFlex 750 Series Drive Frame 2 drive is shown Ports 4 5 6 OZA Rockwell Automation Publication 750 RM001F EN P February 2012 31 Chapter3 Installation and Wiring Installation in Frame 8 and When installed in a Frame 8 or larger drive an EMC Core Kit catalog number Larger Drives 20 750 1 8 is required Terminal Con nections Shielded cable is required Prepare wires for termination on the safety option module with a 6 mm 0 25 in strip length Tighten all terminal screws firmly and recheck them after all connections have been made Recommended terminal screw torque is 0 2 Nem 1 8 Ibein Refer to page 161 for the I O signal electrical specifications Table 2 Safety Option Module TB1 Pinouts Terminal Description Signal Name S11 Pulse Test TEST OUT 0 S11 Pulse Test TEST OUT 0 S11 Pulse Test TEST OUT 0 521 Pulse Test TEST OUT 1 521 Pulse Test TEST OUT 1 521 Pulse Test TEST OUT 1 Table 3 Safety Option Module TB2 Pinouts Terminal Description Signal Name 34 Reset Input RESET IN 52 Door Control Output DC
22. Password Password Password for Lock and Unlock function New Password New Password 32 bit configuration password Password Command Password Command Save new password command Set and Change a Password You can protect the system configuration by using an optional password If you set a password edits to the configuration as well as safety locking and safety option reset operations require the password to be entered You can set a password when the safety option is not safety locked and the P6 Operating Mode parameter value equals 0 Program Follow these steps to set a new password Ifyou previously configured a password enter the password by using the P1 Password parameter Enter the new password by using the P13 New Password parameter Set the P17 Password Command parameter to 1 which equals Change Password Values Read Write Data Type Default N A 32 bit Min Max 0 4 294 967 295 Integer Default RW 32 bit Min Max 0 4 294 967 295 Integer Default 0 No action RW 8 bit Options 0 No action Integer 1 Change PW Change Password 2 Reset PW Reset Password Resetting the Password If you forget the password and need to reset it follow these steps Read the contents of the P18 Security Code parameter Contact Rockwell Automation Technical Support 440 646 5800 and provide the Security Code value and the serial number of
23. Reset Input 534 5 mA per input max Conductor Type Multi conductor shielded cable Conductor size 7 025 25mm 24 14 AWG Strip length 6 mm 0 25 in Terminal screw torque 0 20 0 25 Nem 1 8 2 2 Ib in 1 Referto Industrial Automation Wiring and Grounding Guidelines publication 1770 4 1 2 Safety outputs need additional fuse for reverse voltage protection of the control circuit Install 6 A slow blow or 10 A fast acting fuse Rockwell Automation Publication 750 February 2012 161 Appendix A Specifications Environmental Specifications 162 Category Maximum Surrounding Air Temperature IP20 NEMA UL Open Type 00 NEMA UL Open IP20 NEMA UL Type 1 w Hood 20 NEMA UL Type 1 w Label 20 NEMA UL Type 1 MCC Cabinet Flange Mount Front IP20 NEMA UL Open Type 00 NEMA UL Open Back Heat Sink IP66 NEMA UL Type 4X Stand alone Wall Mount IP54 NEMA UL Type 12 Specification 0 50 C 32 122 F Frame 1 5 All Ratings 0 50 C 32 122 F Frame 6 7 All Ratings 0 40 32 104 F Frame 1 5 All Ratings 0 40 C 32 104 F Frame 6 7 All Ratings 0 40 C 32 104 F Frame 8 10 All Ratings 0 50 32 122 F Frame 2 5 All Ratings 0 50 32 122 F Frame 6 7 All Ratings 0 40 C 32 104 F Frame 2 7 All Ratings 0 40 C 32 104 F Frame 2 7 All Rat
24. SMS limit Door Monitoring DM Door Control DC to control a guardlocking switch TLS 3 GD2 Power to Release style e A Reset button with 1 NO contact Enabling Switch ESM with 2NC contacts Hold the switch in the middle position to access the machine for maintenance while it is running at Safe Limited Speed Oneencoder connected with Sin Cos output signal and resolution of 1024 Each of the following sections describes the settings you need to enter for each parameter group You can use a HIM module DriveExplorer DriveExecutive or RSLogix 5000 software to configure the safety option Example 2 Initial Security Group Settings Figure 53 Security Group Parameters HIM Screen Software Screen Not Enabled AUTO 93 DriveExplorer Beta 0 000 Hz FO File Edit Explore Actions Help Port 04 Param File Group DEH t teI HORR FILE Parameter Groups 4 El Devices EtherNet IP Direct 5 GROUP Security Node 1 PowerFlex 755 Password 9 0 PowerFlex 755 480 22A 1 4 5 Lock State Unlock 2 6 de 4 8 1 20 HIM x6 LCD 5 de 1 4 Safe Speed Montr S1 14 eset Defaults lo Action 1 4 10 Signature ID 0 Device Parameters 1 4 13 New Password 0 El Parameter Groups 1 4 17 Password Command No Action Security 1 4 18 Security Code 256 General 1 4 19 Vendor Password 0 Feedback 1 4 70 Config Flt Code No Fault Stop Limited Speed Door Control
25. Secs RW 16 bit Default 0 Integer Min Max 0 6553 5 Units Secs RW 16 bit Default 0 Integer Min Max 0 6553 5 Units RPM RW 16 bit mm s Integer Default 0 001 Min Max 0 001 65 535 RPM 000 65 535 mm s Rockwell Automation Publication 750 February 2012 69 Chapter 6 File Group 50 51 HOST GROUPS 72 Safe Stop and Safe Stop with Door Monitoring Modes Display Name Full Name Description Standstill Pos Standstill Position Defines the position limit window in encoder 1 degrees or mm that will be tolerated after a safe stop condition has been detected Degrees 360 1 revolution or mm based on rotary or linear configuration defined by P29 Fbk 1 Units Not valid for Safe Torque Off without Standstill Checking Decel Ref Speed Deceleration Reference Speed Determines deceleration rate to monitor for Safe Stop 1 or Safe Stop 2 Units are based on rotary or linear configuration defined by encoder 1 feedback configuration P29 Fbk 1 Units Stop Decel Tol Stop Deceleration Tolerance This is the acceptable tolerance above the deceleration rate set by the Decel Ref Speed parameter Door Out Type Door Output Type Defines the lock and unlock state for door control output DC Out When Door Out Type equals power to release DC Out is OFF in the lock state and ON in the unlock state When Door Out Type equals power to lock DC Out is ON in
26. Slave Safe Stop mode 101 103 SLS with Door Monitoring and Enabling Switch Monitoring mode 90 SLS with Door Monitoring mode 83 SLS with Enabling Switch Monitoring mode 85 Rockwell Automation Publication 750 February 2012 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products At hetp www rockwellautomation com support you can find technical manuals a knowledge base of FAQs technical and application notes sample code and links to software service packs and a MySupport feature that you can customize to make the best use of these tools For an additional level of technical phone support for installation configuration and troubleshooting we offer TechConnect support programs For more information contact your local distributor or Rockwell Automation representative or visit http www rockwellautomation com support Installation Assistance If you experience a problem within the first 24 hours of installation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running United States or Canada 1 440 646 3434 Outside United States or Canada Use the Worldwide Locator at http www rockwellautomation com support americas phone_en html or contact your local Rockwell Automation representative New Product Satisfaction Return R
27. which initiates the configured P45 Safe Stop Type 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 which initiates the configured P45 Safe Stop Type is not monitored until the DM In input is detected as OFF Make sure that the input is not relied upon for safety until the DM In input has transitioned to OFF ATTENTION While Safe Limited Speed Monitoring is active the ESM input 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 Table 15 Safe Limited Speed Operation Safety Function Status Drive In Drive Able Drive Able Safe State To Run Ready To Run Ready DM In Off Rockwell Automation Publication 750 February 2012 87 Chapter7 Safe Limited Speed SLS Modes 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 safety option initiates the configured P45 Safe Stop Type 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 P53 LimSpd Mon Delay However the DM In input must be ON door closed during the delay or a Door Monit
28. 1 Polarity parameter Set the P35 Fbk 2 Polarity parameter so that the resulting speed direction is of the same polarity as encoder 1 Single Encoder If the P27 Fbk Mode parameter is set to 1 Encoder the single encoder input is processed redundantly and cross checked in 1002 architecture The speed direction and stopped status are derived from the single encoder by the 1002 architecture Refer to Considerations for Safety Ratings on page 20 for more information Rockwell Automation Publication 750 February 2012 General Device and Feedback Monitoring Configuration Chapter 5 Dual Encoders If the P27 Fbk Mode parameter is set to 2 Encoders each encoder input is processed by a single channel and cross checked in a 1002 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 IMPORTANT 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 P39 Fbk Speed Ratio e Dual Feedback Position Tolerance P41 Fbk Pos Tol Dual Feedback Speed Discrepancy Tolerance 40 Fbk Speed Tol Dual Feedback Speed Ratio The Dual Feedback Speed Ratio P39 Fbk Speed Ratio parameter is defined as the ratio of the expected speed of enc
29. 5 OUT CHx 68 68 68 68 68 68 ss M ss 34 34 34 34 34 34 IN CHx m LM IN CHx is LM IN CHx X32 X32 X32 X32 X32 X32 W DM IN CHx 582 20 DM IN 24 542 DM CHx 542 532 532 532 532 532 532 562 562 362 SLS_IN_CHx w SLS_IN_CHx 56 SLS IN CHx 367 52 52 52 52 52 552 ESM_IN_CHx 582 542 ESM IN CHx a 2 ESM_IN_CHx 2 572 572 572 572 572 572 20 SS IN 30 zi SS CHx 522 20 SS IN ME 512 512 512 512 512 512 A2 24V COM A2 A2 24V_COM A2 A2 24V COM A2 Al 24V Al Al 24V Al Al 24V Al Power to Release TLS3 GD2 4406 27260 Rockwell Automation Publication 750 February 2012 103 Chapter8 Slave Modes for Multi axis Cascaded Systems Slave Safe Limited Speed When properly configured for Slave Safe Limited Speed mode the safety option Mode performs the same functions as Safe Limited Speed mode as described on page 75 However the safety option 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
30. Acceleration Fault When P66 Max Acc Stop Typ Set to Use Configured Stop Type Safe Stp Stop Request A Acceleration Fault Stop Delay Speed P66 Acc Stop Typ gt P47 Max Stop Time P48 Standstill Speed Ifan Acceleration fault is detected during the Stop Delay P47 Max Stop Time and the P66 Max Acc Stop Typ parameter equals Use Safe Torque Off with Check for Standstill Torque Off the Acceleration fault is reported and Motion Power is removed The Stop Delay P47 Max Stop Time continues with standstill checking enabled 1 100 kHz for Sin Cos or 200 kHz for Incremental Rockwell Automation Publication 750 February 2012 17 Chapter9 Safe Maximum Speed and Direction Monitoring Figure 43 Acceleration Fault When P66 Max Acc Stop Typ Set to Use Safe Torque Off with Check for Standstill Torque OFF Stop Request A Acceleration Fault Stop Delay Speed P66 Max Acc Stop Typ 4 67 Max Stop Time P48 Standstill Speed SS n SS Out Motion Power 7 1 Thissignal is internal between the safety option and drive For more information about faults see Fault Reactions on page 155 Safe Direction Monitoring When configured for Safe Direction Monitoring the safety option monitors the 5 feedback direction and initiates the configured Safe Stop Type when motion the illegal direction is
31. CL3 PL e and CAT 4 For applications that rely on commutation to generate torque and motion a safety rating up to and including SIL CL3 PL e and CAT 4 can be achieved IMPORTANT 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 Rockwell Automation Publication 750 February 2012 Safety Concept Chapter 1 Output Pulse Test Considerations If the pulse testing of any safety output is disabled the maximum safety rating will be up to and including SIL CL2 PL d and CAT 3 for any safety chain incorporating any input or output of the safety option IMPORTANT Setting any of the P72 SS Out Mode P73 SLS Out Mode or P74 DC Out Mode parameters to 1 No Pulse Test disables internal diagnostics as well as external diagnostics required to achieve higher safety ratings You must exercise the 55 In input at least once every six months You may need to disable pulse testing if the connected device does not support OSSD inputs Refer to the product documentation for your connected device Encoder Considerations When configured correctly the safety option performs these diagnostics on the encoder Sin Cos diagnostic Detection of open or short circuit e Encoder supply voltage monitoring Detection of illegal quadrature transitions of the sine and cosine signals You can use motors tha
32. Dual channel SS equivalent 3 s 6 INC 6 Single channel equivalent 1 You must configure this parameter with a non zero value in this mode 84 Rockwell Automation Publication 750 February 2012 SLS with Enabling Switch Monitoring Wiring Example This example illustrates wiring for SLS with enabling switch monitoring Safe Limited Speed SLS Modes Chapter 7 Figure 22 Master Safe Limited Speed with Enabling Switch Monitoring First or Single Unit TB1 s11 s11 91 TEST OUT O 511 PowerFlex 750 Series Safe Speed Monitor 511 n Option Module 521 521 Reset 21 TEST OUT 1 21 51 521 TB2 S34 RESET IN 34 52 52 DC OUT CHx 5 51 Power to 78 78 Release 5 5 OUT CHx 3 TLS3 602 68 68 4406 27260 Safety Stop 4 Safety Switch 55 OUT CHx to Next Axis 34 34 optional Remove 2 xe Internal LM IN CHx Jumpers X32 X32 wince 22 515 532 532 2 Request L362 sisin 552 52 552 IN CHx 72 72 GND A2 24V COM A2 1 24V DC A 24V 440 N21TNPM Enabling Switch SS T Request 9 49 0 1 Lock monitoring connections are not required for Safe Limited Speed with Enabling Switch Monitoring mode operation
33. GND A2 COM A 24V DC Al 24 M 94 Out 0 Out 1 Out 2 Out 3 Out 4 Out 5 Out 6 Out 7 1791DS IB8X0B8 In7 In6 In 5 In4 V0 In3 V1 In2 In 1 60 Ind GND Rockwell Automation Publication 750 February 2012 Safe Limited Speed SLS Modes Chapter 7 Figure 27 Master Safe Limited Speed Status Only First Unit First Axis Next Downstream Axis Safety Option Terminals Safety Option Terminals 511 511 511 511 511 TEST OUT 0 S11 TEST OUT 0 911 511 11 511 511 521 521 521 521 521 TEST OUT 1 91 71 TEST OUT 1 51 51 521 521 521 Reset TB2 Out 0 TB2 ft 534 RESET IN 534 Out 1 S34 RESET_IN 534 52 52 Out 2 52 52 DC_OUT_CHx DC_OUT_CHx 51 51 Out 3 51 51 8 5 5 OUT CHx Guta SLS OUT CHx 18 68 68 Outs 68 68 ss QUT Out 6 44 ss M 34 34 34 34 x42 x42 X42 LM IN CHx L
34. IP Direct 5 npp Safelstoplnplit Node 1 PowerFlex 755 1 Safe Stop Input 2NC Safe Stop Type 9 0 PowerFlex 755 480 22A 1 4 45 Safe Stop Type Torque Off Stop Mon Delay Y 9 1 20 HIM x6 LCD HIM 16 ici eek 4 Stop Time la ESC 3 a 1 448 Standstill Speed 0 001 tia 1 4 49 Standstill Pos 10 El Parameter Groups 1 4 50 Decel Ref Speed 0 Security 1 4 51 Stop Decel Tol 0 General Feedback Limited Speed Door Control Max Speed Faults 8 5 Dual Encoder DENC 1 9 13 EtherNet IP Embedded 9 14 DeviceLogix Embedded Custom Views Follow these steps to configure the Stop operation of the safety option 1 From the Stop group choose the 44 Safe Stop Input parameter 2 Set the P44 Safe Stop Input parameter value to 1 default for 2NC dual channel equivalent operation In this example application the Safe Stop input 55 In monitors E Stop button with two normally closed 2NC contacts 3 Choose the 45 Safe Stop Type parameter Rockwell Automation Publication 750 February 2012 135 Chapter 11 136 Configuration Examples 10 11 Set the 45 Safe Stop Type parameter value to 0 default which equals Safe Torque Off with Standstill Speed Checking Torque Off Safe Torque Off with Standstill Speed Checking Torque Off switches off motion power immediately after an E Stop command and sets door
35. In is not monitored ATTENTION Make sure that the 5 5 In input cannot transition to ON while N 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 SS Reset when the 51 5 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 which initiates the configured Safe Stop Type To configure the safety option for Safe Limited Speed with Enabling Switch Monitoring set the P54 Enable SW Input parameter in addition to the Safe Stop parameters listed on page 69 and the Safe Limited Speed parameters listed on page 78 Display Name Values s Full Name E Description 8 21 Safety Mode Setting 5 Lim Speed ES 8 bit E Safety Mode Integer Defines the primary operating mode ofthe speed monitoring safety functions 54 EnableSW Input Default 0 Not used 1 RW 8 bit Enable Switch Input Options 0 Not used Integer Configuration for the Enabling Switch input ESM 1 1 Dual channel equivalent 2 2 35 2NC 3s 2 Dual channel equivalent 3 s 3 1NC 1N0 1NC 1NO 3 Dual channel complementary 4 1 1 0 35 1NC 1NO 35 4 Dual channel complementary 3 s 5 2 0590 3s 2 OSSD 3s 5
36. Max Speed Faults 9 5 Dual Encoder DENC 1 9 13 EtherNet IP Embedded 9 14 DeviceLogix Embedded Custom Views Follow these steps to put the safety option into Program mode for configuration 1 From the Security group choose the P5 Lock State parameter The default value of the Lock State parameter is 0 or unlocked 2 Ifthe safety option is locked Lock State parameter value equals 1 set the P5 Lock State parameter value to 0 If an error occurs a password has been configured to protect the safety option configuration Rockwell Automation Publication 750 February 2012 141 Chapter 11 142 Configuration Examples 3 Choose the P1 Password parameter 4 Type the password 5 Choose the P6 Operating Mode parameter The default value is 0 which equals Program 6 Ifthe safety option is in Run mode Operating Mode parameter equals 1 set the P6 Operating Mode parameter to 0 to enable you to enter a new configuration 7 Ifyou want to configure a password or change the password choose the P13 New Password parameter The default value is 0 Enter a value from 0 4 294 967 295 8 Type the new password value 9 Choose the P17 Password Command parameter 10 Set the P17 Password Command parameter value to 1 which equals Change Password Change PW 11 Goto the next section to set the parameters found in the General parameters group Example 2 General Group Se
37. OUT CH1 51 Door Control Output DC OUT CHO 78 Safe Limited Speed Output 5 5 OUT CH1 68 Safe Limited Speed Output SLS OUT CHO 44 Safe Stop Output SS OUT CH1 34 Safe Stop Output SS OUT CHO x2 Lock Monitoring Input LM IN CH1 X32 Lock Monitoring Input LM IN CHO 542 Door Monitoring Input DM IN CH1 32 Door Monitoring Input DM IN CHO 562 Safe Limited Speed Input 5 5 IN 52 Safe Limited Speed Input SLS IN CHO 582 Enabling Switch Monitoring Input ESM IN CH1 572 Enabling Switch Monitoring Input IN CHO 522 Safe Stop Input SS IN 1 512 Safe Stop Input 55 CHO A2 Common customer supplied 24V 24V DC customer supplied 24V 32 Rockwell Automation Publication 750 February 2012 Compatible Encoders Cat No and Description Sin Cos Encoders 7 Incremental Encoders 2 842HR xJxxx1 SFWYx 845T xx1 2xxx x and 845T xx13xxx x 845T xx42xxx and 845 4 845T xx52xxx and 845T xx53xxx x 845H SIxxx4xxVxx Installation and Wiring Chapter 3 These feedback devices or equivalents are supported Additional Resources 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 for catalog number dimensions and specifications for Bulletin 845T and 845H Incremental Encoders Rotary Motors 1326AB Byxxx M2L S2L MP Series motors with embedd
38. Position Discrepancy Checking Dual Spd Chk 2 2 Encoders with Speed Discrepancy Checking Dual Pos Chk 3 2 Encoders with Position Discrepancy Checking Fbk 1 Type Feedback 1 Type Selects the type of feedback for encoder 1 When using the Safe Speed Monitor module with a 20 750 UFB 1 Universal Feedback module set this parameter to 0 Sine Cosine and ensure that the Universal Feedback module is set to a Sine Cosine type device P6 FBO Device Sel and or P36 FB1 Device Sel Fbk 1 Units Feedback 1 Units Selects rotary or linear feedback for encoder 1 Fbk 1 Polarity Feedback 1 Polarity Defines the direction polarity for encoder 1 Fbk 1 Resolution Feedback 1 Resolution Counts Revolution 1 65 535 pulses revolution or pulses mm based on rotary or linear configuration defined by P29 Fbk 1 Units Fbk 1 Volt Mon Feedback 1 Voltage Monitor Encoder 1 voltage to be monitored Fbk 1 Speed Feedback 1 Speed Displays the output speed of encoder 1 Units based on rotary or linear configuration defined by P29 Fbk 1 Units Fbk 2 Units Feedback 2 Units Selects rotary or linear feedback for encoder 2 Fbk 2 Polarity Feedback 2 Polarity Defines the direction polarity for encoder 2 Fbk 2 Resolution Feedback 2 Resolution Counts Revolution 0 65 535 pulses revolution or pulses mm based on rotary or linear configuration defined by P34 Fbk 2 Units Values Default Options Default O
39. Publication 750 February 2012 115 Chapter9 Safe Maximum Speed and Direction Monitoring Safe Maximum Acceleration SMA Monitoring 116 P62 Safe Max Speed Configure Safe Maximum Acceleration monitoring by setting the P64 Max Accel Enable parameter to Enable When configured Safe Maximum Acceleration Monitoring is active any time the safety option configuration is valid and Safety mode is not set to Disabled The resolution accuracy of the acceleration monitoring in revolutions second is equal to the speed resolution in RPM x 2 60 OverSpd Response 36 1000 seconds The resolution accuracy of the acceleration monitoring in mm second is equal to the speed resolution in mm s x 2 OverSpd Response 36 1000 seconds IMPORTANT Acceleration is measured within the Overspeed Response Time P24 OvrSpd Response parameter When you configure the safety option for Safe Maximum Acceleration the safety option monitors the acceleration rate and compares it to a configured Safe Maximum Acceleration Limit P65 Safe Accel Limit If the acceleration is greater than or equal to the configured P65 Safe Accel Limit an Acceleration fault Stop Category fault occurs Figure 41 Acceleration Timing Diagram A Acceleration Time Rockwell Automation Publication 750 February 2012 Safe Maximum Speed and Direction Monitoring Chapter 9 You define the
40. Red On Anonrecoverable fault has occurred All other indicators are OFF Red Green Flashing The configuration is being downloaded or a firmware upgrade is in progress MP Green On Motion Power is enabled Off Motion Power is disabled Red Flashing A Motion Power fault has been detected Rockwell Automation Publication 750 February 2012 151 Chapter12 Troubleshooting the PowerFlex Safety Option Module Nonrecoverable Faults Fault Recovery Input and Output Faults Fault Codes and Descriptions 152 In addition to the recoverable faults described in this chapter the safety option also generates nonrecoverable faults when an anomaly with the safety option hardware is detected These faults are Safe State faults If a Safe State fault occurs all safety control outputs are set to their safe state To clear a nonrecoverable fault cycle power If the nonrecoverable fault persists the safety option may need to be replaced If the fault is no longer present you can clear the fault condition with a successful SS Reset and drive fault Clear command except in the case of an Invalid Configuration fault MP Out fault or Reset PwrUp fault An Invalid Configuration fault is cleared by a successful reconfiguration An MP Out fault or Reset PwrUp fault is cleared at power down or by a successful reconfiguration An input or output fault indication can be caused by several wiring fault conditions during commissioni
41. Safe Speed Monitor TEST OUT 0 Option Module 19 51 11 11 51 521 21 TEST OUT 1 521 521 521 Reset TB2 ol 534 RESET_IN 534 32 DC_OUT_CHx 2 51 5 5 OUT CHx 68 ss QUT CHx 34 CHx X32 cal DM_IN_CHx 32 e 5 5 IN CHx 52 ESM IN CHx E SS IN CHx GND 24V COM 24V DC Al 24V Al 1791DS IB8X0B8 Out 0 Out 1 Out 2 Out 3 V0 Out 4 V1 Out 5 Out 6 60 Out 7 G1 GND Rockwell Automation Publication 750 February 2012 Chapter 8 Slave Modes for Multi axis Cascaded Systems Introduction This chapter describes the slave modes of safety operation and wiring examples of cascaded multi axis configurations Topic Page Cascaded Configurations 97 Slave Safe Stop Mode 98 Slave Safe Stop Parameter List 99 Slave Safe Stop Wiring Examples 101 Slave Safe Limited Speed Mode 104 Slave Safe Limited Speed Parameters 104 Slave Safe Limited Speed Wiring Examples 105 Slave Safe Limited Speed Status Only Mode 107 Slave Safe Limited Speed Status Only Parameter List 107 Slave Safe Limited Speed Status Only Wiring Examples 108 Multi axis Connections 110 Cascaded Configurations Use the P20 Cascaded Config parameter to define the safety option s position in the system as Single Unit Single Cascaded First Unit Multi First Cascad
42. Sourcing 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 safety option 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 Rockwell Automation Publication 750 February 2012 Speed Monitoring 1 0 Signals 4 Figure 9 Door Control Cascading Outputs Safety Option Master DC OUT CHO OUT TB2 51 TB2 52 TB2 532 2 542 DM IN CHO DM IN Safety Option Slave Only these wiring configurations shown below are supported for the Door Control output Figure 10 Door Control Output Wiring No Bi polar Single ended Door Status 2 Channel Load Load Load Source 0 DoorConto Tg2 52 TB2 52 82 52 182 52 Sinking Output Door Control a Sourcing Output TB2 51 2 51 2 51 a FE 4 24V DC Common 24V DC 3 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 1 0 module Short circuits of the output loop to ground or 24V will be detected For cascaded outputs cross loops wi
43. Speed parameters listed on page 104 See Multi axis Connections on page 110 for details on configuring slave safety options Values Read Write Data Type 2 Multi Mid 8 bit 3 Multi Last Integer Options Option 10 Slv Spd Stat RW 8 bit Integer Units RW 8 bit Default 0 Integer Rockwell Automation Publication 750 February 2012 107 Chapter8 Slave Modes for Multi axis Cascaded Systems Slave Safe Limited Speed us examples show two different Slave Safe Limited Speed Status Only Status Only Wiring Examples 5 79 The first example is configured as cascaded middle unit via the P20 Cascaded Config parameter Multi Mid It has SS In SLS In and DM In input connections from the previous upstream safety option as well as 55 Out SLS Out and DC Out output connections to the next downstream safety option IMPORTANT TheSLS Out signals change state immediately based on the speed relative to the Safe Speed Limit ifthe Safe Limited Speed Monitoring Delay 515 Mon Delay is set to zero See SLS Status Only Wiring Examples starting on page 94 for an example ofa first master unit Figure 35 Slave Safe Limited Speed Status Only Middle Safety Option
44. Tolerance This is the acceptable tolerance above the deceleration rate set by the Decel Ref Speed parameter Values Default Options Default Options Units Default Min Max Units Default Min Max Units Default Min Max Units Default Min Max Units Default Min Max Units Default Min Max 12 2NC 0 Not Used 1 2NC 2 2NC 3s 3 1NC 1N0 4 1NC 1N0 35 5 0550 35 6 1NC 0 Torque Off 0 Torque Off 1 Safe Stop 1 2 Safe Stop 2 3 Torque Off NoCk Secs 0 0 6553 5 Secs 0 0 6553 5 RPM mm s 0 001 0 001 65535 RPM 000 65535 mm s Deg mm 10 0 65535 deg 0 65535 mm RPM mm s 0 0 65535 RPM 0 65535 mm s 96 0 0 100 Rockwell Automation Publication 750 February 2012 Parameter Data Read Write RW RW RW RW RW RW RW Appendix B 8 bit Integer 8 bit Integer 16 bit Integer 16 bit Integer 16 bit Integer 16 bit Integer 16 bit Integer 8 bit Integer 171 Appendix B E Safe Speed Monitor 172 Group Limited Speed 53 54 55 56 Parameter Data Display Name Full Name Description Lim Speed Input Limited Speed Input Configuration for Safe Limited Speed input 515 In 2NC 1 Dual channel equivalent 2NC 3s 2 Dual channel equivalent 3 s 1NC 1NO
45. Yes Slave Safe Limited Speed Yes Yes Yes Safe Limited Speed with Door Monitoring and Enabling Slave Safe Stop Yes Yes Slave Safe Limited Speed Yes Yes Yes Safe Limited Speed Status Only Slave Safe Stop Yes Yes Slave Safe Limited Speed Status Only Yes Yes 1 Q 110 P20 Cascaded Config parameter equals Cascaded Middle Unit Multi Mid DC Outto DM In connections are required only for systems implementing door control or systems monitoring cascaded stopped status Rockwell Automation Publication 750 February 2012 Slave Modes for Multi axis Cascaded Systems Chapter 8 This table shows the supported Safety modes for slave safety options 7 1 cascaded from slaves 7 Supported Safety Mode Combinations Cascaded Connections Allowed Slave Safety Option n Slave Safety Option n 1 SS Outto SLS Outto DC Outto 55 In SLS In DM In Slave Safe Stop Slave Safe Stop Yes Yes Slave Safe Limited Speed Slave Safe Stop Yes Yes Slave Safe Limited Speed Yes Yes Yes Slave Safe Limited Speed Status Only Slave Safe Stop Yes Yes Slave Safe Limited Speed Status Only Yes Yes Yes 1 DC Outto DM In connections are required only for systems implementing door control Rockwell Automation Publication 750 February 2012 111 Chapter8 Slave Modes for Multi axis Cascaded Systems Notes 112 Rockwell Automation Publ
46. 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 P47 Max 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 Figure 11 Timing Diagram for Safe Torque off with Standstill Checking Stop Request Stop Delay P47 Safe Torque off Active Door Control speed Output Unlock Time SS InInput pss 1 SS Out Output ae Motion Power 7 FUN ee yp EC 1 2 ER DC Out Output j H O 1 Thissignal is internal between the safety option and drive 2 DC Outoutput shown configured as Power to Release See Door Control on page 67 for more information Rockwell Automation Publication 750 February 2012 Speed P48 Standstill Speed Safe Stop and Safe Stop with Door Monitoring Modes Chapter 6 Safe Stop 1 and Safe Stop 2 When Safe Stop 1 or 2 is initiated by a transition of the 55 In input from ON
47. 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 IMPORTANT X AnSSResetis not attempted if the Wait SS Cyc attribute is set 1 indicating that an error other than an invalid configuration fault or ESM input fault occurred The Wait SS Cyc attribute is bit 25 of the P68 Guard Status parameter Rockwell Automation Publication 750 February 2012 Safe Stop and Safe Stop with Door Monitoring Modes Chapter 6 Automatic If the SS Reset is configured as automatic the safety option always attempts a reset if it is in the Safe State or has initiated a Safe Stop Type The reset is attempted when the 55 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 55 In input is ON and the Reset In input is ON Manual Monitored manual monitored reset requires an OFF to ON to OFF transition ofthe Reset In input A Y If at any time before the closing and opening of the Reset In input the 55 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 55 In input must turn OFF and ON again to reset the Wait SS Cyc bit before a successf
48. certification for Declarations of Conformity Certificates 2 Underwriters Laboratories Inc has not evaluated the safe off safe torque off or safe speed monitoring options for functional safety CE Conformity CE Declarations of Conformity are available online at www rockwellautomation com products certification The 20 750 S1 Safe Speed Monitor module is in conformity with the essential requirements of the 2006 42 EC Machinery Directive and the 2004 108 EC EMC Directive when installed and maintained in accordance with the instructions contained in this document The following standards have been applied to demonstrate conformity Machinery Directive 2006 42 EC EN ISO 13849 1 2008 Safety of machinery Safety related parts of control systems Part 1 General principles for design e EN ISO 13849 2 2008 Safety of machinery Safety related parts of control systems Part 2 Validation EN 60204 1 2006 Safety of machinery Electrical equipment of machines Part 1 General requirements EN 62061 2005 Safety of machinery Functional safety of safety related electrical electronic and programmable electronic control systems EN 61800 5 2 2007 Adjustable speed electrical power drive systems Part 5 2 Safety requirement Functional EMC Directive 2004 108 EC EN 61800 3 2004 Adjustable speed electric power drive systems Part 3 EMC requirements and specific test methods Rockwell Automation Publi
49. command status Bit 19 Stop Cmd Stop command status Bit 20 MP Out Ch 0 MP Out Ch 0 status Bit 21 Out Ch 1 MP Out Ch 1 status See page 167 See page 168 See page 168 See page 173 Appendix B 177 AppendixB Parameter Data Notes 178 Rockwell Automation Publication 750 February 2012 Numerics 2 Channel Sourcing 68 A access hazardous area 86 additional resources 13 automatic reset 48 SLS Reset 77 SS reset 67 C cascaded config 47 97 cascaded connections 41 43 45 Cat 4 11 15 performance definition 16 certification Cat4 11 15 150 13849 1 15 PLe 11 15 SIL CL3 11 15 certifications 163 commissioning the system 124 127 commutation 22 conductor requirements 161 configuration confirm 127 example 1 131 example 2 141 lock 121 lock bit 121 127 signature See Signature ID specification 125 configure parameters 126 D DC_Out output 44 wiring 44 45 deceleration monitoring 63 65 66 discrepancy checking 56 encoders 55 DM In input 38 documentation additional resources 13 Door Control 67 68 Door Control output fault conditions 68 Door Control wiring 44 Door Monitoring Fault 89 DriveExecutive software version 27 DriveExplorer software version 27 dual channel operation 35 Index dual encoder configurations 55 resolution 54 dual feedback position discrepancy tolerance definition 56 Dual Feedback Speed D
50. control to Unlock when the Standstill Speed is detected Choose the P47 Max Stop Time parameter The default value is 10 s but you can enter a value from 0 6553 5 s Type the value of the expected coast to stop time plus a reasonable tolerance after the Safe Stop command is initiated If the machine s speed is not below the Standstill Speed within the Stop Delay Max Stop Time period you entered a Stop Speed Fault occurs and door control remains set to Lock until the Standstill Speed is reached Choose the P48 Standstill Speed parameter The default value is 0 001 rpm but you can enter a value from 0 001 65 535 rpm The Standstill Speed is measured in revolutions per minute because the P29 Fbk 1 Units parameter is configured for Rotary feedback Enter a value in the P48 Standstill Speed parameter field to define the speed at which motion is stopped with no relative position change before the safety option determines standstill has been reached Choose the P49 Standstill Pos parameter The default value is 360 degrees but you can enter a value from 0 65 535 degrees The Standstill Position is measured in degrees because the P29 Fbk 1 Units parameter is configured for Rotary feedback Enter the value to define the position limit in encoder units that is tolerated after standstill has been reached Go to the next section to set the parameters found in the Limited Speed parameters group Rock
51. for Master Safe Limited Speed with Door Monitoring mode Lim Speed DM In this mode the door is locked when the machine speed is above a configured Safe Speed Limit The door can be unlocked when the machine is at Standstill Speed or is at or below the Safe Speed Limit and the SLS In input is off Choose the P22 Reset Type parameter Set the P22 Reset Type parameter value to 2 default which equals Manual Monitored Monitored The Manual Monitored setting requires a closing and opening of the reset circuit for a reset Choose the P24 OverSpd Response parameter The default Overspeed Response time is 42 ms Set the P24 OverSpd Response parameter value to 1 which equals 48 ms See Overspeed Response Time on page 49 for details Go to the next section to configure the type of feedback by using the Feedback parameters group Rockwell Automation Publication 750 February 2012 133 11 Configuration Examples HIM Screen Example 1 Feedback Group Settings Figure 48 Feedback Group Parameters Not Enabled 0 000 Hz Software Screen AUTO FO File Edit Explore Actions Help Port O4 Param File Group FILE Parameter Groups GROUP Feedback Fbk 1 Type Fbk 1 Units S 5 wee 134 Ei Devices EtherNet IP Direct E Node 1 PowerFlex 755 1 Fbk Mode Single Fbk 9 0 PowerFlex 755 480 224 1 4 28 Fbk 1 Type In
52. output speed of encoder 2 Units based on rotary or linear configuration defined by P34 Fbk 2 Units Fbk Speed Ratio Feedback Speed Ratio Defines the ratio of the expected speed of encoder 2 divided by the expected speed of encoder 1 Ratio based on rotary or linear configuration defined by P29 Fbk 1 Units Fbk Speed Tol Feedback Speed Tolerance Acceptable difference in speed between P33 Fbk 1 Speed and P38 Fbk 2 Speed Units are based on rotary or linear configuration defined by P29 Fbk 1 Units Fbk Pos Tol Feedback Position Tolerance Acceptable difference in position between encoder 1 and encoder 2 Units are based on rotary or linear configuration defined by P29 Fbk 1 Units Direction Mon Direction Monitoring Defines the allowable direction if Safe Direction Monitoring is enabled Pos Always 1 Positive always Neg Always 2 Negative always Pos in SLS 3 Positive during safe limited speed monitoring Neg in SLS 4 Negative during safe limited speed monitoring Direction Tol Direction Tolerance The position limit in encoder units tolerated in the wrong direction when Safe Direction Monitoring is active Units are based on rotary or linear configuration defined by P29 Fbk 1 Units Values Default Options Units Min Max Default Min Max Units Min Max Units Default Min Max Default Options Units Default Min M
53. switch with two normally closed 2NC contacts If the NC contacts are open and speed exceeds the configured Safe Limited Speed the safety option initiates the configured Safe Stop Type When the safety option is actively monitoring Safe Limited Speed and the machines speed is at or below the configured Safe Speed Limit the gate interlock is released and the door can be opened Choose the P55 Safe Speed Limit parameter The default value is 0 rpm or mm s The valid range is from 0 6553 5 Type the maximum allowable rpm value for safe reduced velocity The speed is calculated in rpm based on the Fbk 1 Units parameter setting 0 Rotary feedback entered previously Go to the next section to set the parameters that configure Door Control operation Rockwell Automation Publication 750 February 2012 137 11 Configuration Examples HIM Screen Example 1 Door Control Group Settings Figure 51 Door Control Group Parameters Not Enabled 0 000 Hz FO AUTO Port O4 Param File Group FILE Parameter Groups GROUP Door Control DM Input Lock Mon Enable 138 Software Screen File Edit Explore Actions Help 5 5 ARA El Devices EtherNet IP Direct Is Node 1 PowerFlex 755 9 0 PowerFlex 755 480 22A 1 Door Out Pwr to Rel 1 4 58 DM Input Not Used 1 20 HIM x6 LCD HIM 1 4 59 Lock Mon Enable Disable 1 1 4 60
54. the speed limit that will be monitored in Safe Limited Speed SLS mode Default 0 Units are based on rotary or linear configuration defined by P29 Fbk 1 Units Min Max 0 6553 5 RPM 0 6553 5 mm s 56 Speed Hysteresis Units 96 RW 8 bit Speed Hysteresis Default 0 Integer Provides hysteresis for 515 Out output when Safe Limited Speed monitoring is active Min Max 0 100 0 when P21 Safety Mode 1 2 3 4 5 6 8 or 9 10 100 when P21 Safety Mode 7 or 10 1 You must configure this parameter with a non zero value in this mode Rockwell Automation Publication 750 February 2012 93 Chapter 7 Safe Limited Speed SLS Modes SLS Status Only Wiring These examples illustrate wiring for SLS status only operation Figure 26 Master Safe Limited Speed Status Only Single Unit PowerFlex 750 Series Safe Speed Monitor Option Module Examples TB1 11 511 S11 TEST OUT 0 911 S11 511 521 521 21 TEST OUT 1 521 521 521 Reset eL 534 RESET 534 52 52 DC OUT CHx 51 51 78 78 H 515 OUT CHx 68 68 L sour ak L 34 34 X42 X42 LM_IN_CHx X32 X32 SLS 542 9 DM IN CHx 7 Request 532 IN 532 1 305 O 0 52 552 55 582 52 gt Request IN CHx E 5 IN CHx ro
55. turned off for any output the SIL Category and PL rating is reduced for the entire safety system Values Default Options Default Options Default Options Default Options Default Options Default Options 0 Single 0 Single 1 Multi First 2 Multi Mid 3 Multi Last 1 Safe Stop 0 Disable 1 Safe Stop 2 Safe Stop DM 3 Lim Speed 4 Lim Speed DM 5 Lim Speed ES 6 LimSpd DM ES 7 Lim Spd Stat 8 Slv Safe Stp 9 Slv Lim Spd 10 Slv Spd Stat 2 0 Automatic 1 Manual 2 Monitored Manual Monitored 0 42 msec 0 42 msec 1 48 msec 2 60 msec 3 84 msec 4 132 msec 5 228 msec 6 420 msec 0 Pulse Test 0 Pulse Test 1 Pulse Tst 0 Pulse Test 0 Pulse Test 1 Pulse Tst Rockwell Automation Publication 750 February 2012 Read Write RW RW RW RW RW 8 bit Integer 8 bit Integer 8 bit Integer 8 bit Integer 8 bit Integer 8 bit Integer File Safe Speed Monitor Display Name Full Name Description Fbk Mode Feedback Mode Selects the number of feedback devices and the type of discrepancy checking Single Fbk 0 1 Encoder Dual S P Chk 1 2 Encoders with Speed and
56. 0 4 35 5 2 0550 35 6 1NC Secs 0 0 6553 5 0 Not Used 0 Not Used 12 2NC 2 2NC 3s 3 1NC 1N0 4 INC 1N0 35 5 0550 3s 6 mm s 0 0 6553 5 RPM 0 6553 5 mm s 96 0 0 100 Rockwell Automation Publication 750 February 2012 Read Write RW RW RW RW 8 bit Integer 16 bit Integer 8 bit Integer 16 bit Integer 8 bit Integer File Safe Speed Monitor Display Name Full Name Description Door Out Type Door Output Type Defines the lock and unlock state for door control output DC Out When Door Out Type equals power to release Out is OFF in the lock state and ON in the unlock state When Door Out Type equals power to lock DC Out is ON in the lock state and OFF in the unlock state The first and middle units of a multi axis system must be configured as cascading 2 DM Input Door Monitor Input Configuration for the Door Monitor input DM In 2NC 1 Dual channel equivalent 2NC 3s 2 Dual channel equivalent 3 s 1NC 1NO 3 Dual channel complementary 1NC 1NO 35 4 Dual channel complementary 3 s 2 OSSD 3s 5 Dual channel SS equivalent 3 5 6 Single channel equivalent Lock Mon Enable Lock Monitor Enable Lock Monitoring can only be enabled when the speed monitoring safety option is a single unit or a
57. 0 Control 521 Pulse Source 1 2 3 3 Solenoid 0 0 Door Monitor Inout 942 1 ou 19 42 In 1 DC 52 h 542 DM In 1 0C 0 52 on p 532 DM In 0 DC Out 0 51 gt 532 DM In 0 DC 0 0 51 gt 532 DM In 0 DC 0 0 51 15927 92 Lock Monitor Input 1 In 1 CS X32 1M In 0 A1 A2 24V DC L __ 1 Bl LOC 534 Reset In Auto 534 Reset In Auto 534 Reset In TLS3 GD2 Manual Reset Reset Reset 440G T27260 Feedback A2 A Feedback A2 A Feedback A2 Power to Release First Axis Second Axis Third Axis Feedback Feedback Feedback Slave Safe Stop Mode 98 The inputs from the safety switches are monitored by the first safety option which is the master A Safe Limited Speed Reset detected by the first safety option is cascaded to the subsequent safety options via the 51 5 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 Any fault or transition ofthe 55 In input to OFF is detected by the first safety option and initiates the configured 45 Safe Stop Type to all of the safety options via the 55 Out to 55 In chain Any fault in a slave safety option initiates the configured P45 Safe Stop Type only to that safety option and to slave safety options further down the chain IMPORTANT Safe Stop monitoring is not initiated for non faulted units ea
58. 1 Safe Stop and Safe Stop with Door Monitoring Modes Safe Stop with Door Monitoring Mode 72 When properly configured for Safe Stop with Door Monitoring the safety option monitors the Safe Stop input 55 In and initiates the configured Safe Stop Type upon deactivation of the input as described in Safe Stop Mode on page 61 In addition the safety option verifies through monitoring the Door Monitor input DM that the door interlock solenoid controlled by the Door Control output 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 safety option initiates the configured Safe Stop Type 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 safety option puts the solenoid into the locked state when the machine is not at a safe speed or at Standstill Speed Lock Monitoring If a Safety mode that includes Door Monitoring is selected and Lock Monitoring is enabled the Lock Monitor input LM In signal must be OFF any time that the Door Monitor input DM transitions from ON to OFF IMPORTANT f 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 SS Reset
59. 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 When both channels are active if one channels input terminal transitions from active to inactive and back to active while the other channel input terminal remains active both channels must go inactive at the same time before the evaluated status may return to ON This condition is called cycle inputs required Rockwell Automation Publication 750 February 2012 35 Chapter4 Speed Monitoring 1 0 Signals Figure 4 Cycle Inputs Required d Cycle Inputs Required Active ChannelO inactive Active C 1 inactive ON Evaluated Status OFF EN EE 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 for longer than 3 seconds e 2 Dual channel equivalent 3 2NC 3s 4 Dual channel complementary 3 s INC 1NO 3s 5 Dual channel SS equivalent 3 s 2 OSSD 35 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 will not occur for any discrepant condition or for any cycle inputs required condition e 1 Dual channel e
60. 2 33 Chapter3 Installation and Wiring Notes 34 Rockwell Automation Publication 750 February 2012 Introduction Inputs Chapter 4 Speed Monitoring 1 0 Signals This chapter describes the input and output signals of the Safe Speed Monitor Option module Topic Page Inputs 35 Outputs 41 The safety option has five inputs capable of safety certified 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 e 1 Dual channel equivalent 2 Normally Closed 2 Dual channel equivalent 3 s 2 Normally Closed 3 Seconds 3 Dual channel complementary 1 Normally Closed 1 Normally Open 4 Dual channel complementary 3 s 1 Normally Closed 1 Normally Open 3 Seconds 5 Dual channel SS equivalent 3 2 Output Signal Switching Devices 3 Seconds Single Channel IMPORTANT Single channel configuration 1NC is not SIL PL e 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
61. 4 IN 34 DC OUT CHx 5 5 OUT CHx Safety Stop M ss ce gt to Next Axis 34 gt optional 8 LM IN CHx X32 SLS 542 DM IN CHx T Request 532 Mosi 5 5 IN CHx Gees SS c Request ESM CHx SS_IN_CHx GND 24V_COM i 24V DC M 24V Al 80 Rockwell Automation Publication 750 February 2012 Safe Limited Speed with Door Monitoring Mode P55 Safe Speed Limit Safe Limited Speed SLS Modes Chapter 7 When properly configured for Safe Limited Speed with Door Monitoring the safety option performs Safe Limited Speed SLS monitoring functions as described in Safe Limited Speed SLS Mode on page 75 in addition to the Safe Stop functions as described in Safe Stop Mode on page 61 In addition the safety option verifies through monitoring the Door Monitor input DM In that the safety option controlled by the Door Control output Out is in the expected state If the door is monitored as opened when it should be closed the safety option initiates the configured Safe Stop Type 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 51 5 In is ON meaning the circuit is closed The DM In input must also be ON door closed during a Safe Limited Speed Monitoring Delay LimSpd Mon Delay A Door Monitor fault is a
62. 4427 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 52 Rockwell Automation Publication 750 February 2012 General Parameter List E HOST GROUPS Group General 20 21 22 24 Display Name Full Name Description Cascaded Config Cascaded Configuration Defines whether the speed monitoring safety option is a single unit or if it occupies a first middle or last position in a multi axis cascaded system Single 0 Single Unit System Milti First 1 Cascaded System First Unit Multi Mid 2 Cascaded System Middle Unit Multi Last 3 Cascaded System Last Unit Safety Mode Safety Mode Defines the primary operating mode ofthe speed monitoring safety functions Safe Stop 1 Master Safe Stop Safe Stop DM 2 Master Safe Stop with Door Monitoring Lim Speed 3 Master Safe Limited Speed Lim Speed DM 4 Master Safe Limited Speed with Door Monitoring Lim Speed ES 5 Master Safe Limited Speed with Enabling Switch Control LimSpd DM ES 6 Master Safe Limited Speed with Door Monitoring and Enabling Switch Control Lim Spd Stat 7 Master Safe Limited Speed Status Only Slv Safe Stp 8 Slave Safe Stop Slv Lim Spd 9 Slave Safe Limited Speed Slv Spd Stat 10 Slave Safe Limited Speed Status Only Reset Type Reset Type
63. 45 lt 7 lt 11V lt 11 5V The encoder must be specified May Trip 4 5 4 754 7 14N 11 11 6V 11 5 12 25V to operate across this complete No Trip 4 75 5 25V 74 114V 11 6 13 3V 12 25 14 75V range or larger May Trip 5 25 5 5V 11 4 12 0 13 3 14 0V 14 75 15 5V Trip Zone 25 5V gt 12 01 gt 14 0V gt 15 5V Your power supply must stay within the No Trip range Rockwell Automation Publication 750 February 2012 57 Chapter 5 Feedback Parameter List File Group HOST GROUPS Feedback 58 28 29 30 31 General Device and Feedback Monitoring Configuration Feedback Fault The allowable frequency of feedback input signals is limited The safety option monitors feedback signals whenever its configuration is valid and the Safety mode is not configured as Disabled Encoder Type Sine cosine Maximum Frequency lt 100 kHz Incremental lt 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 which encoder has the fault Diagnostics are performed on the encoder input signals If the encoder diagnostic tests fail Feedback x fault Safe State fault occurs Display Name Full Name Description Fbk Mode Feedback Mode Selects the number of feedback devices and the type of discrepancy checking Single 0 1 Encoder Dual S P Chk 1 2
64. 55 582 582 777 22 22 SS IN CHx 52 512 2 CM A M 24V M This example shows three safety options connected together in a cascaded system IMPORTANT All safety option modules must share a common ground Rockwell Automation Publication 750 RM001F EN P February 2012 Slave Modes for Multi axis Cascaded Systems Figure 32 First Middle and Last Safety Options in a Cascaded System with Door Control and Lock Monitoring Chapter 8 GND 24V DC First Axis Middle Axis Last Axis Safety Option Terminals Safety Option Terminals Safety Option Terminals TB1 TB1 TB1 11 11 11 11 11 11 11 TEST_OUT_O 11 11 TEST_OUT_O 11 11 TEST_OUT_O 511 11 11 11 11 S11 S11 521 521 521 521 521 521 S21 TEST OUT 1 51 S21 TEST OUT 1 51 21 TEST OUT 1 51 521 521 521 521 521 521 2 TB2 TB2 34 RESET IN 534 534 RESET 534 534 RESET 534 52 52 a DC_OUT_CHx 2 DC_OUT_CHx 32 DC OUT CHx 3 51 51 51 51 51 51 78 78 78 S 5 5 OUT CHx m 5 5 OUT CHx 5
65. 6 Operating Mode parameter to 0 Program The value of the P10 Signature ID parameter will change to 0 3 Allow the controller to perform the ADC operation When the ADC operation is complete the ENET indicator on the drive will change to steady green This indicates that an I O connection has been opened to the drive 4 Use a HIM module DriveExplorer DriveExecutive RSLogix 5000 software to verify that the safety option is configured correctly 5 After verification is complete set the P6 Operating Mode parameter to 1 Run which puts the the safety option into Run mode configuration Signature ID is generated by the safety option 6 Record the configuration Signature ID from the contents of the P10 Signature ID parameter 7 Enter the password 8 Set the P5 Lock State parameter to 1 Lock Rockwell Automation Publication 750 February 2012 129 Chapter 10 Safety Configuration and Verification Editing the Configuration Only authorized specially trained personnel can make edits to the configuration These personnel should use all supervisory methods available for example using the software password protections When authorized specially trained personnel make edits they assume the central safety responsibility while the changes are in progress These personnel must also maintain safe application operation You must sufficiently document all edits including
66. 66 Rockwell Automation Publication 750 February 2012 File Safe Speed Monitor Group Security Display Name Full Name Description Config Code Configuration Fault Code 0 No Fault 1 Password Required Password Req 2 P21 Safety Mode value not legal based on P20 Cascaded Config value 3 P57 Door Out Type value not legal based on P20 Cascaded Config value 4 P46 Stop Mon Delay value not legal based on P45 Safe Stop Type value 5 P50 Decel Ref Speed value not legal based on P31 Fbk 1 Resolution value 6 P48 Standstill Speed value not legal based on P20 Cascaded Config value 7 P53 LimSpd Mon Delay value not legal based on P21 Safety Mode value 8 P55 Safe Speed Limit value not legal based on P21 Safety Mode and P31 Fbk 1 Resolution value 9 P56 Speed Hysteresis value not legal based on P21 Safety Mode value 10 P62 Safe Max Speed value not legal based on P31 Fbk 1 Resolution value 11 P42 Direction Mon value not legal based on P21 Safety Mode value 12 P59 Lock Mon Enable value not legal based on P21 Safety Mode value 13 P36 Fbk 2 Resolution value not legal based on P27 Fbk Mode value 14 P35 Fbk 2 Polarity value not legal based on P27 Fbk Mode value 15 P39 Fbk Speed Ratio value not legal based on P27 Fbk Mode value 16 P41 Fbk Pos Tol value not legal based on P27 Fbk Mode value 17 P40 Fbk Spee
67. 73 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 2442 2 447 2 493 2 962 7 650 Table 6 Encoder Resolution 128 lines rev Overspeed Response Time P24 Speed RPM Overspd Response Setting 1 10 100 1000 10 000 93 750 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 Table 7 Encoder Resolution 1000 lines rev Overspeed Response Time P24 Speed RPM setting 1 10 100 1000 10 000 12 000 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 50 Rockwell Automation Publication 750 February 2012 General Device and Feedback Monitoring Configuration Chapter 5 Table 8 Encoder Resolution 1024 lines rev Overspeed Response Time P24 Speed RPM Response 1 10 100 1000 10 000 11 718 75 42 2 445 2 475 2 775 5 775 35 775 41 504 48 1 222 1 237 1 387 2
68. 750 February 2012 Safe Limited Speed SLS Modes Chapter 7 SLS Status Only Parameter To configure the safety option for Safe Limited Speed Status Only monitoring List set these parameters in addition to the Safe Stop parameters listed on page 69 Display Name Full Name 8 Description 3 IC 21 Safety Mode Setting 7 Lim Spd Stat 8 bit E Safety Mode Integer 5 Defines the primary operating mode ofthe speed monitoring safety functions 52 Lim Speed Input Default 0 Not used 7 RW 8 bit Limited Speed Input Options 0 Not used Integer Configuration for Safe Limited Speed input 515 1 2 2NC 1 Dual channel equivalent 2 2 35 2NC 35 2 Dual channel equivalent 3 s 3 1NC 1N0 1NC 1NO 3 Dual channel complementary 4 1NC 1N0 35 35 4 Dual channel complementary 3 s 5 2 0590 35 2 OSSD 3s 5 Dual channel SS equivalent 3 5 6 e 6 Single channel equivalent 53 _ LimSpd Mon Delay Units Secs RW 16 bit z amp Limited Speed Monitoring Delay Default 0 Integer e Defines the Safe Limited Speed Monitoring Delay between the SLS_In ON to OFF Min Max 0 6553 5 E transition and the initiation of the Safe Limited Speed SLS or Safe Maximum Speed SMS monitoring 55 Safe Speed Limit Units RPM RW 16 bit Safe Speed Limit mm s Integer Defines
69. 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 4472 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 Table 9 Encoder Resolution 3000 lines rev Overspeed Response Time P24 Speed RPM OverSpd Response Setting 1 10 100 1000 4000 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 Table 10 Encoder Resolution 5000 lines rev Overspeed Response Time P24 Speed RPM OverSpd Response Setting 1 10 100 1000 2400 2 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 Rockwell Automation Publication 750 February 2012 51 Chapter 5 General Device and Feedback Monitoring Configuration Speed Resolution Accuracy for Linear Systems Table 11 Encoder Resolution 500 lines mm Overspeed Response Time Speed mm s P24 OverSpd Respo
70. ATTENTION When designing your system consider how personnel will exit safeguarding devices may be required for your specific application Safety Category 4 Performance Definition To achieve Safety Category 4 according to ISO 13849 1 2006 the safety related 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 asingle fault in any of its parts does not lead to a loss of safety function asingle 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 e measures against common cause failure shall be applied 16 Rockwell Automation Publication 750 February 2012 Safety Concept Chapter 1 Stop Category Definitions The selection ofa stop category for each stop function must be determined by a risk assessment Stop Category 0 is achieved with immediate r
71. Ares 35 UU 35 Safe Stop Input SS_In n nessen 38 Safe Limited Speed Input SLS_In i etes 38 Door Monitor Input DM In 38 Enabling Switch Monitor Input ESM 39 Lock Monitor Input EM In escis boc xp Se vates 39 ost abre to caeca 40 Oni UE 41 Safe Stop Output SS_Out 2585 4l Safe Limited Speed Output SES Qut i eese ees 42 Door Control Output DE Qut ee 44 Chapter 5 T ttoductiofis Tu CODD eU ever OU e eas 47 Cascaded Configuration ass 2505 dx restos cu ever S x ERE 47 Safety Mode blat esee ade eds 48 Reset eiut at au odore eroe 48 Overspeed Response Time se ERE em 49 Speed Resolution Accuracy for Rotary 5 50 Speed Resolution Accuracy for Linear 5 52 General Parameter Ee uM 53 Feedback Monitoring en de meses tes cy are Spe Pe Pa 54 Feedback Polarity eee ei NV EE E IEEE 54 Ecole tw m 54 Dual Encoders eee tas peek 55 Feedback Voltage Monitor Range eco yere mee rmx 57 Feedback contentis oa dat cie 58 Feedback Parameter Pe ld ea RUMP 58 Chapter 6 61 Sate Stop
72. Defines the type of reset used by the safety option OverSpd Response Over Speed Response Configuration for the feedback interface sampling rate General Device and Feedback Monitoring Configuration Default Options Default Options Default Options Default Options 0 Single 0 Single 1 Multi First 2 Multi Mid 3 Multi Last 1 Safe Stop 0 Disabled 1 Safe Stop 2 Safe Stop DM 3 Lim Speed 4 Lim Speed DM 5 Lim Speed ES 6 LimSpd DM ES 7 Lim Spd Stat 8 Slv Safe Stp 9 Slv Lim Spd 10 Slv Spd Stat 2 0 Automatic 1 Manual 2 Monitored Manual Monitored 0 42 ms 0 42 1 48 ms 2 60 ms 3 84 ms 4 132 ms 5 228 ms 6 420 ms Rockwell Automation Publication 750 February 2012 Set these parameters to configure general operation of the safety option Read Write RW RW RW Chapter 5 8 bit Integer 8 bit Integer 8 bit Integer 8 bit Integer 53 Chapter5 General Device and Feedback Monitoring Configuration Feedback Monitoring 54 The P27 Fbk Mode parameter defines whether the feedback monitoring devices are configured as a single encoder or as dual encoders When two encoders are used the P27 Fbk Mode parameter also defines the type of
73. Delay 75 76 77 84 86 91 Safe Limited Speed Monitoring Inactive 88 Safe Limited Speed Reset See 515 Reset Safe Limited Speed Status Only mode 91 Safe Limited Speed with Door Monitoring and Enabling Switch Monitoring mode 86 Safe Limited Speed with Door Monitoring mode 81 Safe Limited Speed with Enabling Switch Monitoring mode 83 Safe Max Speed 113 Safe Maximum Acceleration Limit 116 Safe Maximum Acceleration Monitoring 116 118 overview 25 Safe Maximum Speed Monitoring 113 115 overview 25 Safe Speed Limit 75 87 92 Safe State definition 19 Safe State Faults 155 Safe Stop 163 Safe Stop 2 63 Safe Stop mode 61 Safe Stop Reset See SS Reset Safe Stop Types 62 64 Safe Stop with Door Monitoring mode 72 Safe Torque Off with Standstill Checking 62 Safe Torque Off without Standstill Checking 64 safety certification T V Rheinland 15 enable jumper 30 functions overview 23 information 29 lock 121 mode slave combinations 111 modes 24 48 power supply 29 ratings 20 reaction time 20 49 shielded conductor 32 161 shutdown EDS 15 Signature ID 121 126 127 SIL 11 15 163 certification user responsibilities 16 Index single encoder configurations 54 single channel operation 35 Slave Safe Limited Speed mode 104 Slave Safe Limited Speed Status Only mode 107 Slave Safe Stop mode 98 SLS Reset 48 77 84 automatic 76 77 manual 77 manual monitored 77 SLS with Door Monitoring and Enabling Switch Monitoring
74. Device Parameters E Parameter Groups Security General Feedback Stop Limi Max Sp Faults 8 5 Dual Encoder DENC 1 9 13 EtherNet IP Embedded 9 14 DeviceLogix Embedded Custom Views Follow these steps to configure Door Control operation for the safety option 1 From the Door Control group choose the P57 Door Out Type parameter 2 Set the P57 Door Out Type parameter to 0 default which equals Power to Release Pwr to Rel This setting was chosen because power must be applied to the solenoid inside the TLS 3 GD2 gate switch to release the gate interlock 3 Choose the P58 DM Input parameter The default setting is 0 for applications that do not use an interlock switch 4 Setthe P58 DM Input parameter value to 1 for 2NC dual channel equivalent operation In this example application the DM Input DM monitors the TLS 3 GD2 switch which has two normally closed 2 safety contacts 148 Rockwell Automation Publication 750 February 2012 Configuration Examples Chapter 11 5 Choose the P59 Lock Mon Enable parameter The default value is 0 Disabled for applications without an interlock switch 6 Set the P59 Lock Mon Enable parameter value to 1 Enabled because this application uses the TLS 3 GD2 interlock switch 7 Choose the P60 Lock Mon Input parameter The default value is 0 Not Used for applications that do not use an interloc
75. Door Control output IMPORTANT The Safe Speed Monitor option must be used with the 20 750 DENC 1 Dual Incremental Encoder module of the 20 750 UFB 1 Universal Feedback module 24 Rockwell Automation Publication 750 February 2012 About the PowerFlex Safe Speed Monitor Option Module Chapter 2 Disabled Mode When P21 Safety Mode 0 Disabled and P6 Operating Mode 1 Run 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 IMPORTANT The safety option monitors motion for Safe Stop in every mode except Disabled 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 may take a long time to stop Preventing access to the hazard until a safe speed has been detected may 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 Out is in the locked state or if the Lock Monitor input indicates locked when the Door Monitor input DM
76. Enabled which monitors that the encoder feedback signal does not exceed the velocity configured by using the Safe Max Speed parameter Rockwell Automation Publication 750 February 2012 149 Chapter 11 150 Configuration Examples Choose the P62 Safe Max Speed parameter The default value is 0 rpm or mm s Enter a value from 0 6553 5 Type the maximum allowable rpm value for velocity The speed is calculated in rpm based on the Fbk 1 Units parameter setting 0 Rotary feedback entered previously 5 Choose the P63 Max Spd Stop Typ parameter Set the P63 Max Spd Stop Typ parameter value to 1 which equals Use Configured Safe Stop Type Safe Stp Typ With this configuration if speed exceeds the configured Safe Max Speed the safety option initiates the configured Safe Stop Type the next section to put the safety option into Run mode and lock the configuration Example 2 Final Security Group Settings This example includes only the steps for entering a configuration by using the HIM module or software program You must also follow the requirements described in Chapter 10 Safety Configuration and Verification including a complete functional test before the operational startup of any ATTENTION You must verify the configuration and validate the entire system safety related system Only authorized specially trained personnel experienced in the commis
77. Encoders with Speed and Position Discrepancy Checking Dual Spd Chk 2 2 Encoders with Speed Discrepancy Checking Dual Pos Chk 3 2 Encoders with Position Discrepancy Checking Fbk 1 Type Feedback 1 Type Selects the type of feedback for encoder 1 When using the Safe Speed Monitor module with a 20 750 UFB 1 Universal Feedback module set this parameter to 0 Sine Cosine and ensure that the Universal Feedback n is set to a Sine Cosine type device P6 FBO Device Sel and or P36 FB1 Device Sel Fbk 1 Units Feedback 1 Units Selects rotary or linear feedback for encoder 1 Fbk 1 Polarity Feedback 1 Polarity Defines the direction polarity for encoder 1 Fbk 1 Resolution Feedback 1 Resolution Counts Revolution 1 65 535 pulses revolution or pulses mm based on rotary or linear configuration defined by P29 Fbk 1 Units Values Default Options Default Options Default Options Default Options Default Min Max 0 Single Fbk 0 Single Fok 1 Dual S P Chk 2 Dual Spd Chk 3 Dual Pos Chk 1 TIL 0 Sine Cosine 1 Incremental 0 Rev 0 Rev Rotary 1 Linear 0 Normal 0 Normal Same as encoder 1 Reversed 1024 1 65 535 Rockwell Automation Publication 750 February 2012 Read Write RW RW RW RO To define the type of feedback used by the saf
78. Full Name Description Guard Status Guard Status Indicates the state of the safety functions while in Run mode Options SLS In Prog x g Data 32 bit Integer gt DM In Prog SDM In Prog gt lt SMAIn Prog Reserved gt IDC Out gt IDC Lock Default gt SMS In Prog gt SLS Out SLS Req S ISLS In SISS Out 74 SS Stopped 55 Decel SS In Prog gt 255 Req 166 In 9 MP Out gt Config Lock lt lt Status0K amp Wait No Stop Wait SS Reset C gt Reset In S Prog ESM In S S Reserved Reserved 58 Stop Cmd 1515 DM In 7 Mo a w Bit w Bit 0 Status OK 0 Fault 1 OK Bit 1 Config Lock Configuration_Lock 0 Unlock 1 Lock Bit 2 MP Out MP Out Value 0 Off 1 Bit 3 SS In SS In Value 0 Off 1 Bit 4 SS Req 55 Request Status 0 Inactive 1 Active Bit 5 SS Prog SS In Progress 0 Inactive 1 Active Bit 6 SS Decel 55 Decelerating Status 0 Inactive 1 Active Bit 7 SS Stopped SS_Axis_Stopped_Status 0 Inactive 1 Activ
79. In transitions from closed to open the configured Safe Stop Type 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 safety option 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 Safe Stop Type 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 Safe Stop Type is initiated Safe Direction Monitoring is also activated via option configuration The option monitors the feedback direction and executes the configured Safe Stop Type when motion in the illegal direction is detected Refer to Chapter 9 for detailed information on these functions Rockwell Automation Publication 750 February 2012 25 Chapter2 About the PowerFlex Safe Speed Monitor Option Module Hardware Features 26 The saf
80. Integer Real 16 bit Integer 16 bit Integer Secondary feedback parameter settings are not required when P27 Fbk Mode 59 Chapter5 General Device and Feedback Monitoring Configuration Notes 60 Rockwell Automation Publication 750 February 2012 Introduction Safe Stop Mode 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 Topic Page Safe Stop Mode 61 Safe Stop Parameter List 69 Safe Stop Wiring Example 71 Safe Stop with Door Monitoring Mode 2 Safe Stop with Door Monitoring Parameter List 73 Safe Stop with Door Monitoring Wiring Example 74 When properly configured for Safe Stop the safety option monitors the Safe Stop input SS In and initiates the configured Safe Stop Type upon deactivation of the input The Safe Stop Type is configurable as either Safe Torque Off with or without Standstill Checking Safe Stop 1 or Safe Stop 2 The safety option 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 Out is set to Unlock In addition to setting the Standstill Speed you configure both the Stop Delay P47 Max Stop Time the period during which deceleratio
81. Limited Speed It is set to 0 in any other operating mode 16 DC Lock This bit is set to 1 if door control logic status is Lock This bit is set to 0 if door control logic status is Unlock 17 DC Out This bit is set to 1 if the dual channel DC Out output is being commanded to the ON state This is the commanded value not the readback value This bit is set to 0 if the dual channel Out output is being commanded to the OFF state 18 DM In This bit is set to 1 if the logical value of the dual channel DM In input is evaluated as 1 This bit is set to 0 if the logical value of the dual channel DM In input is evaluated as 0 19 DM In Prog The status of this bit is dependent on the safety option s speed monitoring configuration The bit is 1 when the safety option is configured for Safe Stop with Door Monitoring and is monitoring motion or is executing a Safe Stop the safety option is configured for Safe Limited Speed with Door Monitoring and the safety option is not actively monitoring for Safe Limited Speed is in a SLS Monitoring Delay LimSpd Mon Delay or is executing a Safe Stop the safety option is configured for Safe Limited Speed with Door Monitoring and Enabling Switch Monitoring and the safety option is not actively monitoring for Safe Limited Speed is in SLS Monitoring Delay LimSpd Mon Delay or is executing a Safe Stop the safety option is actively monitoring for Safe Limited Speed when the ESM In input is OFF an
82. Lock Mon Input Not Used ae Montr e 4 74 Door Out Mode Pulse Test Device Parameters El Parameter Groups Security General Feedback Stop Limited Speed Max Speed Faults 5 Dual Encoder DENC 1 13 EtherNet IP Embedded 14 DeviceLogix Embedded Custom Views H A Follow these steps to configure Door Control operation for the safety option 1 From the Door Control group choose the P57 Door Out Type parameter Set the P57 Door Out Type parameter to 0 default which equals Power to Release Pwr to Rel This setting was chosen because power must be applied to the solenoid inside the TLS 3 GD2 gate switch to release the gate interlock Choose the P58 DM Input parameter The default setting is 0 for applications that do not use an interlock switch Set the P58 DM Input parameter value to 1 for 2NC dual channel equivalent operation In this example application the DM Input monitors the TLS 3 GD2 switch which has two normally closed 2 safety contacts Choose the P59 Lock Mon Enable parameter The default value is 0 Disabled for applications without an interlock switch Set the P59 Lock Mon Enable parameter value to 1 Enabled because this application uses the TLS 3 GD2 interlock switch Choose the P60 Lock Mon Input parameter The default value is 0 Not Used for applications that do not use an interlock switch Rockwell Autom
83. M IN CHx X32 X32 1791DS IB8X0B8 X32 X32 SLS 42 52 52 542 DM IN CHx DM IN CHx 7 s32 on poi 562 562 562 562 SLS_IN_CHx SLS_IN_CHx pf stg 552 In 5 52 552 5 Request 582 25 582 tM IN Cx 2 52 52 n3 vc 52 72 22 22 22 22 n p T In2 p GND mi Tm 24 A2 5 2 CM A EEE EES EE Ee MI W M M oa M GND Rockwell Automation Publication 750 February 2012 95 Chapter 7 96 Safe Limited Speed SLS Modes This example assumes that a programmable safety controller is monitoring all safety option functions and controlling the safety option 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 safety option in this scenario e Guardlocking switch inputs Door locking Door status open or closed Enabling switch Figure 28 Safe Limited Speed Status Only with Programmable Controller Monitoring TB1 In 7 In 6 In 5 In 4 In3 In 2 In 1 In 0 750 Series 511 511
84. Modes Chapter 7 When properly configured for Safe Limited Speed Status Only the safety option provides Safe Limited Speed status information in addition to the Safe Stop functions as described in Safe Stop Mode on page 61 When the Safe Limited Speed input 51 5 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 P53 LimSpd Mon Delay to delay the start of Safe Limited Speed monitoring TIP In Safe Limited Speed Status Only mode Door Monitoring and Enabling Switch Monitoring are not available Speed Status Only mode it will not automatically initiate a Safe Stop in the ATTENTION When the safety option is properly configured for Safe Limited event of an overspeed condition Safe Limited Speed monitoring is requested by a transition of the 51 5 In input from ON to OFF If you configure a P53 LimSpd Mon Delay the delay begins when Safe Limited Speed monitoring is requested by the SLS In input transition from ON to OFF The safety option begins monitoring for Safe Limited Speed when the delay times out The 51 5 Out output is ON if Safe Limited Speed monitoring is active and the speed is below the configured Safe Speed Limit considering hysteresis Figure 25 Ti
85. O wiring diagrams and references a theory of operation a matrix or table of stepped conditions and the actuators to be controlled including sequence and timing diagrams a definition of marginal conditions for example operating modes The I O portion of the specification must contain the analysis of field circuits that is the type of sensors and actuators Sensors Digital or Analog Signalin standard operation dormant current principle for digital sensors sensors OFF means no signal Determination of redundancies required for SIL levels Discrepancy monitoring and visualization including your diagnostic logic Actuators Position and activation in standard operation normally OFF Safe reaction positioning when switching OFF or power failure Discrepancy monitoring and visualization including your diagnostic logic Rockwell Automation Publication 750 February 2012 125 Chapter 10 Safety Configuration and Verification Configure the Safe Speed Monitor Option Module You configure the safety option by using a HIM module DriveExplorer DriveExecutive or RSLogix 5000 software If you are using the Automatic Device Configuration ADC feature refer to Configure ADC and the Safe Speed Monitor Option Module on page 128 Drive DriveExplorer DriveExecutive RSLogix 5000 RSLogix 5000 with ADC Feature PowerFlex 753 Version 6 02 orlater Version 5 03 orlater Vers
86. OUT 1 51 521 521 TB2 534 IN 34 DC OUT CHx 51 78 68 44 SLS_OUT_CHx SS OUT CHx 34 LM IN Cx 52 532 562 552 DM IN CHx SLS IN CHx ESM IN CHx 522 SS_IN_CHx 512 1532 Next Downstream Axis Safety Option Terminals 32 24V Middle Axis Safety Option Terminals 1 11 S11 11 TEST OUT 0 511 S11 S11 21 521 21 TEST OUT 1 521 521 521 TB2 534 RESET IN 52 DC OUT CHx 5 ES 515 OUT CHx 68 55 QUT Cx 34 LM IN CHx X32 DM_IN_CHx 562 515 IN CHx 52 au ESM_IN_CHx 572 2 55 IN CHx 12 A2 24V COM M 241 Al 241 Al Rockwell Automation Publication 750 February 2012 TB1 TEST OUT 0 TEST OUT 1 51 TB2 534 534 52 52 DC OUT CHx 51 51 OUT ZEH 68 68 44 ss QUT 44 34 34 Ml inna CE 32 32 32 DM IN Cx 152 532 56 562 SLS CHx 52 52 582 52 57 572 27 52 512 M 101 Chapter 8 GND 24V DC 102 Slave Modes for Multi axis Cascaded Systems Previous Upstream Axis
87. Options 5 2 OSSD 3s RW 8 bit Safe Stop Input Integer Configuration for Safe Stop input SS_In 2 OSSD 3s 5 Dual channel SS equivalent 3 5 45 Safe Stop Type Default 0 Torque Off RW 8 bit Safe Stop Type Options 0 Torque Off Integer Safe operating stop type selection This defines the type of Safe Stop that is performed if 1 Safe Stop 1 the Safe Stop function is initiated by a stop type condition 2 Safe Stop 2 3 Torque Off NoCk 46 Stop Mon Delay Units Sec RW 16 bit Stop Monitoring Delay Default 0 Integer Defines the monitoring delay between the request and the Max Stop Time when the Min Max 0 6553 5 request for a Safe Stop 1 or a Safe Stop 2 is initiated by an 55 In input ON to OFF transition If the Safe Stop Type is Safe Torque Off With or Without Standstill Speed Checking the Stop Monitor Delay must be 0 or a Invalid Configuration Fault occurs 47 Time Units Secs RW 16 bit Maximum Stop Time Default 0 Integer Defines the maximum stop delay time that is used when the Safe Stop function is Min Max 0 6553 5 initiated by a stop type condition 2 48 Standstill Speed Units RW 16 bit Standstill Speed mm s Integer Defines the speed limit that is used to declare motion as stopped Default 0 001 Units are based on rotary or linear configuration defined by P29 Fbk 1 Units Min Max 0 001 65 535 RPM Not valid for Safe Torque Off without Standsti
88. P27 Fbk Mode value P36 P27 14 P35 Fbk 2 Polarity value not legal based on 27 Fbk Mode value P35 P27 15 P39 Fbk SpeedRatio value not legal based on P27 Fbk Mode value P39 P27 16 P41 Fbk Pos Tol value not legal based on P27 Fbk Mode value P41 P27 17 P40 Speed Tol value not legal based on P27 Mode value P40 P27 18 P44 Safe Stop Input value not legal based on P21 Safety Mode value P44 P21 19 P52 Lim Speed Input value not legal based on P21 Safety Mode value P52 P21 20 P58 DM Input value not legal based on P20 Cascaded Config and P21 Safety Mode value P58 P20 P21 21 P54 Enable SW Input value not legal based on P21 Safety Mode value P54 P21 22 P60 Lock Mon Input value not legal based on P21 Safety Mode value and P59 Lock Mon Enable value P60 P21 P59 23 Illegal P20 Cascaded Config value P20 24 Illegal P22 Reset Type value P22 25 Reserved Reserved 26 Illegal P45 Safe Stop Type value P45 27 Illegal P51 Stop Decel Tol value P51 28 Illegal P27 Fbk Mode value 27 29 Illegal P28 Fbk 1 Type value 28 30 Illegal P31 Fbk 1 Resolution value P31 31 Illegal P32 Fbk 1 Volt Mon value P32 32 Illegal P37 Fbk 2 Volt Mon value P37 33 Illegal P24 OverSpd Response value P24 34 Reserved Reserved 35 Unknown error Unknown Err Rockwell Automation Publication 750 February 2012 159 Chapter12 Troubleshooting the P
89. S In this mode the door is locked when the machine speed is above a configured Safe Speed Limit The door can be unlocked when a stop has been requested and the machine is at Standstill Speed The door can also be unlocked when Safe Limited Speed monitoring SLS In input OFF and the speed is below the configured Safe Limited Speed When the enabling switch is held in the middle position the door can be opened while the machine is running below Safe Limited Speed 5 Choose the P22 Reset Type parameter Set the P22 Reset Type parameter value to 2 default which equals Manual Monitored Monitored The Manual Monitored setting requires an closing and opening of the reset circuit for a reset Choose the P24 OverSpd Response parameter The default Overspeed Response time is 42 ms Set the P24 OverSpd Response parameter value to 1 which equals 48 ms See Overspeed Response Time on page 49 for details Goto the next section to configure the type of feedback by using the Feedback parameters group Rockwell Automation Publication 750 February 2012 143 11 Configuration Examples Example 2 Feedback Group Settings Figure 55 Feedback Group Parameters HIM Screen Software Screen ab AUTO 0 000 Hz FU File Edit Explore Actions Help Port 04 Param File Group FILE Parameter Groups GROUP Feedback Fbk 1 Type Fbk 1 Units ax Den ites E60
90. S Req This bit is set to 1 when a safe stop is initiated by either a transition of the 55 In input from ON to OFF or by a Stop Category fault This bit is reset to 0 when a successful SS Reset occurs and when the Safety mode is set to Disabled 0 5 SS In Prog This bit is set to 1 when safe stop is initiated by the transition ofthe 55 In input from ON to OFF with no active fault conditions It is not set to 1 when a Safe Stop is initiated by a Stop Category fault While set to 1 this bit will be reset 0 if Standstill Speed is reached or any fault condition is detected 6 SS Decel This bit is set to 1 if the configured Stop Delay Max Stop Time is active for a Safe Stop 1 or Safe Stop 2 while the safety option is executing the Safe Stop This bit is not set during a Category 0 Safe Torque Off Safe Stop This bit is reset 0 when Standstill Speed is detected a Safe State fault occurs or a SS Reset occurs 7 SS Stopped This bit is set to 1 if a successful Safe Stop has been executed and the speed is less than or equal to the Standstill Speed This bit is set to 0 by an SS Reset or the occurrence of a Stop Category fault It is always 0 when the safety option is configured for a Safe Torque Off without Standstill Speed Checking 156 Rockwell Automation Publication 750 February 2012 Troubleshooting the Safety Option Module Chapter 12 Bit D
91. 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 which initiates the configured Safe Stop Type SLS with Door Monitoring To configure the safety option for Safe Limited Speed with Door Monitoring set Parameter List Display Name Full Name Description 21 Safety Mode Safety Mode Defines the primary operating mode ofthe speed monitoring safety functions 58 DM Input Door Monitor Input Configuration for the Door Monitor input DM In 1 Dual channel equivalent 2NC 3s 2 Dual channel equivalent 3 s 1NC 1NO 3 Dual channel complementary 1NC 1N0 35 4 Dual channel complementary 3 s 2 OSSD 3s 5 Dual channel SS equivalent 3 5 INC 6 Single channel equivalent General Group HOST GROUPS Door Control 1 You must configure this parameter with a non zero value in this mode Default Options Setting 4 Lim Speed DM 0 Not used 47 0 Not used 12 2NC 2 2NC 3s 3 1NC 1N0 4 1NC 1N0 3s 5 0550 35 6 1NC 82 Rockwell Automation Publication 750 February 2012 the DM Input parameter in addition to the Safe Stop parameters listed on page 69 and the Safe Limited Speed parameters listed on page 78 Rea
92. Safe Stop Type initiated by the safety option in the event of an Acceleration fault by using the P66 Max Acc Stop Typ parameter P66 Max Acc Stop Typ Parameter Description 0 Use Safe Torque Off with Check for The safety option initiates Safe Torque Off with Check for Standstill any Standstill Torque Off time an Acceleration fault is detected while the safety option is monitoring motion 1 Use Configured Stop Type Safe Stp Typ The safety option initiates the configured Safe Stop Type any time Acceleration fault is detected while the safety option is monitoring motion If an Acceleration fault is detected during a Stop Monitoring Delay 46 Stop Mon Delay and the P66 Max Acc Stop Typ parameter is configured as Use Safe Torque Off with Check for Standstill Torque Off the Stop Monitoring Delay 46 Stop Mon Delay ends immediately and Stop Delay P47 Max Stop Time begins If an Acceleration fault is detected during the Stop Delay P47 Max Stop Time and the P66 Max Acc Stop Typ parameter equals Use Configured Stop Type Safe Stp Typ and feedback signals indicate less than the maximum frequency for your encoder type then the fault occurs with no further action Deceleration Monitoring performs the safety function during the Stop Delay P47 Max Stop Time That is if an Acceleration fault occurs during the Stop Delay P47 Max Stop Time the fault is ignored and the stopping action continues Figure 42
93. Safety Reference Manual Allen Bradley Safe Speed Monitor Option Module for PowerFlex 750 Series AC Drives Catalog Numbers 20 750 51 0 _ Ay Allen Bradley Rockwell Software Automation Important User Information 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 available from your local Rockwell Automation sales office or online at http www rockwellautomation com literature describes some 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 ofthis 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 info
94. Set the P30 Fbk 1 Polarity parameter to 0 default to set up the direction for monitoring to be the same as the encoder direction Normal 9 Choose the P31 Fbk 1 Resolution parameter 10 Choose 1024 default or enter value between 1 65 535 pulses revolution based on the encoder specifications 11 Choose the P32 Fbk 1 Volt Mon parameter Rockwell Automation Publication 750 February 2012 Configuration Examples Chapter 11 12 Enter 5 9 or 12V to monitor voltage in accordance with the encoder s specifications or enter 0 default to disable encoder voltage monitoring TIP The P33 Fbk 1 Speed parameter displays the output speed of the encoder as a value between 214 748 364 8 214 748 364 8 rpm based on the encoder s configuration You do not need to enter a setting or value for this parameter 13 Choose the P42 Direction Mon parameter 14 Set the P42 Direction Mon parameter value to 2 to set up the normal monitored direction as Negative Always 15 Choose the P43 Direction Tol parameter 16 Enter value between 0 65 535 degrees based on the encoder s specifications The default value is 10 degrees This sets the position limit tolerated in the wrong direction when Safe Direction Monitoring is enabled Entering 360 equals one revolution in the forward direction before a Direction Fault occurs 17 Goto the next section to set the parameters found in the Stop paramete
95. Speed monitoring If Safe Limited Speed monitoring is configured the SLS In input is monitored from the time ofa successful Safe Stop Reset or Safe Limited Speed Reset until the time that the configured Safe Stop Type 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 safety option In a cascaded configuration the SLS In inputs of the middle and last drives are connected to the Safe Limited Speed 51 5 Out output of an upstream safety option 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 safety option is configured as a master device with door monitoring When the safety option is configured as slave in a cascaded system its In input is connected to the Door Control output Out of the upstream safety option Refer to Door Control Output DC Out on page 44 for more information Rockwell Automation Publication 750 February 2012 Speed Monitoring 1 0 Signals 4 Enabling Switch Monitor Input ESM The ESM In input is intended to be connected to an
96. Stop Category fault which initiates the configured Safe Stop Type If Safe Limited Speed Monitoring is active 51 5 In input is OFF and the safety option 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 N situation If a Safe Stop Type is initiated or a fault occurs while the safety option is actively monitoring Safe Limited Speed door control remains unlocked The safe state of the SLS_In input may allow the door to be unlocked 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 Figure 20 Timing Diagram for Safe Limited Speed SLS with Door Monitoring Mode SLS SLS Request Request Removed A A SLS Monitoring Delay Safe Limited Speed A 3 s Active Speed SLS Fault gt Acceptable Speed Range lime M C Door can be opened Rockwell Automation Publication 750 February 2012 81 Chapter7 Safe Limited Speed SLS Modes Safe Limited Speed Reset When properly configured for Safe Limited Speed with Door Monitoring the safety option must be monitoring motion 51 5 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
97. TIP Only the middle and last safety option in a multi axis system can be configured for slave modes Slave Safe Limited Speed To configure the safety option for Slave Safe Limited Speed monitoring set Parameters these parameters in addition to the Slave Safe Stop parameters listed on page 99 See Multi axis Connections on page 110 for details on configuring slave safety options Values Display Name o Full Name e 5 Description D a Cascaded Config Option 2 Multi Mid 8 bit Cascaded Configuration 3 Multi Last Integer Defines whether the speed monitoring safety option is a single unit or if it occupies a E first middle or last position in a multi axis cascaded system n Safety Mode Optio 9 Slv Lim Spd RW 8 bit Safety Mode Integer Defines the primary operating mode of the speed monitoring safety functions Slv Lim Spd 9 Slave Safe Limited Speed 52 Lim Speed Input Option 5 2 OSSD 35 RW 8 bit 25 Limited Speed Input Integer 2 Configuration for Safe Limited Speed input SLS In 2 0550 3s 5 Dual channel SS equivalent 3 s 212053 Mon Delay Units Sec RW 8 bit 2 Limited Speed Monitoring Delay Default 0 Integer Defines the Safe Limited Speed Monitoring Delay between the 515 In ON to OFF Min Max 0 6553 5 2 transition and the initiation of the Safe Limited Speed SLS or Safe Maximum Speed SMS monitoring 55 Sa
98. Terminals Safety Option Terminals TB1 TB1 TB1 S11 S11 S11 511 511 511 TEST OUT 0 511 TEST OUT 0 11 TEST OUT 0 511 S11 S11 S11 511 521 521 521 521 521 TEST OUT 1 51 TEST OUT 1 21 TEST OUT 1 51 521 521 821 521 2 TB2 RESET 534 RESET IN 534 534 RESET IN 34 52 52 52 52 DC OUT CHx DC OUT CHx DC OUT CHx 51 51 5 51 78 78 515 OUT CHx SLS_OUT_CHx 28 SLS OUT CHx 68 68 68 68 44 SS QUT CHx LS ss our M ss H 3 34 34 34 34 X42 X42 Me LM_IN_CHx LM_IN_CHx LM_IN_CHx X32 X32 X32 X32 X32 DM IN CHx DM_IN_CHx 2 il DM_IN_CHx 32 532 532 532 532 562 562 5 5 CHx 5 5 IN CHx 7 5 5 CHx 2 52 52 52 52 ESM IN CHx 587 ESM IN CHx 24 ESM_IN_CHx ES 572 572 572 572 A SS_IN_CHx SS CHx 2 SS_IN_CHx 18 512 512 512 512 512 A2 24V COM 2 24V COM A2 A2 24V COM A2 Al 24V Al 24V Al Al 24V Al Rockwell Automation Publication 750 February 2012 105 Chapter 8 106 Slave Modes for Multi axis Cascaded Systems This second example is configured as a cascaded last unit via the P20 Cascaded Config parameter Multi Last It has 55 In SLS In and DM In input connections from the previous upstream safety option but its DC Out output is connected to a guardlocking interlock switch Figure 34 Slave Safe Limited Speed Last Unit
99. afe Limited Speed SLS Mode 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 Chapter 7 each mode Topic Page Safe Limited Speed 515 Mode 75 Safe Limited Speed Parameter List 78 Safe Limited Speed Wiring Example Safe Limited Speed with Door Monitoring Mode SLS with Door Monitoring Parameter List SLS with Door Monitoring Wiring Example Safe Limited Speed with Enabling Switch Monitoring Mode SLS with Enabling Switch Monitoring Parameter List SLS with Enabling Switch Monitoring Wiring Example Safe Limited Speed with Door Monitoring and Enabling Switch Monitoring Mode SLS with Door Monitoring and Enabling Switch Monitoring Parameter List SLS with Door Monitoring and Enabling Switch Monitoring Wiring Example Safe Limited Speed Status Only Mode SLS Status Only Parameter List SLS Status Only Wiring Examples When properly configured for Safe Limited Speed the safety option performs Safe Limited Speed SLS monitoring functions in addition to the Safe Stop function described in Safe Stop Mode on page 61 When the Safe Limited Speed input SLS In is OFF feedback velocity is monitored and compared against a configurable Safe Speed Limit If the feedback velocity is below the Safe Speed Limi
100. ailable Frames 1 7 with Drives AOP v3 01 or later PowerFlex 755 Version 6 01 or later Version 5 01 or later Version 16 or later Version 20 or later Frames 1 7 with Drives AOP v2 01 or later PowerFlex 755 Version 6 02 orlater Version 5 03 orlater Version 16 or later Version 20 or later Frames 8 10 with Drives AOP v3 02 or later All of these software configuration tools let you save the configuration and download it to another PowerFlex 750 Series drive DriveExecutive and RSLogix 5000 software also let you edit the configuration offline RSLogix 5000 software version 20 or later allows you to configure a Logix controller for Automatic Device Configuration ADC a feature that allows the controller to download the configuration into a new device When this feature is used with the safety option manual steps are required after the controller downloads the configuration into the safety option When the safety option configuration is complete it can be safety locked to prevent unauthorized changes to the safety configuration If a password was set to protect the safety configuration you must enter the password before you can lock or unlock the configuration Refer to Chapter 10 for instructions on setting up and resetting passwords If you are using a HIM module DriveExplorer Drive Executive or RSLogix 5000 software to configure the safety option refer to the PowerFlex 750 Series Drives Programming Manual pub
101. al or manual monitored reset types Wire the reset input terminal TB2 S34 to the 24 DC input terminal TB2 1 depending on the configured reset type as shown 2 534 RESET N bw mu Manual Monitored TB2 534 RESET IN IMPORTANT Ifyou configure the safety option for automatic reset wiring of the reset input terminal TB2 S34 is not required 40 Rockwell Automation Publication 750 February 2012 Outputs Speed Monitoring 1 0 Signals Chapter 4 The safety option 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 55 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 safety option to a slave ForSS OuttoSS 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 when the P72 SS Out Mode parameter is configured for pulse testing IMPORTANT Ifyou disable pulse testing on this output the achievable SIL Category and PL ratings of your entire safety system are reduced Figure 6 SS OuttoSS In Connections for Multi a
102. ary operating mode of the speed monitoring safety functions 52 Lim Speed Input Limited Speed Input Configuration for Safe Limited Speed input SLS_In 2NC 1 Dual channel equivalent 2NC 3s 2 Dual channel equivalent 3 s 1NC 1NO 3 Dual channel complementary 1NC 1NO 35 4 Dual channel complementary 3 s 2 OSSD 3s 5 Dual channel SS equivalent 3 5 6 Single channel equivalent 53 LimSpd Mon Delay Limited Speed Monitoring Delay Defines the Safe Limited Speed Monitoring Delay between the 515 In ON to OFF transition and the initiation of the Safe Limited Speed SLS or Safe Maximum Speed SMS monitoring 55 Safe Speed Limit Safe Speed Limit Defines the speed limit that will be monitored in Safe Limited Speed SLS mode Units are based on rotary or linear configuration defined by P29 Fbk 1 Units General HOST GROUPS Limited Speed 73 SLS Out Mode Defines whether the 5 5 Out output is pulse tested If pulse testing is turned off for any output the SIL Category and PL rating is reduced for the entire safety system General 1 If pulse testing is turned off for any output the SIL Category and PL rating is reduced for the entire safety system 2 You must configure this parameter with a non zero value in this mode Setting Default Options Units Default Min Max Units Default Min Max Default Options 3 L
103. ascading 2 Cascading ON Door is unlocked 2 Ch Sourcing 2 Ch Sourcing OFF Door is locked A single or last safety option 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 safety option in a cascaded system must be configured as 2 Ch Sourcing ATTENTION When the Out output is configured as Power to Lock P57 N Door Out Type 1 the safe state and faulted state is Unlocked Make sure that this possibility does not create a hazard IMPORTANT X WhentheDC Out output is configured for no pulse testing P74 Door Out Mode 1 and the P57 Door Out Type setting is Power to Lock and a reset is attempted the Out output is pulsed low for 12 ms During the 12 ms the door is unlocked Effect of Faults These fault conditions which affect the integrity of the Out output will force the Out output to its safe state OFF regardless of the status of door control logic e 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 Out output can maintain its integrity both door control logic and the DC_Out output hold last state Ifhold last state cannot be maintained faults may turn the Out output OFF 68 Roc
104. ast publication Topic Page Drive Frames 1 and 10 added Throughout PFD and PFH for 20 year Proof Test Interval table updated 19 Environmental Specifications added 162 Compliance clarified under CE in Certifications section 163 Rockwell Automation Publication 750 February 2012 3 Summary of Changes Notes 4 Rockwell Automation Publication 750 February 2012 Preface Safety Concept About the PowerFlex Safe Speed Monitor Option Module Installation and Wiring Table of Contents About This curo Suo ice aei Tonic Who Should Use ee etel Conventions ee DURUM E E ee REED ES BE QD Tm Additional Chapter 1 DNtFOLDUGHOD ide ev Safety Certification s eer E Cx Important Safety Considerations Safety Category 4 Performance Stop Category Definitlofisi s PES Performance Level and Safety Integrity Level SIL CL3 Functional Proof Tests eoe eter en kar aedem va ed tuts Safety Reaction Dimes ceo Mascot c eta e cut Considerations for Safety Ratings er sien te eras Output Pulse Test Encoder Considerations sioe od i exter rerere
105. ation Publication 750 February 2012 HIM Screen 8 Configuration Examples Chapter 11 Set the P60 Lock Mon Input parameter value to 1 for 2NC dual channel equivalent operation In this example application the Lock Monitor Input LM In monitors the TLS 3 GD2 switch which has two normally closed 2NC interlock monitoring contacts Go to the next section to set the parameters that configure Safe Maximum Speed monitoring Example 1 Max Speed Group Figure 52 Max Speed Group Parameters Not Enabled 0 000 Hz AUTO Port 04 File Group FILE Parameter Groups GROUP Max Speed Safe Max Speed Max Spd Stop Typ Software Screen 5 Beta File Edit Explore Actions Help We E Devices EtherNet IP Direct 512 1 PowerFlex 755 1 Max Speed Enable Disable 9 0 PowerFlex 755 480 22A 1 4 62 Safe Max Speed 0 8 1 20 HIM x6 LCD HIM 1 4 63 Max Spd D vetri Off L 1 4 64 Max Accel Enable isable E wies z 1 4 65 Safe Accel Limit 0 1 4 66 Max Stop Torque Off El Parameter Groups Security General Feedback Stop Limited Speed Door Control Faults 5 Dual Encoder DENC 1 9 13 EtherNet IP Embedded 9 14 DeviceLogix Embedded Custom Views Follow these steps to configure Maximum Speed monitoring for the safety option 1 From the Ma
106. ations 97 98 connections 110 111 wiring 41 43 0 output faults 152 output test pulse 21 outputs 41 OverSpd Response 49 P parameter list all parameters 166 2 feedback 58 general 53 Max Speed and Direction Monitoring 120 Safe Limited Speed 78 Safe Limited Speed Status Only 93 Safe Stop 69 Safe Stop With Door Monitoring 73 Slave Safe Limited Speed 104 Slave Safe Limited Speed Status Only 107 Slave Safe Stop 99 SLS With Door Monitoring 82 SLS With Door Monitoring and Enabling Switch Monitoring 89 SLS With Enabling Switch Monitoring 84 parameters complete list 166 configure 126 edit 126 130 groups 165 password change 122 new 122 reset 122 PFD data 19 definition 12 18 PFH data 19 definition 12 18 pinouts 26 32 PL 18 definition 12 PLe15 PLe 11 163 polarity 54 power supply 29 Power to Lock 68 Power to Release 68 probability of failure on demand 12 probability of failure per hour 12 proof tests 18 pulse test outputs 35 recover from fault 152 reset device configuration 123 password 122 See also SS Reset SLS Reset or Reset Type Reset input wiring Reset_In input 40 Reset Type 48 Reset_In input 77 risk assessment 29 125 Rockwell Automation Publication 750 February 2012 S Safe Accel Limit See Safe Maximum Acceleration Limit Safe Direction Monitoring 118 negative 119 overview 25 positive 119 Safe Limited Speed mode 75 Safe Limited Speed Monitoring
107. aults 69 70 72 73 74 Parameter Data Rockwell Automation Publication 750 February 2012 Display Name 2 Full Name E Description S 5 e 10 Diag Status RO 32 bit 1 0 Diagnostics Status Integer Indicates present state of 1 0 used for diagnostics Important When the safety option is not in the Run mode this parameter is not updated Options 21 55 5 5 6 lels elise Default 0000000000000 Bt 37 30 29 28 07 26 25 24 D3 22 21 1615 4 B 009 6 5 4 B 2 10 0 Open 1 Closed Bit 0 SS In Ch 0 55 in ch Ostatus Bit 1 55 In Ch 1 55 in ch 1status Bit 2 SS Out Ch 0 55 out ch Ostatus Bit 3 SS Out Ch 1 55 out ch 1status Bit4 SLSIn Ch 0 515 in ch Ostatus Bit 5 SLS In Ch 1 515 in ch 1 status Bit 6 SLS Out Ch 0 SLS out ch Ostatus Bit 7 SLS Out Ch 1 SLS out ch 1 status Bit 8 ESM In Ch 0 ESM in ch 0 status Bit 9 ESM In Ch 1 ESM in ch 1 status Bit 10 DM In Ch 0 DM in ch Ostatus Bit 11 DM In Ch 1 2 DM in ch 1 status Bit 12 DC Out Ch 0 DC out ch O status Bit 13 DC Out Ch 1 DC out 1 status Bit 14 LM In Ch 0 LM in ch Ostatus Bit 15 LM In Ch 1 LM in ch 1 status Bit 16 Reset In Reset In status Bit 17 Reserved Bit 18 SLS Cmd 9 9
108. authorization impact analysis execution test information revision information This flowchart shows the steps necessary to edit the safety options configuration C Edit the Configuration Y Unlock the Configuration Make Desired Modifications to Safety Parameters Apply Changes Configuration Signature ID Generated Make Required Modifications Project Verification Test Tests Passed Confirm the Project Record the Configuration Signature ID Lock the Configuration Verify the Lock Status and Signature ID 130 Rockwell Automation Publication 750 February 2012 Introduction Example Application 1 Chapter 1 1 Configuration Examples These examples guide you through the basic steps required to program an application that uses some of the safety option functions The remaining chapters of this manual provide detailed information on the operation of each safety function Topic Page Example Application 1 131 Example Application 2 11 Asan alternative to using the steps listed in this chapter the safety option can also be configured by using the Safe Speed Monitor Startup Wizard that is available in these software applications Use of the wizard is recommended DriveExplorer software version 6 01 or later DriveExecutive software version 5 01 or later RSLogix 5000 software version 16 01 or later TIP Drives AOP version 2 01 o
109. ax 0 Voltage not monitored 0 Voltage not monitored 5 5V 5 9 7 12 12 12 5 24 24 10 24 5 mm s 214748364 8 214748364 7 RPM 214748364 8 214748364 7 mm s 0 0000 0 0001 10000 0 RPM mm s 0 6553 5 RPM 0 6553 5 mm s Deg mm 0 0 65535 deg 0 65535 mm 0 Disable 0 Disable 1 Pos Always 2 Neg Always 3 Pos in SLS 4 Neg in 515 Deg mm 10 0 65535 deg 0 65535 mm Rockwell Automation Publication 750 February 2012 Read Write RW RO RW RW RW RW RW Data Type 8 bit Integer 32 bit Integer Real 16 bit Integer 16 bit Integer 8 bit Integer 16 bit Integer E Safe Speed Monitor Group Stop 45 46 47 48 49 50 51 Display Name Full Name Description Safe Stop Input Safe Stop Input Configuration for Safe Stop input SS_In 2NC 1 Dual channel equivalent 2NC 3s 2 Dual channel equivalent 3 s 1NC 1NO 3 Dual channel complementary 1NC 1N0 3s 4 Dual channel complementary 3 s 2 OSSD 3s 5 Dual channel SS equivalent 3 s 6 Single channel equivalent Safe Stop Type Safe Stop Type Safe operating stop type selection This defines the type of Safe Stop that is performed if the Safe Stop function is initiated by a stop type condition Torque Off 0 Safe Torque Off With Stand
110. ay be configured for Automatic reset single reset by the first unit also resets all following units in the chain If a fault occurs after the first axis in the cascaded chain only the subsequent axis enters the safe state To reset all axes you must cycle the 55 In input on the first axis For slave units in a multi axis system the 55 In SLS In and DM In input signal types if used must be configured for output switching signal devices OSSD because the output from the previous unit is also configured for OSSD For middle or last units in multi axis systems the safety option 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 For information on door control in the master unit see Door Control on page 67 Typical Safety Mode Combinations Cascaded Connections Allowed Master Safety Option First Slave Safety Option 0 SS Outto SLS Outto DC Outto Second Safety Option in System SS In SLS In DM In 2 Safe Stop Slave Safe Stop Yes Yes Safe Stop with Door Monitoring Slave Safe Stop Yes Yes Safe Limited Speed Slave Safe Stop Yes Yes Slave Safe Limited Speed Yes Yes Yes Safe Limited Speed with Door Monitoring Slave Safe Stop Yes Yes Slave Safe Limited Speed Yes Yes Yes Safe Limited Speed with Enabling Switch Monitoring Slave Safe Stop Yes
111. based on rotary or linear configuration defined by P29 Fbk 1 Units Max Speed Enable Maximum Speed Enable Enable Safe Maximum Speed Monitoring Safe Max Speed Safe Maximum Speed Defines the maximum speed limit that will be tolerated if Safe Maximum Speed monitoring is enabled Max Spd Stop Typ Maximum Speed Stop Type Defines the safe stop type that will be initiated in the event of a SMS Speed Fault Torque Off 0 Safe Torque Off With Standstill Checking Safe Stp Typ 1 Safe Torque Off Without Standstill Checking Max Accel Enable Maximum Acceleration Enable Enable Safe Maximum Acceleration Monitoring Safe Accel Limit Safe Acceleration Limit Defines the Safe Maximum Acceleration Limit relative to encoder 1 for which the System is being monitored Units are based on rotary or linear configuration defined by P29 Fbk 1 Units Max Acc Stop Typ Maximum Acceleration Stop Type Defines the safe stop type that will be initiated in the event of an Acceleration Fault Torque Off 0 Safe Torque Off With Standstill Checking Safe Stp Typ 1 Safe Torque Off Without Standstill Checking Values Default Options Default Options Default Options Units Default Min Max Default Options Units Default Min Max Default Options Default Options Units Default Min Max Default Options 0 Normal 0 Normal Same as encoder
112. begins when Safe Limited Speed monitoring is requested by the SLS In transition from ON to OFF The safety option 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 safety option initiates the configured Safe Stop Type Figure 18 Timing Diagram for Safe Limited Speed SLS SLS SLS Request Request Removed A SLS Monitoring Delay Safe Limited Speed A 7 P53 Active Speed SLS Fault Acceptable Speed Range gt Time Rockwell Automation Publication 750 February 2012 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 P53 LimSpd Mon Delay if one is configured When an SLS Reset occurs the safety option 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 safety option checks that no faults are present and verifies that the 515 In input is ON closed circuit before the reset is performed When the input is OFF Safe Limited Speed monitoring takes place after the P53 LimSpd Mon Delay if one is configured An SLS Reset can be reque
113. blication 750 February 2012 123 Chapter 10 Safety Configuration and Verification Commissioning the System 124 The flowchart shows the steps required for commissioning a Speed Monitoring safety system The items in bold are explained in the following sections Specify the Safety Configuration Configure the System Configuration Signature ID Generated Project Verification Test Tests Passed Yes Confirm the Project Record the Configuration Signature ID Lock the Configuration Configuration Signature ID Generated Make Required Modifications Verify Signature ID and Lock Status Rockwell Automation Publication 750 February 2012 Safety Configuration and Verification Chapter 10 Specifying the Safety Configuration You must create a specification for the system configuration that addresses the safety requirements identified by a risk assessment of your application Use the specification to verify that the configuration is selected correctly and that it fully addresses your application s functional and safety control requirements The specification must be a detailed description that may include if applicable a sequence of operations flow and timing diagrams sequence charts a configuration description of each parameter documented descriptions of the steps with step conditions and actuators to be controlled input and output definitions I
114. bute equals 1 It is set to 0 if the 55 In input is detected as OFF 26 Wait No Stop This bit is set to 1 when stop request is made by using the HIM stop button It is set to 0 when the HIM start button is pushed following a reset or at powerup 27 SLS Cmd This bit is set to 1 when the safety option is commanding the drive to operate in limited speed mode 28 Stop Cmd This bit is set to 0 when the safety option is commanding the drive to stop 29 Reserved 31 Rockwell Automation Publication 750 February 2012 157 Chapter12 Troubleshooting the PowerFlex Safety Option Module 1 0 Diagnostic Status Attributes These attributes are stored in the P69 IO Diag Status parameter Each bit reflects the present state of I O signal and is used for diagnostics 0 open 1 closed Bit Display Text 0 SS In Ch 0 1 SS In Ch 1 2 SS Out Ch 0 3 SS OutCh1 4 SLS In Ch 0 5 SLS In Ch 1 6 SLS Out Ch 0 7 SLS Out Ch 1 8 ESM In Ch 0 9 ESM In Ch 1 10 DM In Ch 0 11 DM In Ch 1 12 DC Out Ch 0 13 DC Out Ch 1 14 LM In Ch 0 15 LM In Ch 1 16 Reset In 17 Reserved 18 SLS Cmd 19 Stop Cmd 20 MP Out Ch 0 21 MP Out Ch 1 Bits 22 31 are Reserved 1 Refer to Guard Status Attributes bit 2 on page 156 IMPORTANT When the safety option is not in Run mode the P69 10 Diag Status parameter is not updated 158 Rockwell Automation Publication 750
115. cation 750 February 2012 163 Appendix A Specifications Encoder Specifications Use Belden 9728 cable with the following encoder specifications Type Parameter Description Generic Incremental encoder support 5 9 and 12V differential A quad B Incremental Differential input voltage AM and BM 1 0 7 0V High threshold level min 3 5V Low threshold level max 0 4V DC current draw AM and BM 60 mA max Input signal frequency AM and BM 200 kHz max Cable length max 183 600 ft max cable length with 12V encoder 30 5 m 100 ft max cable length with 5V encoder Generic AM BM input frequency 100 kHz max Sin Cos AM BM differential input voltage p p 0 6 1 2V Stegmann Sin AM BM input frequency 100 kHz max Cos differential input voltage p p 1V 10 164 Rockwell Automation Publication 750 February 2012 Parameter Data This appendix provides a description of the safety parameters organized into Appendix B both a linear list by parameter number and into device specific files and groups Parameter Groups Parameters for the Safe Speed Monitor Option module appear in the groups Security General Feedback Stop Limited Speed Door Control Max Speed and Faults Figure 60 Safety Option Parameter Groups File Group Parameters Host Groups Security Password 1 Reset Defaults 7 Password Command 17 Con
116. ccurs during the Stop Delay P47 Max Stop Time the fault is ignored and the stopping action continues 1 100 kHz for Sin Cos or 200 kHz for Incremental 114 Rockwell Automation Publication 750 February 2012 Safe Maximum Speed and Direction Monitoring Chapter 9 Figure 39 SMS Speed Fault When P63 Max Spd Stop Typ Set to Use Configured Stop Type Safe Stp Typ Stop Request SMS Speed Fault A Stop Delay Speed P46 Stop Mon 47 Max Stop Time Delay CC P62 Safe Max Speed gt lt P51 Stop Decel Tol P48 Standstill Speed gt lime If an SMS Speed fault is detected during the Stop Delay P47 Max Stop Time and the P63 Max Spd Stop Typ parameter equals Use Safe Torque Off with Check for Standstill Torque Off the SMS Speed fault is reported and motion power is removed The Stop Delay P47 Max Stop Time continues with standstill checking enabled Figure 40 SMS Speed Fault When P63 Max Spd Stop Typ Set to Use Safe Torque Off with Check for Standstill Torque OFF Stop Request A SMS Speed Fault Stop Delay Speed NC P46 Max Stop Time P62 Safe Max Speed P48 Standstill Speed SS In s SS Out NU Motion Power 9 1 Thissignal is internal between the safety option and drive For more information about faults see Fault Reactions on page 155 Rockwell Automation
117. ccurs if the speed is detected at greater than the limit specified for the configured Stop Delay Max Stop Time when the configured Safe Stop Type is Safe Stop 1 or 2 12 Stop Spd Flt A Stop Speed fault occurs when the safety option is configured for a Safe Stop Type that includes Standstill Speed checking Safe Stop 1 or 2 and Safe Torque Off with Standstill Speed Checking and the detected speed is greater than the configured Standstill Speed at the end of the configured Stop Delay Max Stop Time Rockwell Automation Publication 750 February 2012 153 Chapter 12 Table 19 Stop Category Faults Troubleshooting the PowerFlex Safety Option Module Code Display Text Description 9 SS In Flt 1 0 An 55 fault occurs if an error is detected in the 55 In dual channel input Faults 10 SS Out Fit AnSS Out fault occurs if an error is detected in the SS_Out dual channel output 14 SLS In Flt An 515 fault occurs if an error is detected in the SLS_In dual channel input 15 SLS Out Fit An SLS_Out fault occurs if an error is detected in the SLS_Out dual channel output 20 DM In Fit ADM fault occurs if an error is detected in the DM dual channel input 22 DC Out Fit ADC Out fault occurs if an error is detected in the Out dual channel output 23 LM In Fit AnLM fault occurs if an error is detected in the LM In dual channel i
118. ched The safety option continues to monitor for faults These Stop Category faults 515 Speed fault 515 Spd e Direction fault Dir Flt if the fault was detected before the safe stop was initiated In this case the safety option does not perform Direction Monitoring while executing the configured Safe Stop Type Door Monitoring fault Door Mon ESM Monitoring fault ESM Mon Fit Lock Monitoring fault Lock Mon SMS Speed fault when the P63 Max Spd Stop Typ is configured for Use Configured Safe Stop Type Safe Stp Typ Acceleration fault when the P66 Max Acc Stop Typ is configured for Use Configured Safe Stop Type Safe Stp Typ Rockwell Automation Publication 750 February 2012 The safety option continues to execute the configured Safe Stop Type and monitor for faults 155 Chapter 12 Status Attributes Troubleshooting the PowerFlex Safety Option Module If outputs are already in a faulted state due to a previous fault and a subsequent Stop Category fault or Fault While Stopping fault occurs outputs remain in a faulted state door control logic can be set to Unlock if feedback signals indicate that Standstill Speed has been reached and the safety option continues to monitor for faults If a Stop Category fault or Fault While Stopping fault occurs after Standstill Speed has been reached and the safety option has set door control logic to Unlock the safety opti
119. configuration defined by P29 Fbk 1 Units Fbk Pos Tol Feedback Position Tolerance Acceptable difference in position between encoder 1 and encoder 2 Units are based on rotary or linear configuration defined by P29 Fbk 1 Units TIP General Device and Feedback Monitoring Configuration Values Default 0 Voltage not monitored Options 0 Voltage not monitored 5 5V 5 9 7 12V 122 12V 596 24 24V 1096 24V 596 Units RPM mm s Min Max 214 748 364 8 214 748 364 7 RPM 214 748 364 8 214 748 364 7mm s Default 0 Rev Options 0 Rev Rotary 1 mm Linear Default 0 Normal Options 0 Normal Same as encoder 1 Reversed Default 0 Min Max 1 65 535 Default 0 Voltage not monitored Options 0 Voltage not monitored 5 5V 5 9 7 12V 122 12V 596 24 24V 1096 24V 596 Units RPM mm s Min Max 214 748 364 8 214 748 364 7 RPM 214 748 364 8 214 748 364 7mm s Default 0 0000 Min Max 10 0001 10 000 0 Units RPM mm s Min Max 0 6553 5 RPM 0 6553 5 mm s Units Deg mm Default 0 Min Max 0 65 535 deg 0 65 535 mm is set to 0 Single Fok Rockwell Automation Publication 750 February 2012 Read Write RO RW RW RO RW RO RW RW RW Chapter 5 8 bit Integer 32 bit Integer 8 bit Integer 8 bit Integer 16 bit Integer 8 bit Integer 32 bit
120. cremental Y 9 1 20 HIM x6 LCD HIM Pus i3 i B T 4 olarity rmal baden 22 1 431 Resolution 1024 H 1 4 32 Fbk 1 Volt Mon 0 El Parameter Groups 1 4 33 Fbk 1 Speed 0 0 Security 1 4 34 Fbk 2 Units Rev General 1 4 35 Fbk 2 Polarity Normal 1 4 36 Fbk 2 Resolution 0 Stop 1 4 37 EL 2 Volt 0 P 1 4 38 Fbk 2 Spee 0 0 Linked Speed 1 439 Fbk Speed Ratio 0 00000 Door Control 1 440 FbkSpeed Tol 0 0 Max Speed 1 4 41 Fbk Pos Tol 0 Faults 1 4 42 Direction Mon Disable H 5 Dual Encoder DENC 1 1 4 43 Direction Tol 10 9 13 EtherNet IP Embedded 8 14 DeviceLogix Embedded Custom Views Follow these steps to configure the type of feedback used by the safety option 1 From the Feedback group choose the P27 Fbk Mode parameter 2 Set the P27 Fbk Mode parameter value to 0 default for redundant processing and cross checking of the single encoder input in a 1002 architecture 3 Choose the P28 Fbk 1 Type parameter The default value is 1 for incremental encoder input 4 Setthe P28 Fbk 1 Type parameter value to 0 for Sine Cosine and internal monitoring of the single encoder input 5 Choose the P29 Fbk 1 Units parameter 6 Set the P29 Fbk 1 Units parameter to 0 default which equals Rotary feedback 7 Choose the P30 Fbk 1 Polarity parameter 8 Set the P30 Fbk 1 Polarity parameter to 0 default to set up the direction for monitoring to be the same as the encoder directio
121. d Tol value not legal based on P27 Fbk Mode value 18 P44 Safe Stop In Typ value not legal based on P21 Safety Mode value 19 P52 Lim Spd In Typ value not legal based on P21 Safety Mode value 20 P58 DM Input Type value not legal based on P20 Cascaded Config and P21 Safety Mode value 21 P54 Enable SW In Typ value not legal based on P21 Safety Mode value 22 P60 Lock Mon In Type value not legal based on P21 Safety Mode value and P59 Lock Mon Enable value 23 Illegal P20 Cascaded Config value 24 Illegal P22 Reset Type value 25 Reserved 26 Illegal P45 Safe Stop Type value 27 Illegal P51 Stop Decel Tol value 28 Illegal P27 Fbk Mode value 29 Illegal P28 Fbk 1 Type value 30 Illegal P31 Fbk 1 Resolution value 31 Illegal P32 Fbk1 Volt Mon value 32 Illegal P37 Fbk 2 Volt Mon value 33 Illegal P24 OverSpd Response value 34 Reserved 35 Reserved 36 Unknown Error Unknown Err Values Default Options Rockwell Automation Publication 750 February 2012 Parameter Data Appendix B Read Write 8 bit Integer 167 Appendix B a 28 21 8 5 2 22 a 24 72 73 168 Parameter Data Display Name Full Name Description Cascaded Config Cascaded Configuration Defines whether the speed monitoring safety option i
122. d Write RW 8 bit Integer 8 bit Integer SLS with Door Monitoring Wiring Exam ple Figure 21 Master Safe Limited Speed with Door Monitoring First or Single Unit TB1 S11 511 11 TEST OUT 0 S11 PowerFlex 750 Series Safe Speed Monitor n 51 Option Module 21 21 Reset 21 TEST OUT 1 21 521 521 gly TB2 34 34 52 52 DC OUT CHx p 51 51 ower to 78 78 Release SLS_OUT_CHx 3 TLS3 602 68 68 4406 27260 44 44 Safety Stop Safety Switch m 55 OUT CHx m to Next Axis optional Remove 2 X42 1 Internal 3 LM IN CHx 37 Jumpers SLs 542 542 DM IN CHx Request 532 532 a SLS_IN_CHx 52 552 382 ESM_IN_CHx 382 55 572 572 22 Request SS IN CHx d a GND PESE 2 24 A2 24V DC Al 24V Al Safe Limited Speed with Enabling Switch Monitoring Mode Safe Limited Speed SLS Modes This example illustrates wiring for SLS with door monitoring Chapter 7 1 Lock monitoring connections are not required for Safe Limited Speed with Door Monitoring mode operation When properly configured for Safe Limited Speed with Enabling Switch Monitoring the safety option performs Safe Limited Speed SLS monitoring functions as described
123. d the DM In input is ON This bit is always set to 0 when the safety option is not configured for Door Monitoring 20 LM In This bit is set to 1 if the logical value of the dual channel LM In input is evaluated as 1 This bit is set to 0 if the logical value of the dual channel LM In input is evaluated as 0 21 ESM In This bit is set to 1 if the logical value of the dual channel input is evaluated as 1 This bit is set to 0 if the logical value of the dual channel input is evaluated as 0 22 ESM In Prog This bit is set to 1 if the Safety mode is configured for Enabling Switch Monitoring Safe Limited Speed monitoring is active and the 515 In input is OFF It is also set to 1 if the Safety mode is configured for Enabling Switch Monitoring and Door Monitoring and the DM In input is OFF This bit is set to 0 when the Safety mode is not configured for Enabling Switch Monitoring 23 Reset In This status bit reflects the state ofthe Reset In input 1 indicates the Reset In input is ON a 0 indicates the Reset In input is OFF 24 Wait Reset This bit indicates when an SS Reset is required The bit is set to 1 whenever the safety option is successfully configured and is in the Safe State or when Standstill Speed has been reached 25 Wait SS Cyc This bit indicates when the 55 In input must be cycled prior to a SS Reset being performed The bit is set to 1 if the 55 In input is ON and a fault is detected or the Wait Stop Request attri
124. d to the operation of the safety option If you are not using the 010 input as a hardware enable do not remove the ENABLE jumper 30 Rockwell Automation Publication 750 February 2012 Installation and Wiring Chapter 3 ere are multiple option module port positions in PowerFlex 750 Series drives Install the PowerFlex Safety 1 Itiple op dule port p PowerFl Series d tion Module Restrictions and or recommendations apply to selected option modules IMPORTANT safety option module must be installed in port 4 5 or 6 and must be used with the 20 750 DENC 1 Dual Incremental Encoder module or the 20 750 UFB 1 Universal Feedback module When used in an Integrated Motion application the Safe Speed Monitor option must be installed in port 6 installed or removed while the drive has power applied To avoid damaging the drive verify that the voltage on the bus capacitors has discharged before performing any work on the drive Refer to the PowerFlex 750 Series AC Drive Installation Instructions publication 750 IN001 for more information ATTENTION Hazard of equipment damage exists if an option module is Follow these steps to install the PowerFlex safety option 1 Firmly press the option module edge connector into the desired option module port 2 Tighten the top and bottom retaining screws Recommended torque 0 45 Nem 4 0 Ibein Recommended screwdriver T15 Hexalobular
125. detected You configure Safe Direction Monitoring by using the P42 Direction Mon parameter This parameter also determines the direction positive or negative in which motion is allowed Table 16 Enable Safe Direction Monitoring P42 Direction Mon Parameter Description 0 Disabled Safe Direction Monitoring is disabled 1 Positive Always Safe Direction Monitoring is active any time the configuration is valid and not Disabled 2 Negative Always 3 Positive During SLS Safe Direction Monitoring is performed only when the safety option is actively monitoring Safe Limited Speed 4 Negative During SLS IMPORTANT Besureto set the P30 1 Polarity and P35 2 Polarity configuration parameters properly for a consistent direction between encoder 1 and encoder 2 You may configure a position limit in encoder units tolerated in the wrong direction before a Direction fault occurs by using the P43 Direction Tol parameter 118 Rockwell Automation Publication 750 February 2012 Safe Maximum Speed and Direction Monitoring Chapter 9 Figure 44 Positive Safe Direction Monitoring Timing Diagram P42 Direction Mon 1 Pos Always Speed 300 Safe Direction Fault Figure 45 Negative Safe Direction Monitoring Timing Diagram P42 Direction Mon 2 Neg Always Safe Direction Fault Time 300 Safe Direction Speed If motion is detected in the inco
126. ding to ISO 13849 1 Safety requirements are based on the standards current at the time of certification TUV Rheinland group has approved the PowerFlex 750 Series safety option for use in safety related applications where the de energized state 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 750 February 2012 15 Chapter1 Safety Concept Important Safety Considerations The system user is responsible for e the setup safety rating and validation of any sensors or actuators connected to the system completing a system level risk assessment and reassessing the system any time a change is made certification of the system to the desired safety performance level project management and proof testing programming the application software and the safety option 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 IMPORTANT When applying functional safety restrict access to qualified authorized personnel who are trained and experienced the machine ifthe door locks while they are in the machine Additional
127. discrepancy checking that is performed between the two encoders IMPORTANT Feedback device 1 can be a Sin Cos or incremental feedback device Feedback device 2 can only be an incremental feedback device You choose the type of feedback device either sine cosine or incremental for encoder 1 by using the P28 Fbk 1 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 Fbk x Units parameter Configure the resolution in lines per revolution or lines per millimeter by using the Fbk x Resolution parameter In these parameter names the x is 1 for encoder 1 and 2 for encoder 2 For dual encoder configurations the resolution of the first encoder may be different than the resolution of the second encoder After discrepancy testing has passed the speed relative position and direction used by the safety option are based on encoder 1 IMPORTANT For dual encoder configurations the resolution of the first encoder may 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 P30 Fbk 1 Polarity parameter The safety option defines the normal positive direction for encoders as A leading B To use encoders where B leads A you must enter 1 for the P30 Fbk
128. e Terminology This table defines abbreviations used in this manual Abbreviation Full Term Definition 1002 One out of Two Refers to the behavioral design of a dual channel safety system CAT Category Capability Level DC Door Control DM Door Monitoring EN European Norm The official European Standard ESD Emergency Shutdown Systems ESM Enabling Switch Monitoring ESPE Electro sensitive Protective Equipment An assembly of devices and or components working together for protective tripping or presence Sensing purposes and comprising as a minimum e asensing device controlling monitoring devices output signal switching devices OSSD FMEA Failure Mode and Effects Analysis FV Flux Vector HFT Hardware Fault Tolerance The HFT equals n where n 1 faults could cause the loss of the safety function An HFT of 1 means that 2 faults are required before safety is lost HIM Human Interface Module A module used to configure a device IEC International Electrotechnical Commission IGBT Insulated Gate Bi polar Transistors Typical power switch used to control main current 150 International Organization for Standardization Lock Monitoring MP Motion Power NC Normally Closed A set of contacts on a relay or switch that are closed when the relay is de energized or the switch is de activated NO N
129. e Bit 8 SS Out SS_Output_Value 0 Off 1 On Bit 9 SLS In SLS In Value 0 Off 1 Bit 10 SLS Req SLS_Request_Status 0 Inactive 1 Active Bit 11 SLS In Prog SLS Progress 0 Inactive 1 Active Bit 12 SLS Out SLS_Output_Value 0 Off 1 On Bit 13 SMS In Prog SMS In Progress 0 Inactive 1 Active Bit 14 SMA In Prog SMA In Progress 0 Inactive 1 Active Bit 15 SDM In Prog SDM In Progress 0 Inactive 1 Active Bit 16 DC Lock DC Lock Status 0 Lock 1 Unlock Bit 17 DC Out DC_Out_Value 0 Off 1 Bit 18 DM In DM In Value 0 Off 1 On Bit 19 DM In Prog DM Progress 0 Inactive 1 Active Bit 20 LM In LM In Value 0 Off 1 On Bit 21 ESM In ESM_In_Value 0 Off 1 Bit 22 ESM In Prog ESM_In_Progress 0 Inactive 1 Active Bit 23 Reset In Reset In Value 0 Off 1 On Bit 24 Wait Reset Waiting_for_SS_Reset 0 Inactive 1 Active Bit 25 Wait SS Waiting for SS In 0 Inactive 1 Active Bit 26 Wait No Stop Waiting_for_Stop_Request_Removal 0 Inactive 1 Active Bit 27 SLS SLS_ Command 0 Off 1 On Bit 28 Stop Stop Command 0 Off 1 Rockwell Automation Publication 750 February 2012 File Safe Speed Monitor F
130. e safety option in the event of an SMS Speed fault by using the P63 Max Spd Stop Typ parameter P63 Max Spd Stop Typ Parameter Description 0 Use Safe Torque Off with Check for The safety option initiates Safe Torque Off with Check for Standstill any Standstill Torque Off time an SMS Speed fault is detected while the safety option is monitoring motion 1 Use Configured Stop Type Safe Stp Typ The safety option initiates the configured P45 Safe Stop Type parameter any time an SMS Speed fault is detected while the safety option is monitoring motion If an SMS Speed fault is detected during a Stop Monitoring Delay P46 Stop Mon Delay the delay ends immediately and the configured Stop Delay 47 Max Stop Time begins Figure 38 SMS Speed Fault During Stop Monitoring Delay SMS Speed Fault Speed Stop Delay Begins Immediately P47 Max Stop Time P62 Safe Max Speed p P48 Standstill Speed E l gt lime Configured Stop P46 Stop Mon Delay Ifan SMS Speed fault is detected during the Stop Delay Max Stop Time and the P63 Max Spd Stop Typ parameter equals Use Configured Stop Type Safe Stp Typ and the feedback signals indicate less than maximum frequency for your encoder type the fault is reported but no further action is taken Deceleration monitoring performs the safety function during the Stop Delay P47 Max Stop Time That is ifan SMS Speed fault o
131. ed Middle Unit Multi Mid or Cascaded Last Unit Multi Last Only the middle or last safety option in a multi axis system can be configured for slave modes For cascaded safety options connect the safety switches to the safety inputs SS In SLS In DM In ESM In and LM In of the first master axis only Each feedback for Safe Stop functions are connected to their respective axis The inputs are cascaded from one safety option to the next by connecting the outputs from the previous safety option to the inputs of the next safety option Rockwell Automation Publication 750 February 2012 97 Chapter8 Slave Modes for Multi axis Cascaded Systems Figure 29 Cascaded Connections First Axis Middle Axis Last Axis Master Slave Slave gt Axis 1 Axis 2 Axis 3 5 f St t gt 522 55 In 1 55 Out 144 522 SS In 1 SS Out 1 44 gt 522 55 In 1 SS Out 1 44 dle top INDUL 5 512 sc ss Qut 0 34 gt 51255 In 0 SS Out 0 34 gt 512 55 In 0 SS 0 0 34 inu p 562 45111 45 Out 178 gt 562 SLS_In_1 SLS_Out_1 78 562 515 In 1 5L5 Out 1 78 Safe Limited Speed Input 552515 In 0 915 0 0 68 3J9 552 515 In 0 SLS Out 0 68 552 515 In 0 SLS Out 0 68 2 582 ESM In 1 Enabling Switch Monitor Input 72 SM ERR To Door 11 Pulse Source
132. ed Sin Cos or incremental encoders Refer to the Kinetix Motion Control Selection Guide publication GMC SG001 for more information on these motors Any motor with SRS 60 Stegmann encoder Any motor with SRM 60 Stegmann encoder Any motor with SHS 170 Stegmann encoder Any motor with SCS 60 Stegmann encoder HPK Series Asynchronous Servo Motor Any motor with SCS Kit 101 Stegmann encoder Any motor with SRS660 Stegmann encoder 1 Maximum cable length for sin cos encoders is 90 m 295 ft 2 Maximum cable length for incremental encoders is 183 m 600 ft when using 12V or 30 5 m 100 ft when using 5V Connect an Encoder Refer to the product documentation for your specific motor to determine the encoder type Refer to the product documentation for your specific motor to determine the encoder type The PowerFlex 750 Series safety option uses feedback that is connected to a 20 750 DENC 1 Dual Incremental Encoder module or a 20 750 UFB 1 Universal Feedback module Refer to the PowerFlex 750 Series AC Drive Installation Instructions publication 750 IN001 for information on how to connect encoders to these option modules IMPORTANT The 20 750 DENC 1 Dual Incremental Encoder module and the 20 750 UFB 1 Universal Feedback module have specified jumper or slider settings to enable use with the Safe Speed Monitor option module Rockwell Automation Publication 750 February 201
133. eets ISTA 2B packaging standards Random Secured Frame 1 5 Frequency Hz PSD g2 Hz 1 0 00005 4 0 01 16 0 01 40 0 001 80 0 001 200 0 00001 Frame 6 10 Meets International Safe Transit Association ISTA test procedure 2B Rockwell Automation Publication 750 February 2012 Certifications Specifications Appendix A See the Product Certification link at www rockwellautomation com products certification for Declarations of Conformity Certificates and other certifications details Certification CUL us 2 CE Value UL Listed certified for US and Canada European Union 2004 108 EC EMC Directive compliant with EN 61800 3 PowerFlex 750 Series AC Drive Emissions and Immunity EN 62061 Safety Function Immunity European Union 2006 42 EC Machinery Directive EN ISO 13849 1 Safety Function EN ISO 13849 2 Safety Function EN 60204 1 Safety Function EN 62061 Safety Function EN 61800 5 2 Safety Function Australian Radiocommunications Act compliant with EN 61800 3 categories C2 and C3 Functional Safety Certified by T V for Functional Safety up to SIL according to EN 61800 5 2 EN 61508 and EN 62061 up to Performance Level PL e and Category 4 according to EN ISO 13849 1 when used as described in this PowerFlex 750 Series Safety Reference Manual publication 750 RMO001 1 When product is marked refer to www rockwellautomation com products
134. emoval 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 61 for more information IMPORTANT When designing the machine application timing and distance should 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 Rockwell Automation Publication 750 February 2012 17 Chapter1 Safety Concept Functional Proof Tests PFD and PFH Definitions 18 Performance Level and Safety Integrity Level SIL CL3 For safety related control systems Performance Level PL according to 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 ISO 13849 1 EN 61508 and EN 62061 standards for complete information on requirements for PL and SIL determination Refer to Chapter 10 for more information
135. enabling switch A 440 N21TNPM enabling switch is recommended The safety option uses the ESM In input asa safety enable only 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 Lim Speed ES and Safe Limited Speed with Door Monitoring and Enabling Switch Monitoring LimSpd DM ES modes Refer to Safe Limited Speed with Door Monitoring Mode on page 81 and Safe Limited Speed with Door Monitoring and Enabling Switch Monitoring Mode on page 86 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 Stop Category Fault occurs and the safety option initiates the configured Safe Stop Type Refer to Chapter 12 for information on faults and how to recover from them 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 750 February 2012 39 Chapter4 Speed Monitoring 1 0 Signals Reset Input Reset In The Reset input is for reset and monitoring of the safety circuit The reset input can be configured for automatic manu
136. er standstill has been reached and the door is unlocked a Motion After Stopped fault occurs This type of fault results in the safety option entering the safe state 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 For rotary systems the time in seconds will exceed 15 Standstill Speed RPM x Encoder 1 Resolution For linear systems the time in seconds will exceed 0 25 Standstill Speed mm s x Encoder 1 Resolution Deceleration Monitoring Deceleration monitoring takes place during the configured Stop Delay P47 Max Stop Time when the Safe Stop Type is configured as Safe Stop 1 or Safe Stop 2 The deceleration start speed is captured at the beginning of the Stop Delay 47 Stop Time and used to calculate the deceleration profile These parameters define the deceleration profile Deceleration Reference Speed P50 Decel Ref Speed Deceleration Tolerance P51 Stop Decel Tol Stop Delay P47 Max Stop Time The Deceleration Reference Speed is relative to encoder 1 The P51 Stop Decel Tol parameter defines the percentage of the Deceleration Reference Speed that will be tolerated above the calculated deceleration profile Rockwell Automation Publication 750 February 2012 65 Chapter 6 66 Safe Stop and Safe Stop with Door Monit
137. eter List 4 2 eH o Poe ds ee Slave Safe Stop Wiring Exathplesucuisicevee deti twee Slave Safe Limited Speed Mode cce Slave Sate Limited Speed Parameters Slave Safe Limited Speed Wiring Examples suus Slave Safe Limited Speed Status Only Mode ee rhe Slave Safe Limited Speed Status Only Parameter List Slave Safe Limited Speed Status Only Wiring Examples Multi axis CONE CHONG DA E err ce d EUER Cre ra tdi des Rockwell Automation Publication 750 RM001F EN P February 2012 Table of Contents Safe Maximum Speed and Direction Monitoring Chapter 9 Jntrod ction s coo rate pos Ebr Safe Maximum Speed SMS Monitoring Safe Maximum Acceleration SMA Safe Direction Monitoring SDM oe e eet rre enm em end Max Speed Max Accel and Direction Monitoring Parameter List Chapter 10 Safety Configuration and Verification Introduction 000 cece cece cence eee eee nent I Configuration Examples Safety hos SR des RP REN Configuration Signature ID 52 rius Satety lock sites Set and Change Dasssword ccs s e er edere ad Resetting the Password qeu oet d does citus v d Resetting the Cohnfigitauons ise bosch hii ee eere EL Basics of Application Development and
138. ety option set these parameters Data Type 8 bit Integer 8 bit Integer 8 bit Integer 8 bit Integer 16 bit Integer File Group HOST GROUPS Feedback 33 34 35 36 37 38 39 40 4 Display Name Full Name Description Fbk 1 Volt Mon Feedback 1 Voltage Monitor Encoder 1 voltage to be monitored Fbk 1 Speed Feedback 1 Speed Displays the output speed of encoder 1 Units based on rotary or linear configuration defined by P29 Fbk 1 Units Fbk 2 Units Feedback 2 Units Selects rotary or linear feedback for encoder 2 Fbk 2 Polarity Feedback 2 Polarity Defines the direction polarity for encoder 2 Fbk 2 Resolution Feedback 2 Resolution Counts Revolution 0 65 535 pulses revolution or pulses mm based on rotary or linear configuration defined by P34 Fbk 2 Units Fbk 2 Volt Mon Feedback 2 Voltage Monitor Encoder 2 voltage to be monitored Fbk 2 Speed Feedback 2 Speed Displays the output speed of encoder 2 Units based on rotary or linear configuration defined by P34 Fbk 2 Units Fbk Speed Ratio Feedback Speed Ratio Defines the ratio of the expected speed of encoder 2 divided by the expected speed of encoder 1 Ratio based on rotary or linear configuration defined by P29 Fbk 1 Units Fbk Speed Tol Feedback Speed Tolerance Acceptable difference in speed between P33 Fbk 1 Speed and P38 Fbk 2 Speed Units are based on rotary or linear
139. ety option 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 IMPORTANT Single channel operation does not meet SIL CL3 PL e Cat 4 safety integrity These inputs also support output signal switching devices OSSD Each output has integral pulse test checking circuitry Figure 1 PowerFlex 750 Series Safety Option Module E Lzy S11 TB1 s11 11 521 521 521 0000 534 TB2 51 78 68 44 34 xa X32 542 532 562 552 582 572 522 512 OOOOOOOOOCOOOOOO0000 OOOOO0 110 T Rockwell Automation Publication 750 RM001F EN P February 2012 About the PowerFlex Safe Speed Monitor Option Module Chapter 2 Configuration Configure the PowerFlex 750 Series safety option by setting the configuration parameters with a HIM module DriveExplorer DriveExecutive or RSLogix 5000 software Drive DriveExplorer DriveExecutive RSLogix 5000 RSLogix 5000 with ADCFeature PowerFlex 753 Version 6 02 or later Version 5 03 or later Version 16 or later Not Av
140. fe Speed Limit Units RPM RW 16 bit Safe Speed Limit mm s Integer Defines the speed limit that will be monitored in Safe Limited Speed SLS mode Default 0 Units are based on rotary or linear configuration defined by P29 Fbk 1 Units Min Max 0 6553 5 RPM 0 6553 5 mm s 104 Rockwell Automation Publication 750 February 2012 Slave Safe Limited Speed Wiring Examples GND 24V DC Slave Modes for Multi axis Cascaded Systems Chapter 8 These examples show two different Slave Safe Limited Speed configurations The first example is configured as a cascaded middle unit via the P20 Cascaded Config parameter Multi Mid It has SS_In SLS_In and DM_In input connections from the previous upstream safety option as well as SS_Out SLS_Out and DC_Out output connections to the next downstream safety option See SLS with Door Monitoring Wiring Example on page 83 for an example of a first master unit Figure 33 Slave Safe Limited Speed Middle Unit Previous Upstream Axis Middle Axis Next Downstream Axis Safety Option Terminals Safety Option
141. fig Fit Code 70 Hume Lock State 5 Signature ID 10 Security Code 18 Operating Mode 6 Password 13 Vendor Password 19 General Cascaded Config 20 ResetType 22 SSOut Mode 72 Safety Mode 21 OverSpd Response 24 515 Out Mode 73 Feedback Fbk Mode 27 Fbkilype 28 Fbk2Units 34 FbkSpeed Ratio 39 Fbk 1 Units 29 Fbk2Polarity 35 FbkSpeedTol 40 Fbk 1 Polarity 30 Fbk2Resolution 36 FbkPosTol 41 1 Resolution 31 Fbk 2 Volt Mon 37 Direction Mon 42 Fbk 1 Volt Mon 32 Fbk2Speed 38 Direction Tol 43 Fbk 1 Speed 33 Stop Safe Stop Input 44 Stop Mon Delay 46 Standstill Speed 48 Decel Ref Speed 50 Safe Stop Type 45 MaxStop Time 47 Standstill Pos 49 Decel Tol 51 Limited Speed Lim Speed Input 52 EnableSW Input 54 SafeSpeed Limit 55 Speed Hysteresis 56 LimSpd Mon Delay 53 Door Control Door Out Type 57 DMInput 58 Lock Mon Enable 59 Door Out Mode 74 Lock Mon Input 60 Max Speed Max Speed Enable 61 Max Spd Stop Typ 63 Safe Accel Limit 65 Safe Max Speed 62 Accel Enable 64 Max Acc Stop Typ 66 Faults Fault Status 67 GuardStatus 68 10 Diag Status 69 Config Flt Code 70 Rockwell Automation Publication 750 February 2012 165 AppendixB Parameter Data Parameters and Settings ina This table lists the configurable parameters and their valid settings in numerical Linear List order If any values other than those listed in the table are configured for any of the parameters an Invalid Configuration fault occurs
142. gnal transitions are detected Fbk 2 Fit A Feedback 2 fault occurs if any of these conditions are detected at encoder 2 Illegal encoder signal transitions are detected The feedback signals indicate a frequency greater than or equal to 200 kHz Dual Fbk Spd A Dual Feedback Speed fault occurs if an error is detected between the speed from the first encoder and the speed from the Second encoder Valid speed comparison values are determined by the configured Feedback Speed Ratio and Feedback Speed Tolerance Dual Fbk Pos A Dual Feedback Position fault occurs if a discrepancy is detected between the relative position change of the encoder 1 and the relative position change of encoder 2 since the last SS Reset Mov in Stop If the safety option is configured for a stop type that includes stopped speed checking a Mov in Stop fault occurs if either of the following is detected after the system is stopped and the door has been unlocked Speed greater than the configured Standstill Speed A position change greater than the configured Standstill Position limit 27 Fbk 1 V Fault An Encoder 1 Voltage fault occurs if the encoder voltage at encoder 1 is detected as out of range 28 Fbk 2 V Fault Table 18 Fault While Stopping Faults An Encoder 2 Voltage fault occurs if the encoder voltage at encoder 2 is detected as out of range Code Display Text Description 11 Decel Fit A Deceleration fault o
143. he DM In input transitions from ON to OFF door is opened while the ESM_In input is OFF 26 ESM Mon If the safety option is configured for enabling switch monitoring and is actively monitoring safe limited speed the ESM In input must be ON or an ESM Monitoring fault occurs If the safety option is configured for enabling switch monitoring only and a configured SLS monitoring delay LimSpd Mon Delay is in progress the ESM_In input must be ON when the delay times out or an ESM Monitoring fault occurs If the ESM_In input is ON while the safety option is actively monitoring safe limited speed the door can be opened DM In transitions from ON to OFF if no Lock Monitoring fault exists However if the ESM In input transitions to OFF after the door has been opened an ESM Monitoring fault occurs If you attempt an SS Reset while the SLS In input is OFF and the ESM input is OFF an ESM Monitoring fault occurs 24 Lock Mon Flt If the safety option is configured for lock monitoring a Lock Monitoring fault occurs when e the LM_In input is detected as OFF while the door control output is in the Lock state except for the 5 seconds following the transition of the DC_Out output from Unlock to Lock e the LM_In input is detected as ON when the DM In signal transitioned from ON to OFF 1 Refer to Input and Output Faults on page 152 for more information 154 Rockwell Automation Publication 750 February 2012 Fa
144. ication 750 February 2012 Introduction Safe Maximum Speed SMS Monitoring Chapter 9 Safe Maximum Speed and Direction Monitoring This chapter describes Safe Maximum Speed SMS Safe Maximum Acceleration SMA and Safe Direction SDM monitoring modes of safety operation and provides a list of configuration parameters Topic Page Safe Maximum Speed SMS Monitoring 113 Safe Maximum Acceleration 5 Monitoring 116 Safe Direction Monitoring SDM 118 Max Speed Max Accel and Direction Monitoring Parameter List 120 Configure Safe Maximum Speed monitoring by setting the P61 Max Speed Enable parameter to Enable When configured Safe Maximum Speed monitoring is active any time the safety option configuration is valid and the Safety mode is not Disabled When you configure the safety option for Safe Maximum Speed the feedback velocity is monitored and compared against a user configurable limit The P62 Safe Max Speed parameter is relative to encoder 1 If the monitored speed is greater than or equal to the configured P62 Safe Max Speed value an SMS Speed fault Stop Category fault occurs Figure 37 Safe Max Speed Timing Diagram Speed P62 afe Max Speed ON p gt Time Rockwell Automation Publication 750 February 2012 113 Chapter9 Safe Maximum Speed and Direction Monitoring You define the Safe Stop Type initiated by th
145. im Speed 0 Not used 9 0 Not used 12 2NC 2 2NC 3s 3 1NC 1NO 4 1 1 0 3s 5 2 0550 3s 6 INC Secs 0 0 6553 5 mm s 0 0 6553 5 RPM 0 6553 5 mm s 0 Pulse test 0 Pulse test 1 pulse test 78 Rockwell Automation Publication 750 February 2012 Read Write RW RW RW RW To configure the safety option for Safe Limited Speed monitoring set these parameters in addition to the Safe Stop parameters listed beginning on page 69 8 bit Integer 8 bit Integer 16 bit Integer 16 bit Integer 8 bit Integer Configuring the PowerFlex 750 Series Drive for SLS Operation Safe Limited Speed SLS Modes Chapter 7 The safety option commands the drive to enter Manual Mode during Safe Limited Speed monitoring IMPORTANT The drive parameters listed below must be configured for the drive to accept this command P326 Manual Cmd Mask Turn off the bit corresponding to the safety options port to allow modules installed in other ports to continue to control the drive when it is operating in Manual Mode For example if the safety option is installed in port 6 then turn off bit 6 in this parameter Refer to Install che PowerFlex Safety Option Module on page 31 to review the location of ports used by the safety option P327 Manual Ref Mask Turn on the bit corresponding to the safety option s port t
146. in Safe Limited Speed SLS Mode on page 75 in addition to the Safe Stop functions as described in Safe Stop Mode on page 61 In addition the safety option monitors the Enabling Switch Monitor input ESM_In after the Safe Limited Speed Monitoring Delay LimSpd Mon 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 which initiates the configured Safe Stop Type IMPORTANT Rockwell Automation Publication 750 February 2012 When Safe Limited Speed Monitoring is inactive the ESM In input is not monitored 83 Chapter 7 SLS with Enabling Switch Monitoring Parameter List Safe Limited Speed SLS Modes 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 safety option can be reset without cycling the SS In input To perform an 51 5 Reset first return the ESM_In input to ON grip the enabling switch in the middle position Then press and release the reset button This is the only case where the 55 In input does not need to be cycled to reset the safety option following a fault While Safe Limited Speed is being monitored after the P53 LimSpd Mon Delay times out if the 51 5 In input is ON and an SLS Reset occurs the ESM
147. ing the P1 Password parameter Place the safety option in Program mode by setting the P6 Operating Mode parameter to 0 Program Edit parameters to meet your system configuration specification and risk assessment requirements Enter the desired password value on the password entry page of the Add On Profile Enable the ADC function for the safety option using the AOP Configure the drive and other option cards installed in the drive Apply the changes Save the program and download to the controller IMPORTANT Atthis point the controller will attempt to open an 1 0 connection to the drive Part of this process is to verify that the ADC Configuration Signatures match for each device Since the ADC Configuration Signatures have not yet been written by the controller the controller will configure each device including writing each devices ADC Configuration Signature The controller will then open 1 0 connection to the drive Allow the controller to perform the ADC operation When the ADC operation is complete the ENET indicator on the drive will change to steady green This indicates that an I O connection has been opened to the drive Use a HIM module DriveExplorer DriveExectutive or RSLogix 5000 software to verify that the safety option is configured correctly After verification is complete set the P6 Operating Mode parameter to 1 Run which puts the the safety optio
148. ings Storage Temperature all const 40 70 40 158 F Atmosphere Important Drive must not be installed in an area where the ambient atmosphere contains volatile or corrosive gas vapors or dust If the drive is not going to be installed for a period of time it must be stored in an area where it will not be exposed to a corrosive atmosphere UV Radiation The HIM and IP54 NEMA UL Type 12 drive plastics are not UV rated Relative Humidity 5 95 non condensing Shock Operating Frame 1 6 15 peak for 11 ms duration 2 1 0 ms Frame 7 10 g peak for 11 ms duration 1 0 ms Frame 8 10 Power Core 10 g peak for 11 ms duration 1 0 ms in Cabinet w Option Bay 5 peak for 11 ms duration 1 0 ms Shock Packaged for Shipment Frame 1 2 381 mm 15 in drop height Frame 3 4 330 mm 13 in drop height Frame 5 305 mm 12 in drop height Frame 6 10 Meets International Safe Transit Association ISTA test procedure 2B Vibration Operating Frame 1 2 1 000 mm 0 040 in displacement 2 g peak Frame 3 5 1 000 mm 0 040 in displacement 1 5 g peak Frame 6 7 1 000 mm 0 040 in displacement 1 g peak Frame 8 10 Power Core Drive in Cabinet w Option Bay 1 000 mm 0 040 in displacement 1 g peak Vibration Packaged for Shipment Sinusoidal Loose Load Frame 1 5 20 0 mm 0 8 in peak to peak 2 5 186 Hz 1 1 peak from 5 186 20 Hz Frame 6 10 M
149. ion Safety Mode Reset Type 48 You can configure the safety option to operate in one of 11 user selectable Safety modes based on combinations of the safety functions the option supports The modes except for Disabled are described in detail in subsequent chapters of this manual For these modes See Master Safe Stop Safe Stop Chapter 6 Safe Stop and Safe Master Safe Stop with Door Monitoring Safe Stop DM Master Safe Limited Speed Lim Speed Chapter 7 Safe Limited Speed Master Safe Limited Speed with Door Monitoring 515 Modes Lim Speed DM Master Safe Limited Speed with Enabling Switch Control Lim Speed ES Master Safe Limited Speed with Door Monitor and Enabling Switch LimSpd DM ES Master Safe Limited Speed Status Only Lim Spd Stat Slave Safe Stop Slv Safe Stp Chapter 8 Slave Modes for Slave Safe Limited Speed Slv Lim Spd Mutin Cascaded Systems Slave Safe Limited Speed Status Only 51 Spd Stat You can configure the P22 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 TIP The Reset input does not require wiring for automatic reset configurations See Safe Stop Reset on page 66 and page 72 and Safe Limited Speed Reset on page 77 page 82 and page 84 for details on how the P22 Reset Type parameter affects Safe St
150. ion 16 or later Not Available Frames 1 7 with Drives AOP v3 01 or later PowerFlex 755 Version 6 01 or later Version 5 010rlater Version 16 or later Version 20 or later Frames 1 7 with Drives AOP v2 01 or later PowerFlex 755 Version 6 02 or later Version 5 03 or later Version 16 or later Version 20 or later Frames 8 10 with Drives AOP v3 02 or later The safety option is configured in the Safe State The safety option must be unlocked to be configured If a password exists you must provide the password to unlock the safety option Follow these steps to configure the safety option 1 If the safety option configuration is locked you can unlock the configuration by setting the P5 Lock State parameter to 0 Unlock If an error occurs you need to enter the password by using the P1 Password parameter Place the safety option in Program mode by setting the P6 Operating Mode parameter to 0 The value of the P10 Signature ID parameter value will change to 0 IMPORTANT When the safety option is in Program mode the P69 IO Diag Status 6 7 parameter is not updated or refreshed Edit parameters to meet your system configuration specification and risk assessment requirements When you are finished editing parameters set the P6 Operating Mode parameter to 1 which puts the safety option into Run mode configuration Signature ID is generated by the safety option Record the configuration Signat
151. isable 1 Enable 0 Not used 0 Not used 12 2 2 2NC 3s 3 1NC 1N0 4 1NC 1N0 35 5 0550 3s 6 1NC 0 Pulse test 0 Pulse test 1 pulse test Rockwell Automation Publication 750 February 2012 Read Write RW RW RW RW RW RW 16 bit Integer 16 bit Integer 8 bit Integer 8 bit Integer 8 bit Integer 8 bit Integer 8 bit Integer Safe Stop and Safe Stop with Door Monitoring Modes Chapter 6 Safe Stop Wiring Example This example illustrates safe stop wiring Figure 16 Master Safe Stop First or Single Unit TB1 S11 511 PowerFlex 750 Series 11 TEST OUT 0 s11 Safe Speed Monitor RT Option Module 521 521 21 TEST OUT 1 21 521 521 Reset TB2 os 534 RESET IN 34 52 52 DC OUT CHx 51 51 a SLS_OUT_CHx 8 68 68 Safety Stop 44 44 gt 3 55 OUT CHx 34 to Next Axis optional 8 LM IN CHx M X32 X32 DM IN CHx 2 32 532 307 5 9 CHx 302 52 52 55 582 582 lt gt Request Sn IN CHx 57 d SS_IN_CHx E GND bed A2 24V COM A2 24V DC Al 24V Al 1 24V_Com must be at the same potential as the drive common because of the encoder signal Rockwell Automation Publication 750 February 2012 7
152. iscrepancy Tolerance definition 57 Dual Feedback Speed Ratio definition 55 edit the configuration 126 130 emergency shutdown systems 15 EN 60204 1 17 EN 61508 18 SIL CL3 certification 15 EN 61508 5 2 163 EN 61800 5 2 SIL CL3 certification 15 EN 62061 18 encoder compatible 33 diagnostics 21 resolution 49 single encoder 21 specifications 164 ESM In input 39 83 European Norm definition 12 failure contact information 22 fault Door Monitoring 89 fault codes configuration faults 159 Fault While Stopping Faults 153 input 152 nonrecoverable 152 output 152 recovery 152 Safe State Faults 153 Stop Category Faults 154 fault history queue 152 fault recovery 152 Fault While Stopping Faults 155 features 26 feedback device types 54 fault 58 parameters 58 polarity 54 resolution 54 type 54 voltage monitor range 57 feedback monitoring 54 57 Rockwell Automation Publication 750 February 2012 179 Index 180 G Guard Status attributes 156 HIM module 27 hold last state 95 Out output 92 1 0 Diagnostic Status attributes 158 input faults 152 inputs 35 installing 31 150 13849 1 15 16 18 163 J J2 jumper 30 L LED Indicators 151 LM In input 39 Lock Monitoring 25 69 Lock Monitoring wiring 44 lock state 121 M manual monitored reset 48 SLS Reset 77 SS Reset 67 manual reset 48 SLS Reset 77 SS Reset 67 Max Stop Time definition 61 multi axis configur
153. isplay Text Description 8 SS Out This bit is set to 1 if the dual channel SS_Out output is being commanded to the ON state This bit is the commanded value not readback value This bit is set to 0 if the SS_Out output is being commanded to the OFF state 9 SLS In This bit reflects the logical value evaluated for the dual channel SLS_In input 10 SLS Req This bit is set to 1 if the Safe Limited Speed operation has been requested while the safety option is actively monitoring motion or a SLS Monitoring Delay LimSpd Mon Delay is in progress 11 SLS In Prog This bit is set to 1 when Safe Limited Speed monitoring is active 12 SLS Out This bit is set to 1 if the dual channel SLS_Out output is being commanded to the ON state This bit is the commanded value not a readback value 13 SMS In Prog This bit is set to a 1 if Safe Maximum Speed monitoring is enabled and Safe Maximum Speed is being monitored 14 SMA In Prog This bit is set to 1 if Safe Maximum Acceleration monitoring is enabled and safe maximum acceleration is actively being monitored 15 SDM In Prog If Safe Direction monitoring is enabled and configured for Positive Always or Negative Always the SDM Progress bit is set to 1 any time the safety option is configured for any Safety mode other than Disabled If Safe Direction monitoring is enabled and configured for Positive During 515 or Negative During SLS then this bit is set to 1 if the safety option is actively monitoring for Safe
154. ive 2004 108 163 Encoder Specifications suu d e d RDUM 164 Appendix B Parameter 165 Parameters and Settings in a Linear List 166 Rockwell Automation Publication 750 RM001F EN P February 2012 9 Table of Contents 10 Rockwell Automation Publication 750 February 2012 About This Publication Who Should Use This Manual Conventions Preface This manual explains how PowerFlex 750 Series drives can be used in Safety Integrity Level SIL CL3 Performance Level PL e or Category CAT 4 applications It describes the safety requirements including PFD and PFH values and application verification information and provides information on installing configuring and troubleshooting the PowerFlex Safe Speed Monitor Option module Use this manual if you are responsible for designing installing configuring or troubleshooting safety applications that use the PowerFlex Safe Speed Monitor Option module You must have a basic understanding of electrical circuitry and familiarity with PowerFlex 750 Series drives You must also be trained and experienced in the creation operation and maintenance of safety systems In this manual configuration parameters are listed by number followed by the name in brackets For example P24 OverSpd Response Rockwell Automation Publication 750 February 2012 11 Prefac
155. k switch 8 Set the P60 Lock Mon Input parameter value to 1 for 2NC dual channel equivalent operation In this example application the Lock Monitor Input LM In monitors the TLS 3 GD2 switch which has two normally closed 2NC interlock monitoring contacts 9 Goto the next section to set the parameters that configure Safe Maximum Speed monitoring Example 2 Max Speed Group Figure 59 Max Speed Group Parameters HIM Screen Software Screen Not AUTO 0 000 Hz EM File Edi Explore Actions Help a lt aa porot Param FieGreup S O seee GROUP Max Speed E Devices EtherNet IP Direct 5 npp Node 1 PowerFlex 755 1 Max Speed Enable Disable Safe Max Speed 9 0 PowerFlex 755 480 22 1 4 62 Safe Speed 0 Max Spd Stop Y 89 1 20 HIM x6 LCD HIM M Off Bid safe speed Montr si 1 465 Safe Accel Limit B 1 Device Parameters 1 4 66 Max Stop Torque Off E Parameter Groups Security General Feedback Stop Limited Speed Door Control Faults 9 5 Dual Encoder DENC 1 9 13 EtherNet IP Embedded 9 14 DeviceLogix Embedded Custom Views Follow these steps to configure Maximum Speed monitoring for the safety option 1 From the Max Speed group choose the P61 Max Speed Enable parameter The default value is 0 Disabled for no maximum speed limitation 2 Set the P61 Max Speed Enable parameter value to 1
156. kwell Automation Publication 750 February 2012 Safe Stop Parameter List HOST GROUPS Stop General Group 45 46 47 48 Display Name Full Name Description Safety Mode Safety Mode Defines the primary operating mode ofthe speed monitoring safety functions Safe Stop Input Safe Stop Input Configuration for Safe Stop input 55 In 2NC 1 Dual channel equivalent 2NC3s 2 Dual channel equivalent 3 s 1NC 1NO 3 Dual channel complementary 1NC 1NO 35 4 Dual channel complementary 3 s 2 OSSD 3s 5 Dual channel SS equivalent 3 5 6 Single channel equivalent Safe Stop Type Safe Stop Type Safe operating stop type selection This defines the type of Safe Stop that is performed if the Safe Stop function is initiated by a stop type condition Torque Off 0 Safe Torque Off With Standstill Checking Torque Off NoCk 3 Safe Torque Off Without Standstill Checking Stop Mon Delay Stop Monitoring Delay Defines the monitoring delay between the request and the Max 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 Ifthe Safe Stop Type is Safe Torque Off With or Without Standstill Speed Checking the Stop Monitor Delay must be 0 or a Invalid Configuration Fault occurs Max Stop Time Maximum Stop Time Defines the maximum stop delay time that is
157. lication 750 001 Rockwell Automation Publication 750 February 2012 27 Chapter2 About the PowerFlex Safe Speed Monitor Option Module Notes 28 Rockwell Automation Publication 750 February 2012 Introduction General Safety Information Power Supply Requirements Chapter 3 Installation and Wiring This chapter provides details on connecting devices and wiring the PowerFlex safety option board Topic Page General Safety Information 29 Power Supply Requirements 29 Set Safety Enable Circuitry 30 Install the PowerFlex Safety Option Module 31 Install the PowerFlex Safety Option Module 3 Terminal Connections 32 Compatible Encoders 33 Connect an Encoder 33 control system of a machine Before installation a risk assessment should be ATTENTION The safety option is intended to be part ofthe safety related performed to determine whether the specifications of this safety option are suitable for all foreseeable operational and environmental characteristics for the system to which it is to be installed Observe all electrical safety regulations stipulated by the appropriate technical authorities 750 Series drive is switched off before installing the safety option or making ATTENTION Make sure that the electrical power supplied to the PowerFlex connections Refer to the PowerFlex 750 Series AC Drive Installation Instructions publicatio
158. ll Checking 000 65 535 mm s 49 Standstill Pos Units Deg RW 16 bit Standstill Position mm Integer Defines the position limit window in encoder 1 degrees or mm that will be tolerated Default 10 after a safe stop condition has been detected Min Max 0 65 535 deg Degrees 360 1 revolution or mm based on rotary or linear configuration defined by 0 65 535 mm P29 Fbk 1 Units Not valid for Safe Torque Off without Standstill Checking 50 Decel Ref Speed Units RPM RW 16 bit Deceleration Reference Speed mm s Integer Determines deceleration rate to monitor for Safe Stop 1 or Safe Stop 2 Default 0 Units are based on rotary or linear configuration defined by encoder 1 feedback Min Max 0 65 535 RPM configuration P29 Fbk 1 Units 0 65 535 mm s 51 Stop Decel Tol Units 96 RW 8 bit Stop Deceleration Tolerance Default 0 Integer This is the acceptable tolerance above the deceleration rate set by the Decel RefSpeed 0 100 parameter Rockwell Automation Publication 750 February 2012 99 Chapter 8 File HOST GROUPS 100 Slave Modes for Multi axis Cascaded Systems Display Name Full Name Description Door Out Type Door Output Type Defines the lock and unlock state for door control output DC Out When Door Out Type equals power to release Out is OFF in the lock state and ON in the unlock state When Door Out Type equals power to lock DC Out is ON in
159. ll also be detected The outputs are pulse tested when the P74 Door Out Mode parameter is configured for pulse testing IMPORTANT Ifyou disable pulse testing on this output the achievable SIL Category and PL ratings of your entire safety system are reduced Rockwell Automation Publication 750 February 2012 45 Chapter4 Speed Monitoring 1 0 Signals Notes 46 Rockwell Automation Publication 750 February 2012 Chapter 5 General Device and Feedback Monitoring Configuration Introduction This chapter describes the general and feedback configuration settings that must be configured to operate the safe speed monitor option module Topic Page Cascaded Configuration 47 Safety Mode 48 Reset Type 48 Overspeed Response Time 49 General Parameter List 53 Feedback Monitoring 54 Feedback Parameter List 58 Cascaded Configu ration The safety option may be used in single axis or multi axis applications The P20 Cascaded Config parameter indicates the safety option 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 750 February 2012 47 Chapter5 General Device and Feedback Monitoring Configurat
160. ming Diagram for Safe Limited Speed Status Only SLS 515 Request Request Removed SLS Monitoring Delay Safe Limited Speed m P53 Active g Speed Low Threshold 0 1 1 1 l Time 1 LN 22779 poor i EY 1 SIS Out ee 1 Low Threshold P56 Speed Hysteresis 100 x P55 Safe Speed Limit Rockwell Automation Publication 750 February 2012 91 Chapter 7 92 Safe Limited Speed SLS Modes Speed Hysteresis The P56 Speed Hysteresis parameter provides hysteresis for the 51 5 Out output when the safety option is configured for SLS Status Only and Safe Limited Speed monitoring is active The 51 5 Out output is turned ON if the speed is less than the Low Threshold which equals Speed Hysteresis 100 x Safe Speed Limit The 51 5 Out output is turned OFF when the speed is greater than or equal to the configured P55 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 Rockwell Automation Publication
161. mited Speed Reset E eoa deny SLS with Door Monitoring Parameter 1486 SLS with Door Monitoring Wiring Example Safe Limited Speed with Enabling Switch Monitoring Mode Safe Stop Reset SS Reset and Safe Limited Speed Reset SLS Reset 53 SLS with Enabling Switch Monitoring Parameter List SLS with Enabling Switch Monitoring Wiring Example Safe Limited Speed with Door Monitoring and Enabling Switch Monitoring sias qd abes tdeo Behavior During SLS Monitoring eese Behavior While SLS Monitoring is Behavior During SLS Monitoring Safe Stop Reset SS Reset and Safe Limited Speed Reset SLS Reset SLS with Door Monitoring and Enabling Switch Monitoring Parameter 486 SLS with Door Monitoring and Enabling Switch Monitoring Wiring Safe Limited Speed Status Only Mode Speed IN tun hind SLS Status Only Parameter eee SLS Status Only Wiring Chapter 8 Cascaded s e Slave Safe Stop Mode Slave Safe Stop Param
162. mode Rockwell Automation Publication 750 February 2012 73 Chapter 6 Safe Stop and Safe Stop with Door Monitoring Modes Safe Stop with Door Monitoring Wiring Example 74 This example illustrates wiring for safe stop with door monitoring Figure 17 Master Safe Stop with Door Monitoring First or Single Unit TB1 S11 S11 PowerFlex 750 Series 911 TEST OUT 0 11 Safe Speed Monitor 511 ST Option Module 521 521 Reset 521 TEST OUT 1 521 gale 521 521 TB2 534 RESET IN 34 DC_OUT_CHx 32 Power to e 51 TOL 51 Release 78 78 TLS3 602 SLS OUT CHx 440G 127260 68 68 USE 7 Safety Switch Safety Stop 2 SS OUT CHx to Next Axis Remove 2 34 34 Internal x42 x42 Jumpers LM IN X32 X32 30 DM IN 532 32 ur SLS IN CHx L 52 52 l 55 582 ESM_IN_CHx 0 Z Request 572 572 ur SS IN CHx E GND EE m A2 24V COM A2 24V DC 24V Al 1 Lock monitoring connections are not required for Safe Limited Speed with Door Monitoring mode operation 2 24V must be at the same potential as the drive common because of the encoder signal Rockwell Automation Publication 750 February 2012 Introduction S
163. mode 89 SLS with Door Monitoring mode 82 SLS In input 38 77 configuring drive 79 SLS Reset 77 84 SLS Out output 42 hold last state 92 specifications encoder 164 general 161 speed hysteresis 92 speed resolution 49 speed resolution accuracy example 49 linear 52 rotary 50 SS Reset 48 66 67 SLS with Door Monitoring and Enabling Switch Monitoring mode 89 SS Ininput 38 SS Outoutput 41 Standstill Position Tolerance definition 65 Standstill Speed definition 65 status attributes 156 status indicators 151 stop category definitions 17 Stop Category Faults 155 Stop Delay See Max Stop Time Stop Monitoring Delay definition 61 T terminal screws connections 32 strip length 32 torque 32 timing diagram Safe Limited Speed 76 81 87 Safe Limited Speed Status Only 91 Safe Stop 1 63 Safe Stop 2 64 Safe Torque Off with Standstill Checking 62 Safe Torque Off Without Standstill Checking 64 Rockwell Automation Publication 750 February 2012 181 Index 182 V validation third party 127 verify configuration 127 lock status 127 Signature ID 127 W wiring DC Out output 44 45 DM In input 44 LM In input 44 multi axis connections 41 43 safety input examples 37 wiring example Safe Limited Speed mode 80 Safe Limited Speed Status Only mode 94 96 Safe Stop mode 71 Safe Stop with Door Monitoring mode 74 Slave Safe Limited Speed 105 106 Slave Safe Limited Speed Status Only mode 108 109
164. n Normal 9 Choose the P31 Fbk 1 Resolution parameter 10 Choose 1024 default or enter value between 1 65 535 pulses revolution based on the encoder s specifications 11 Choose the P32 Fbk 1 Volt Mon parameter Rockwell Automation Publication 750 February 2012 Configuration Examples Chapter 11 12 Enter 5 9 or 12V to monitor voltage in accordance with the encoder s specifications or enter 0 default to disable encoder voltage monitoring TIP The P33 Fbk 1 Speed parameter displays the output speed of the encoder as value between 214 748 364 8 214 748 364 8 rpm based on the encoder s configuration You do not need to enter a setting or value for this parameter 13 Choose the P42 Direction Mon parameter 14 Set the P42 Direction Mon parameter value to 0 default which equals Disabled You may disable Safe Direction Monitoring if only one direction of rotation is possible or there is no safety related restriction on the direction of rotation 15 Go to the next section to set the parameters found in the Stop parameters group Example 1 Stop Group Settings Figure 49 Stop Group Parameters HIM Screen Software Screen Not Enabled AUTO DriveExplorer Beta 0 000 Hz FU File Edit Explore Actions Help ile Se RT TREE TEES a teere GROUP Stop E Devices EtherNet
165. n 750 IN001 for more information 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 24V DC 10 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 publication 1770 4 1 Rockwell Automation Publication 750 February 2012 29 Chapter3 Installation and Wiring Set Safety Enable Circuitry The PowerFlex 750 Series drive ships with the safety enable jumper SAFETY installed The jumper located on the main control board must be removed when using the Safe Speed Monitor Option module IMPORTANT Failure to remove the SAFETY jumper will cause the drive to fault when a start command is issued Figure 2 PowerFlex 753 SAFETY Jumper Location Note Frame 8 drives do not have a safety enable jumper TIP The 010 digital output on the main control board can be designated as a hardware enable function by removing the ENABLE jumper If this jumper is removed the drive will not run unless the 010 digital input is activated The 010 input is not relate
166. n in run mode configuration Signature ID is generated by the safety option Record the configuration Signature ID from the contents of the P10 Signature ID parameter 128 Rockwell Automation Publication 750 February 2012 Safety Configuration and Verification Chapter 10 13 Enter the password into the P1 Password parameter 14 Set the P5 Lock State parameter to 1 Lock Refer to Appendix B for a complete list of parameters and settings for the safety option After the system has been placed in service if a controller determines that it needs to configure the safety option several manual steps are required IMPORTANT Ifthe controller is the network and powered up it will attempt to open 1 0 connection to the drive when the drive is powered up When the controller detects that the ADC Configuration Signature for the safety option is invalid the controller will attempt to configure the safety option If the safety option is locked or in Run mode you will have to unlock the safety option and place it in Program mode before the controller can successfully configure the safety option 1 Ifthe safety option configuration is locked you must unlock the configuration by setting the P5 Lock State parameter to 0 Unlock If an error occurs you need to enter the password by using the P1 Password parameter 2 Ifthe safety option is in Run mode change it to Program mode by setting the P
167. n occurs after a Safe Stop is initiated and an optional Stop Monitoring Delay 46 Stop Mon Delay which is a delay between the action that requests the Safe Stop and the initiation of the configured Safe Stop Type A 46 Stop Mon Delay can be configured only for Safe Stop 1 or Safe Stop 2 When properly configured for Safe Stop mode the safety option also monitors for faults and initiates the appropriate reaction If the fault is a Safe State fault the safety option enters the Safe State If the fault is a Stop Category fault the safety option initiates the configured Safe Stop Type Rockwell Automation Publication 750 February 2012 61 Chapter 6 62 P48 Standstill Speed Safe Stop and Safe Stop with Door Monitoring Modes Safe Stop Types Use the P45 Safe Stop Type 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 55 In input from ON to OFF or by the occurrence ofa Stop Category fault While the safety option executes the configured Safe Stop Type it continues to monitor the system If a Stop Category fault is detected the safety option sets the outputs to a faulted state but allows for the door controllogic to be set to Unlock if the feedback signals indicate Standstill Speed has been reached Safe Torque Off with Standstill Checking This Safe Stop Type lets you access the hazard area immediately
168. n 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 may occur when encoder 1 is at 80 135 RPM However the SMS Speed fault may not occur until encoder 1 reaches 119 865 RPM 100 80 135 119 865 L No Trip May Trip Trip Zone RPM If your encoder resolution is not listed in the tables use these equations For rotary systems the conversion from Overspeed Response Time OverSpd Response to Speed Resolution in revolutions per minute is 15000 Speed RPM x 0 02 OverSpd Response 36 x Feedback Resolution OverSpd Response 36 Speed Resolution RPM For linear systems the conversion from Overspeed Response Time OverSpd Response to mm s is 250 Speed RPM x 0 02 OverSpd Response 36 x Feedback Resolution OverSpd Response 36 Speed Resolution mm s Rockwell Automation Publication 750 February 2012 49 Chapter5 General Device and Feedback Monitoring Configuration Speed Resolution Accuracy for Rotary Systems Table 5 Encoder Resolution 16 lines rev Overspeed Response Time P24 Speed RPM Overspa Response setting 1 10 100 1000 10 000 100 000 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 5
169. n the reset is requested by a transition ofthe 55 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 which initiates the configured P45 Safe Stop Type 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 which initiates the configured 45 Safe Stop Type To configure the safety option for Safe Limited Speed with Door Monitoring and Enabling Switch Monitoring set the P58 DM Input and P54 Enable SW Input parameters in addition to the Safe Stop parameters listed on page 69 and the Safe Limited Speed parameters listed on page 78 amp Setting 6 LimSpd DM ES 8 bit Integer Default 0 Not used RW 8 bit Options 0 used Integer 12 2NC 2 2NC3s 3 1NC 1N0 4 1 1 0 35 5 2 0550 3s 6 1NC Default 0 Not used 1 RW 8 bit Options 10 Not used Integer 12 2NC 2 2NC3s 3 1NC 1NO 4 1NC 1N0 35 5 2 0550 3s 6 1 1 You must configure this parameter with a non zero value in this mode Rockwell Automation Publication 750 February 2012 89 Chapter7 Safe Limited Speed SLS Modes SLS with Door Monitoring This example illustrates wiring f
170. ndix B E Safe Speed Monitor 174 Group Max Speed 62 63 64 65 66 Parameter Data Display Name Full Name Description Max Speed Enable Maximum Speed Enable Enable Safe Maximum Speed Monitoring Safe Max Speed Safe Maximum Speed Defines the maximum speed limit that will be tolerated if Safe Maximum Speed monitoring is enabled Max Spd Stop Typ Maximum Speed Stop Type Defines the safe stop type that will be initiated in the event of a SMS Speed Fault Torque Off 0 Safe Torque Off With Standstill Checking Safe Stp Typ 1 Safe Torque Off Without Standstill Checking Max Accel Enable Maximum Acceleration Enable Enable Safe Maximum Acceleration Monitoring Safe Accel Limit Safe Acceleration Limit Defines the Safe Maximum Acceleration Limit relative to encoder 1 for which the system is being monitored Units are based on rotary or linear configuration defined by P29 Fbk 1 Units Max Acc Stop Typ Maximum Acceleration Stop Type Defines the safe stop type that will be initiated in the event of an Acceleration Fault Torque Off 0 Safe Torque Off With Standstill Checking Safe Stp Typ 1 Safe Torque Off Without Standstill Checking Values Default Options Units Default Min Max Default Options Default Options Units Default Min Max Default Options 0 Disable 0 Disable 1 Enable
171. nes the discrepancy that will be 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 P27 Fbk Mode Parameter Settings 1 Dual encoder with speed and position discrepancy checking 2 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 P27 Fbk Mode Parameter Dual Feedback Speed Discrepancy Tolerance P40 Fbk Values Speed Tol Parameter Values 0 One encoder 0 1 Dual encoder with speed and position 0 1 6553 5 in rev min rotary encoders or mm s linear discrepancy checking encoders 2 Dual encoder with speed discrepancy 0 1 6553 5 in rev min rotary encoders or mm s linear checking encoders 3 Dual encoder with position discrepancy 0 checking If an illegal value is detected an Invalid Configuration fault occurs and the safety option remains in the Safe State Feedback Voltage Monitor Range Use the P32 Fbk 1 Volt Mon and P37 Fbk 2 Volt Mon parameters to set the feedback voltage monitoring range The monitoring ranges help define the trip zone for encoder 1 and encoder 2 respectively Fbk x Volt Mon 5 9 12 14 Setting Range 4 5 5 5V 7 12V 11 14V 11 5 15V Trip Zone lt
172. ng or normal operation If an input fault occurs check for the following Oneofthe channels may have shorted to a 24V DC source One of the channels may have shorted toa GND source Two input channels have shorted together One or both output channels have an overcurrent condition An input fault may also occur if only one of the channels in a dual channel system changed state after a 3 second discrepancy time interval and if the inputs are configured with one of these settings e 2 Dual channel equivalent 3 s 2NC 3s e 4 Dual channel complementary 3 s INC 1NO 35 e 5 Dual channel SS equivalent 3 s 2 OSSD 3s Faults fall into one of three categories Stop Category fault Fault While Stopping fault and Safe State fault Stop Category faults can be Motion faults Monitor faults or I O faults The HIM module or configuration software can display a fault history queue which provides a record of the faults detected by the safety option The fault history queue stores the fault codes and timestamps for the last 10 faults that occurred To avoid confusion about when faults occurred a power up marker code 32 is placed between faults in the queue if the safety option is powered up or reset when the queue is not empty Code 0 equals No Entry Rockwell Automation Publication 750 February 2012 Table 17 Safe State Faults Code 0 Display Text Combined Troubleshooting the PowerFlex Safet
173. ng 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 5 5 In input cannot transition to ON while N 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 86 Rockwell Automation Publication 750 February 2012 P55 Safe Speed Limit Safe Limited Speed SLS Modes Chapter 7 Figure 23 Timing Diagram for Safe Limited Speed SLS with Door Monitoring and Enabling Switch Monitoring Mode SLS SLS Request Request Removed 2 A SLS Monitoring Delay Safe Limited Speed e cw p Active Speed SLS Fault Acceptable Speed Range lime Door is unlocked if the enabling switch is in the middle position 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
174. nly while the Fbk Mode parameter is equal to one of these values Feedback Mode P27 Fbk Mode Parameter Settings 1 Dual encoder with speed and position discrepancy checking 3 Dual encoder with position discrepancy checking This table defines the legal values for each Feedback mode value Feedback Mode P27 Fbk Mode Values Dual Feedback Position Discrepancy Tolerance P41 Fbk Pos Tol Legal Values 0 One encoder 0 1 Dual encoder with speed and position 1 65 535 in degrees rotary encoders or mm linear discrepancy encoders relative to the resolution of encoder 1 2 Dual encoder with speed discrepancy checking 0 3 Dual encoder with position discrepancy 1 65 535 in degrees rotary encoders or mm linear checking encoders relative to the resolution of encoder 1 If an illegal value is detected an Invalid Configuration fault occurs and the safety option remains in the Safe State IMPORTANT When setting discrepancy tolerances consider that configuring a high gear ratio between encoder 1 and encoder 2 could lead to unexpected dual feedback position faults This is because a very large encoder 1 movement would translate into a very small encoder 2 movement Rockwell Automation Publication 750 February 2012 General Device and Feedback Monitoring Configuration Chapter 5 Dual Feedback Speed Discrepancy Tolerance The Dual Feedback Speed Discrepancy Tolerance P40 Fbk Speed Tol defi
175. nput 25 ESM In An ESM In fault occurs if an error is detected in the ESM_In dual channel input 16 SLS Speed Fit Motion The monitored speed was detected at greater than or equal to the Safe Speed Limit during Safe Limited Speed Faults monitoring 17 SMS Spd A Safe Maximum Speed fault indicates that Safe Maximum Speed SMS monitoring is enabled and the monitored speed was detected at greater than or equal to the configured Safe Max Speed 18 Accel An Acceleration fault indicates that the monitored speed was detected as greater than or equal to the configured Safe Accel Rate during safe acceleration monitoring 19 Dir Fit A Direction fault indicates that motion was detected in the restricted direction during safe direction monitoring SDM 21 Door Mon Flt Monitor If the safety option is configured for Safe Limited Speed SLS but SLS monitoring is not active the DM_In input Fault must be ON door closed or a Door Monitoring fault occurs A Door Monitoring fault occurs if the door is open DM In input is OFF when an SS Reset SLS Reset is requested SLS_In transitions to ON If a configured SLS Monitoring Delay P53 LimSpd Mon Delay is in progress prior to Safe Limited Speed monitoring being active and the DM In input is OFF door open a Door Monitoring fault occurs If the safety option is configured for door monitoring and enabling switch monitoring and is actively monitoring safe limited speed a Door Monitoring fault occurs if t
176. nse Setting 0 01 01 1 10 100 400 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 Table 12 Encoder Resolution 1000 lines mm Overspeed Response Time P24 Speed mm s OverSpd Response Setting 0 01 01 1 10 100 200 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 Table 13 Encoder Resolution 5000 lines mm Overspeed Response Time P24 Speed mm s OverSpd Response Setting 0 01 01 1 10 40 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 Table 14 Encoder Resolution 20 000 lines mm Overspeed Response Time P24 Speed mm s OverSpd Response Setting 0 01 01 1 10 2 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 00
177. o allow the safety option to command the drive to use its Manual Speed Reference when it is operating in Manual Mode For example if the safety option is installed in port 6 then turn on bit 6 in this parameter P328 Alt Man Ref Sel Set this parameter to select the desired speed reference when the drive is operating in Manual Mode For example set this parameter to the value Port 0 Preset Speed 1 to configure the drive to use its P571 Preset Speed 1 parameter as the Manual Speed Reference In this case the drives P571 Preset Speed 1 parameter must be less than the P55 Safe Speed Limit parameter in the safety option to avoid causing an SLS Speed Fault When a Safe Limited Speed Reset occurs the safety option commands the drive to exit Manual Mode and the drive will resume operation using the speed reference that was selected prior to Safe Limited Speed monitoring Rockwell Automation Publication 750 February 2012 79 Chapter7 Safe Limited Speed SLS Modes Safe Limited Speed Wiring This example illustrates wiring for safe limited speed Example Figure 19 Master Safe Limited Speed First or Single Unit TB1 511 511 PowerFlex 750 Series 11 TEST OUT 0 511 Safe Speed Monitor 511 Option Module 521 521 521 TEST OUT 1 521 521 521 Reset TB2 s 53
178. ockwell Automation tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned follow these procedures United States Contact your distributor You must provide a Customer Support case number call the phone number above to obtain one to your distributor to complete the return process Outside United States Please contact your local Rockwell Automation representative for the return procedure Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document complete this form publication RA DU002 available at hrtp www rockwellautomation com literature www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation NV Pegasus Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 750 RMOOTF EN P February 2012 Supersedes Publication 750 RMOOTE EN P January 2012 Copyright 2012 Rockwell Automation Inc All rights reserved Printed in the U S A
179. oder 2 divided by the expected speed of encoder 1 This parameter configures the anticipated gearing between encoder 1 and encoder 2 Dual Feedback Speed Ratio Expected Speed of Encoder 2 P39 Fdk Speed Ratio Parameter Expected Speed of Encoder 1 If P27 Fbk Mode equals 0 1 encoder the only legal value for P39 Fbk Speed Ratio parameter is 0 0 If P27 Fbk Mode is greater than 0 the range of legal values for P39 Fbk Speed 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 15 speed is expected to be 100 revolutions per second then the P39 Fbk Speed Ratio should be configured 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 Rockwell Automation Publication 750 February 2012 55 Chapter 5 56 General Device and Feedback Monitoring Configuration Dual Feedback Position Discrepancy Tolerance The Dual Feedback Position Discrepancy Tolerance P41 Fbk Pos Tol parameter defines the cumulative position discrepancy that will be tolerated between encoder 1 and encoder 2 The position discrepancy is defined as position change relative to encoder 1 IMPORTANT relative position discrepancy difference is reset to zero at each Safe Stop Reset This discrepancy checking is performed o
180. on Power 7 Stop Command m DC Out Output 0 1 Thissignal is internal between the safety option and drive 2 DC Outoutput shown configured as Power to Release See Door Control on page 67 for more information TIP All Stop Types require an encoder to be connected 64 Rockwell Automation Publication 750 February 2012 Safe Stop and Safe Stop with Door Monitoring Modes Chapter 6 Standstill Speed and Position Tolerance For Safe Stop Types that include Standstill Checking you set the Standstill Speed and Standstill Position Tolerance IMPORTANT The P48 Standstill Speed and P49 Standstill Pos 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 P48 Standstill Speed parameter defines the speed limit before the safety option determines standstill has been reached and the door control logic is set to Unlock IMPORTANT Standstill detection relies on the encoder 1 signal The encoder 2 signal is used for fault diagnostics The P49 Standstill Pos 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 aft
181. on goes to the Safe State ATTENTION If a fault occurs after Standstill Speed has been reached door N control logic remains unlocked A Safe State fault may set the Door Control output DC Out to OFF For diagnostic purposes only you can view status attributes by accessing the P68 Guard Status parameter and the P69 Diag Status parameter from HIM module DriveExplorer DriveExecutive or RSLogix 5000 software The status attributes are valid only when the safety option is in Run mode If the safety option is in Program mode or has an Invalid Configuration Fault the status attributes are not updated Guard Status Attributes These attributes are stored in the P68 Guard Status parameter Each bit corresponds to a different attribute Bit Display Text Description 0 StatusOK This bit indicates when there are no faults It is set 1 when all of the Fault Status bits 1 31 are 0 no faults The bit is 0 if any Fault Status bit from 1 31 indicates a fault 1 1 Config Lock This bit shows the status of the P5 Lock State parameter A 1 indicates the configuration is locked a 0 indicates the configuration is unlocked 2 MP_Out This bit shows the status of the safety option s Motion Power command to the drive A 1 indicates Motion Power is enabled a 0 indicates Motion Power is disabled 3 SS In This bit displays the logical value 1 or 0 evaluated for the dual channel 55 In input 4 S
182. on the requirements for configuration and verification of a safety related system containing the PowerFlex 750 Series drives 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 IMPORTANT Your specific application determines the time frame for the proof test interval 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 order of 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 Rockwell Automation Publication 750 February 2012 PFD and PFH Data Safe State Safety Concept Chapte
183. op and Safe Limited Speed operation a reset ofthe 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 ATTENTION For all types of reset automatic manual manual monitored if 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 Rockwell Automation Publication 750 February 2012 General Device and Feedback Monitoring Configuration Chapter 5 Overspeed Response Time The P24 OverSpd Response parameter setting determines the maximum reaction time from an overspeed event to the initiation of the configured 45 Safe Stop Type The safety reaction time from an overspeed event that triggers a Safe Stop to the actual initiation of that Safe Stop Type is equal to the value of the 24 OverSpd Response parameter The configurable options are 42 48 60 84 132 228 and 420 ms The P24 OverSpd Response 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 For example an encoder resolutio
184. or SLS with door monitoring and enabling switch monitoring and Enabling Switch 5 Monitoring Wiring Example Figure 24 Master Safe Limited Speed with Door Monitoring and Enabling Switch Monitoring First or Single Unit TB1 S11 11 TEST OUT 0 511 PowerFlex 750 Series LLL Safe Speed Monitor 51 511 Option Module 071 521 Reset 521 TEST OUT 1 521 51 521 os TB2 534 34 ae DC OUT CHx p 51 51 ower to sal 78 78 Release SLS_OUT_CHx 3 1153 GD2 68 68 440G T27260 Safety Sto 44 44 ___ gt y top Safety Switch 5 0UT to Next Axis 1 optional Remove 2 x42 M x42 Internal 3 LM IN CHx Jumpers 92 oy iN oc 515 32 32 Request 562 562 t SLS_IN_CHx Mu 52 52 352 ESM IN CHx 572 SS CHx GND A2 24V COM 1 24V DC 4 Al 24V Al 440J N21TNPM Enabling Switch SS 4 Request 1 Lock monitoring connections are not required for Safe Limited Speed with Door Monitoring and Enabling Switch Monitoring mode operation 90 Rockwell Automation Publication 750 February 2012 Safe Limited Speed Status Only Mode P55 Safe Speed Limit Safe Limited Speed SLS
185. oring Modes Figure 15 Deceleration Monitoring Stop Request A Stop Delay Speed P47 Max Stop Time i Av Deceleration Tolerance 96 Actual speed measured at the start of the Stop x Deceleration Reference Delay P47 Max Stop Time 75 Speed P51 Standstill Speed lime TIP To account for system overshoot and drive delay choose Av and set P50 Decel Ref Speed to the highest normal operating speed to calculate the Deceleration Tolerance Remember that P51 Stop Decel Tol parameter is a percentage When deceleration monitoring is being performed the speed limit monitored during the Stop Delay P47 Max 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 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 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 For all types of reset automatic manual manual monitored if When an SS Reset is requested all diagnostic tests that can
186. oring fault occurs and the safety option initiates the configured P45 Safe Stop Type 88 Rockwell Automation Publication 750 February 2012 SLS with Door Monitoring and Enabling Switch Monitoring Parameter List Display Name Full Name Description 21 Safety Mode Safety Mode General Group 58 DM Input Door Monitor Input Door Control HOST GROUPS 54 Enable SW Input Enable Switch Input Defines the primary operating mode ofthe speed monitoring safety functions Configuration for the Door Monitor input DM In 2NC 1 Dual channel equivalent 2NC3s 2 Dual channel equivalent 3 s 1NC 1NO 3 Dual channel complementary 1NC 1NO 35 4 Dual channel complementary 3 s 2 OSSD 3s 5 Dual channel SS equivalent 3 5 6 Single channel equivalent Configuration for the Enabling Switch input ESM 2 1 Dual channel equivalent 2NC 3s 2 Dual channel equivalent 3 s 1NC 1NO 3 Dual channel complementary 1NC 1NO 35 4 Dual channel complementary 3 s 2 OSSD 3s 5 Dual channel SS equivalent 3 s 6 Single channel equivalent Safe Limited Speed SLS Modes Chapter 7 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 whe
187. oring safety functions Slv Spd Stat 10 Slave Safe Limited Speed Status Only Speed Hysteresis Speed Hysteresis Provides hysteresis for SLS_Out output when Safe Limited Speed monitoring is active Min Max 0 100 0 when P21 Safety Mode 1 2 3 4 5 6 8 or 9 10 100 when P21 Safety Mode 7 or 10 Slave Modes for Multi axis Cascaded Systems Chapter 8 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 91 However the safety option 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 safety option 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 TIP Only the middle and last safety option in a multi axis system can be configured for slave modes To configure the safety option for Slave Safe Limited Speed Status Only monitoring set these parameters in addition to the Slave Safe Stop parameters listed on page 99 and the Slave Safe Limited
188. ormally Open A set of contacts on a relay or switch that are open when the relay is de energized or the switch is de activated 0550 Output Signal Switching Device The component of the electro sensitive protective equipment ESPE connected to the control system ofa machine which when the sensing device is actuated during normal operation responds by going to the OFF state PC Personal Computer Computer used to interface with and program your safety system PELV Protective Extra Low Voltage An electrical system in which the voltage cannot exceed ELV under normal conditions and under single fault conditions except earth faults in other circuits 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 ISO 13849 1 safety rating PM Permanent Magnet PTI Proof Test Interval SDM Safe Direction Monitoring SELV Safety Extra Low Voltage Circuit A secondary circuit which is so designed and protected that under normal and single fault conditions its voltages do not exceed a safe value 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 SLS Safe Limited S
189. owerFlex Safety Option Module Notes 160 Rockwell Automation Publication 750 February 2012 Introduction General Specifications Specifications Appendix A This appendix provides product specifications for the PowerFlex safety option module Topic Page General Specifications 161 Environmental Specifications 162 Certifications 163 CE Conformity 163 Encoder Specifications 164 These specifications apply to the PowerFlex safety option module Attribute Value Standards IEC EN60204 1 15012100 IEC 61508 IEC 61800 5 2 Safety category Cat 4 and PL e per EN ISO 13849 1 SIL CL3 per IEC 61508 and EN 62061 Power supply user 1 0 24V DC 10 0 8 1 1 x rated voltage 2 PELV or SELV Power consumption 36W SLS outputs 68 78 24V DC 20 mA short circuit protected SS outputs 34 44 24V DC 20 mA short circuit protected Door control outputs 24V DC short circuit protected 51 52 0 75 A bipolar Power to Release Power to Lock configuration 20 mA cascading 2Ch Source configuration Pulse outputs 11 21 24V DC 50 mA short circuit protected Pulse inputs 12 522 32 42 52 562 72 82 X32 X42 5 mA per input max Input ON Voltage min 15V Input OFF Voltage max 5V Input OFF Current max 2 Input to output response time 20 ms SS In 515 In DM In ESM In LM In Overspeed Response Time User configurable
190. peed SMA Safe Maximum Acceleration SMS Safe Maximum Speed SS Safe Stop 12 Rockwell Automation Publication 750 February 2012 Additional Resources Preface These documents contain additional information concerning related Rockwell Automation products Resource PowerFlex 750 Series AC Drive Installation Instructions publication 750 IN001 Description Provides information on installing the safety option module in your PowerFlex 750 Series drive PowerFlex 750 Series AC Drives Programming Manual publication 750 PM001 Provides information on mounting installing and configuring your PowerFlex 750 Series drive Enhanced PowerFlex 7 Class Human Interface Module HIM User Manual publication 20HIM UM001 Provides information on using the 20 HIM A6 HIM module to configure the PowerFlex 750 Series drive and safety option module DriveExplorer Online Help DriveExplorer online help provides information on the release quick start steps general information about DriveExplorer software descriptions of the elements in the DriveExplorer window step by step procedures and troubleshooting information PowerFlex 750 Series Safe Torque Off User Manual publication 750 UM002 Provides information on installing and configuring your Safe Torque Off module with PowerFlex 750 Series drives System Design for Control of Electrical Noise Reference Manual publication GMC RM001
191. peed with Door Monitor and Enabling Switch In addition to 86 monitoring for Safe Stop and Safe Limited Speed the safety option monitors the status of the door and the Enabling Switch input 7 Safe Limited Speed status only In addition to monitoring for Safe Stop the safety 91 option 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 safety programmable logic controller No stopping action takes place 8 Slave Safe Stop The safety option performs the same functions as Safe Stop However 98 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 9 Slave Safe Limited Speed The safety option performs the same functions as Safe 104 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 10 Slave Safe Limited Speed status only The safety option performs the same 107 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
192. ptions Default Options Default Options Default Min Max Default Options Units Min Max Default Options Default Options Default Min Max Parameter Data 0 Single Fok 0 Single Fok 1 Dual S P Chk 2 Dual Spd Chk 3 Dual Pos Chk I 1 Incrementa 0 Sine Cosine 1 Incremental 0 Rev 0 Rev Rotary 1 Linear 0 Normal 0 Normal Same as encoder 1 Reversed 1024 1 65535 0 Voltage not monitored 0 Voltage not monitored 5 5V 5 9 7 12V 12 12V 5 24 241 10 24V 5 RPM mm s 214748364 8 214748364 7 RPM 214748364 8 214748364 7mm s 0 Rev 0 Rev Rotary 1 Linear 0 Normal 0 Normal Same as encoder 1 Reversed 0 1 65535 Rockwell Automation Publication 750 February 2012 Appendix B Read Write RW RW RW RW RO RW RO RW RW RW Data Type 8 bit Integer 8 bit Integer 8 bit Integer 8 bit Integer 16 bit Integer 8 bit Integer 32 bit Integer 8 bit Integer 8 bit Integer 16 bit Integer 169 Appendix B File Safe Speed Monitor 170 Parameter Data Display Name Full Name Description Fbk 2 Volt Mon Feedback 2 Voltage Monitor Encoder 2 voltage to be monitored Fbk 2 Speed Feedback 2 Speed Displays the
193. quivalent 2NC 3 Dual channel complementary INC INO For all input settings except Dual channel SS equivalent 3 s 2 OSSD 35 if one or two channels are connected to a24V DC source other than terminals 11 and 21 a fault occurs I O faults are Stop Category faults which initiate the configured Safe Stop Type I O faults are latched until the safety option is successfully reset For more information on I O faults refer to Troubleshooting the PowerFlex Safety Option Module on page 151 When using dual channel complementary INC 1NO 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 36 Rockwell Automation Publication 750 February 2012 Speed Monitoring 1 0 Signals Chapter 4 Figure 5 Safety Input Wiring Examples 2NCor 2 NC3s 1NC 1NO or 1NC 1NO 35 Safety Option Safety Option Test Out 0 511 Test Out 0 511 Test Out 1 521 4 Test Out 1 521 Dual channel Dual channel Equivalent Complementary 7 Safety Device Safety Device 1NC 2 OSSD 3s Safety Option Safety Option J Test_Out_0 S11 CJ Test_Out_0 11 4 Test Out 1 521 N C
194. r 1 These PFD and PFH calculations are based on the equations from Part 6 of EN 61508 and show worst case values This table provides data for a 20 year proof test interval and demonstrates the worst case effect of various configuration changes on the data Table 1 PFD and PFH for 20 year Proof Test Interval Attribute Value Drive Frames 1 7 Drive Frame 8 Drive Frame 9 Drive Frame 10 PFD 2 35E 4 5 83E 4 4 67 4 5 58E 4 PFH 2 67E 9 1 h 6 75E 9 1 h 5 33E 9 1 h 6 38E 9 1 h SFF 99 596 98 496 98 296 98 296 DC High Medium 9896 Medium 9896 Medium 9896 SIL CL 3 3 3 3 PL e e e e CAT 4 4 4 4 HFT 1 1002 1 1002 1 1002 1 1002 PTI Proof Test Interval 20 years 20 years 20 years 20 years The Safe State encompasses all operation that occurs outside of the other monitoring and stopping behavior defined as part of the safety option In addition configuration takes place in the Safe State While the safety option is in the Safe State all safety control outputs except the Door Control DC Out output their safe state de energized The Door Control DC Out output will be 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 safety option enters the Safe State for self testing If the self tests pass and there is a valid configuration the safety option remains in the Safe State until a succes
195. r 12 Rockwell Automation Publication 750 February 2012 43 Chapter 4 Speed Monitoring 1 0 Signals 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 P57 Door Out Type parameter setting and any Safe State faults that may 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 TEST OUT CHO TEST OUT CH1 TEST OUT CHO TEST OUT 1 DC OUT CHO 2 511 2 521 2 511 2 521 182 51 TB2 532 2 542 TB2 X32 TB2 X42 TB2 52 DM IN DM IN LM IN CHO DC OUT CHI Door Status Locking Mechanism Status TIP Check your interlock switch for internal jumpers before installation If an error is detected on either channel of the dual channel output a fault occurs I O faults are Stop Category faults which initiate the configured Safe Stop Type The fault is latched until the safety option is successfully reset For more information on faults refer to Chapter 12 The DC_Out output may be used as a bipolar output in Power to Release or Power to Lock configurations or it may be configured as Cascading 2Ch
196. r later must be installed to enable support for this wizard in RSLogix 5000 software This example application uses the following basic configuration in a single axis system Safe Stop SS enabled with an E stop button Safe Limited Speed SLS initiated with a 2NC contact switch e Door Monitoring DM of a guardlocking switch TLS 3 GD2 configured as Power to Release e A Reset button with 1 NO contact One encoder connected with Sin Cos output signal and resolution of 1024 Aconfigured Safe Maximum Speed SMS limit Each of the following sections describes the settings you need to enter for each parameter group You can use a HIM module DriveExplorer DriveExecutive or RSLogix 5000 software to configure the safety option Rockwell Automation Publication 750 February 2012 131 11 Configuration Examples Example 1 Initial Security Group Settings Figure 46 Security Group Parameters HIM Screen Software Screen Not Enabled AUTO 3 DriveExplorer Beta 0 000 Hz FU File Edit Explore Actions Help Port 04 Param File Group 25 14 R UE EIE leds x E Devices EtherNet IP Direct Node 1 PowerFlex 755 4 Password Lock State 9 0 PowerFlex 755 480 22A 1 45 Lock State Unlock Operating Mode H 1 20 HIM x6 LCD HIM 1 4 6 Operating Mode Program 2 4 Safe Speed Montr 51 1 4 7 Reset Defaults No Ac
197. re Understanding Commutation ete ex as Contact Information if Safety Option Failure Occurs Chapter 2 a Site ee doge ene Mie a tenes SatetyoM Odes coru os ce ien Disabled Modes deca suu uA qe ERES Lock Monitoring e etate nara Safe Maximum Speed Safe Maximum Acceleration and Safe Direction Monitoring ovo qax mesa Por eto d Hardware Feed tame dE SR Pies E PM M M Chapter 3 Titroductoli ete tiii b cd RET DH Li RII General Safety Information Fe AUS VIRA QUOTES Power Supply Requirements exe yas pr EET os reese Set Safety Enable Circuit yids ev oet edendis Install the PowerFlex Safety Option Installation in Frame 8 and Larger Drives Terminal COSI Chon sia a oa erue odore bnt dace eaten adora Compatible Encoders abo ee DEO aa lcd Connect an Encoder s iesu tee egre ek ets Rockwell Automation Publication 750 February 2012 Table of Contents Speed Monitoring 1 0 Signals General Device and Feedback Monitoring Configuration Safe Stop and Safe Stop with Door Monitoring Modes Chapter 4 Introductiof soe Le ec p Pp d
198. re 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 Safety 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 safety options in multi axis applications For 51 5 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 The outputs are read back and pulse tested when the P73 SLS Out Mode parameter is configured for pulse testing IMPORTANT Ifyou disable pulse testing on this output the achievable SIL Category and PL ratings of your entire safety system are reduced For a single unit system or the last unit in a cascaded system the 51 5 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 55 In For the first or middle units in a cascaded system the 51 5 Out is intended to be connected to the Safe Limited Speed input 51 5 In ofthe next safety option in the cascaded system This lets one SLS switch enable Safe Limi
199. rification including a complete functional test before the operational startup of any ATTENTION You must verify the configuration and validate the entire system safety related system Only authorized specially trained personnel experienced in the commissioning and operation of safety related systems may configure test and confirm the project Follow these steps to put the safety option into Run mode generate a configuration signature and lock the configuration 1 2 From the Security group choose the P6 Operating Mode parameter Set the P6 Operating Mode parameter value to 1 which equals Run mode A configuration signature is generated Choose the P10 Signature ID parameter and record the configuration signature value stored in this parameter Ifyou configured a password choose the P1 Password parameter and type the password 5 Choose the P5 Lock State parameter Set the P5 Lock State parameter value to 1 Lock to lock the configuration 140 Rockwell Automation Publication 750 February 2012 Configuration Examples Chapter 11 Example Application 2 This example application shows how to change the default configuration settings to set up the safety option for an application with these basic parameters Safe Stop SS enabled with an E stop button Safe Limited Speed SLS initiated with a 2NC contact switch Aconfigured Safe Maximum Speed
200. rlier in the cascaded chain IMPORTANT Thesafety reaction time for a cascaded system includes the sum of the reaction times of each safety option in the chain When properly configured for Slave Safe Stop mode the safety option performs the same functions as Safe Stop except that the safety option 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 Rockwell Automation Publication 750 February 2012 Slave Modes for Multi axis Cascaded Systems Chapter 8 Slave Safe Stop Parameter To configure the safety option for a Slave Safe Stop mode set these parameters List See Multi axis Connections on page 110 for details on configuring slave safety options Display Name Values 3 Full Name z 8 Description O Cascaded Config Option 2 Multi Mid 8 bit Cascaded Configuration 3 Multi Last Integer Defines whether the speed monitoring safety option is a single unit or if it occupies a 5 first middle or last position in a multi axis cascaded system 21 Safety Mode Option 18 Slv Safe Stp RW 8 bit Safety Mode Integer Defines the primary operating mode ofthe speed monitoring safety functions 44 Safe Stop Input
201. rmation 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 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 Pe ee IMPORTANT Identifies information that is critical for successful application and understanding of the product Allen Bradley Rockwell Software Rockwell Automation and TechConnect are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Summary of Changes The information below summarizes the changes to this manual since the l
202. rrect direction while Safe Direction Monitoring is active a Direction fault occurs Ifa Direction fault is detected while the safety option is monitoring motion the configured P45 Safe Stop Type is initiated and direction monitoring is not performed during the safe stop If a Direction fault is first detected after the initiation of the safe stop then all outputs go to their faulted state For more information about faults see Fault Reactions on page 155 Rockwell Automation Publication 750 February 2012 119 Chapter 9 Max Speed Max Accel and Direction Monitoring Safe Maximum Speed and Direction Monitoring Parameter List File Group 35 Feedback 42 Feedback 43 HOST GROUPS 120 Display Name Full Name Description Fbk 1 Polarity Feedback 1 Polarity Defines the direction polarity for encoder 1 Fbk 2 Polarity Feedback 2 Polarity Defines the direction polarity for encoder 2 Direction Mon Direction Monitoring Defines the allowable direction if Safe Direction Monitoring is enabled Pos Always 1 Positive always Neg Always 2 Negative always Pos in SLS 3 Positive during safe limited speed monitoring Neg in SLS 4 Negative during safe limited speed monitoring Direction Tol Direction Tolerance The position limit in encoder units tolerated in the wrong direction when Safe Direction Monitoring is active Units are
203. rs group Example 2 Stop Group Settings Figure 56 Stop Group Parameters HIM Screen Software Screen Not Enabled AUTO DriveExplorer Beta 0 000 Hz FU File Edit Explore Actions Help Port 04 Param File Grou lun j A OH 1 9 x GROUP Stop E Devices EtherNet IP Direct 5 npp safeStopiinpit 1 PowerFlex 755 1 Safe Stop Input 2NC Safe Stop Type 90 PowerFlex 755 480 22A 1 4 45 Safe Stop Type Torque Stop Mon Delay Y 4 1 20 HIM x6 LCD HIM MEM ne 5 4 14 lax Stop Time 5 4 Bde Mcd s 1 4 48 Standstill Speed 0 001 ee een 1 4 49 Standstill Pos 10 El Parameter Groups 1 4 50 Decel Ref Speed 0 Security 1 4 51 Stop Decel Tol 0 General Feedback Limited Speed Door Control Max Speed Faults 9 5 Dual Encoder DENC 1 9 13 EtherNet IP Embedded 9 14 DeviceLogix Embedded Custom Views Follow these steps to configure the Stop operation of the safety option 1 From the Stop group choose the 44 Safe Stop Input parameter 2 Set the P44 Safe Stop Input parameter value to 1 default for 2NC dual channel equivalent operation Rockwell Automation Publication 750 February 2012 145 11 Configuration Examples In this example application the Safe Stop input 55 In monitors E Stop button with two normally closed 2NC contacts 3 Choo
204. s a master or slave based on its location in the system Rockwell Automation Publication 750 February 2012 23 Chapter2 About the PowerFlex Safe Speed Monitor Option Module Safety Modes Parameter 21 Safety Mode is used to configure the safety option to operate in one of 11 user selectable safety modes based on combinations of the safety functions listed on the previous page P210ption Mode Description Page 0 Disabled In this mode all safety functions are disabled 25 1 Safe Stop The safety option activates the configured Safe Stop Type upon deactivation 61 of the Safe Stop input or the occurrence of a Stop Category fault 2 Safe Stop with Door Monitoring In addition to monitoring for Safe Stop the safety 72 option monitors the status of the door 3 Safe Limited Speed In addition to monitoring for Safe Stop the safety option monitors 75 the feedback velocity and compares it to a configurable Safe Speed Limit If the velocity exceeds the limit the safety option initiates the configured Safe Stop Type 4 Safe Limited Speed with Door Monitoring In addition to monitoring for Safe Stop 81 and Safe Limited Speed the safety option monitors the status of the door 5 Safe Limited Speed with Enabling Switch Control In addition to monitoring for 83 Safe Stop and Safe Limited Speed the safety option monitors the status of the Enabling Switch input 6 Safe Limited S
205. s a single unit or if it occupies a first middle or last position in a multi axis cascaded system Single 0 Single Unit System Milti First 1 Cascaded System First Unit Multi Mid 2 Cascaded System Middle Unit Multi Last 3 Cascaded System Last Unit Safety Mode Safety Mode Defines the primary operating mode of the speed monitoring safety functions Safe Stop 1 Master Safe Stop Safe Stop DM 2 Master Safe Stop with Door Monitoring Lim Speed 3 Master Safe Limited Speed Lim Speed DM 4 Master Safe Limited Speed with Door Monitoring Lim Speed ES 5 Master Safe Limited Speed with Enabling Switch Control LimSpd DM ES 6 Master Safe Limited Speed with Door Monitoring and Enabling Switch Control Lim Spd Stat 7 Master Safe Limited Speed Status Only Slv Safe Stp 8 Slave Safe Stop Slv Lim Spd 9 Slave Safe Limited Speed Slv Spd Stat 10 Slave Safe Limited Speed Status Only Reset Type Reset Type Defines the type of reset used by the safety option OverSpd Response Over Speed Response Configuration for the feedback interface sampling rate SS Out Mode Defines whether the 55 Out output is pulse tested If pulse testing is turned off for any output the SIL Category and PL rating is reduced for the entire safety system SLS Out Mode Defines whether the SLS_Out output is pulse tested If pulse testing is
206. s the first unit in a multi axis system P20 Cascaded Config 0 or 1 Lock Mon Input Lock Monitor Input Configuration for the Lock Monitor input In 2NC 1 Dual channel equivalent 2NC3s 2 Dual channel equivalent 3 s 1NC 1NO 3 Dual channel complementary 1NC 1NO 35 4 Dual channel complementary 3 s 2 OSSD 3s 5 Dual channel SS equivalent 6 Single channel equivalent Door Out Mode Defines whether the Out output is pulse tested If pulse testing is turned off for any output the SIL Category and PL rating is reduced for the entire safety system Values Default Options Default Options Default Options Default Options Default Options 0 Pwr to Rel 0 Pwr to Rel 1 Pwr to Lock 2 2 Ch Sourcing 0 Not Used 0 Not Used 1 2 2 2NC 3s 3 1NC 1NO 4 1NC 1N0 35 5 2 0550 3s 6 1NC 0 Disable 0 Disable 1 Enable 0 Not Used 0 Not Used 12 2NC 2 2NC 3s 3 1NC 1NO 4 1NC 1N0 35 5 2 0550 3s 6 INC 0 Pulse Test 0 Pulse Test 1 Pulse Tst Rockwell Automation Publication 750 February 2012 Parameter Data Read Write RW RW RW RW RW Appendix B Data Type 8 bit Integer 8 bit Integer 8 bit Integer 8 bit Integer 8 bit Integer 173 Appe
207. se the P45 Safe Stop Type parameter 10 11 12 13 14 15 Set the P45 Safe Stop Type parameter value to 1 which equals Safe Stop 1 Safe Stop 1 monitors deceleration profiles When Standstill Speed is detected within the Stop Delay Max Stop Time the safety option switches off Motion Power and sets door control logic to Unlock Choose the P47 Max Stop Time parameter The default value is 0 s but you can enter a value from 0 6553 5 s Type the value of the expected ramp to stop time plus a reasonable tolerance after the Safe Stop command is initiated Ifthe machine s speed is not below the Standstill Speed within the Max Stop Time period you entered a Stop Speed Fault occurs and door control logic remains set to Lock until Standstill Speed is reached Choose the P48 Standstill Speed parameter The default value is 0 001 rpm but you can enter a value from 0 001 65 535 rpm The Standstill Speed is measured in revolutions per minute because the P29 Fbk 1 Units parameter is configured for Rotary feedback Enter a value in the P48 Standstill Speed parameter field to define the speed at which the safety option determines standstill has been reached Choose the P49 Standstill Pos parameter The default value is 10 degrees but you can enter a value from 0 65 535 degrees The Standstill Position is measured in degrees because the P29 Fbk 1 Units parameter is configured for Ro
208. sful request for safe speed monitoring occurs If a Safe State fault is detected the safety option goes to the Safe State This includes faults related to integrity of hardware or firmware For more information on faults refer to Chapter 12 Rockwell Automation Publication 750 February 2012 19 Chapter1 Safety Concept Safety Reaction Time Considerations for Safety Ratings 20 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 for drive Frames 1 10 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 P24 OverSpd Response parameter For more information on overspeed response time see Overspeed Response Time on page 49 The achievable safety rating of an application that uses the safety option installed in PowerFlex 750 Series drives is dependent upon many factors including the encoder setup drive options output pulse testing 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 PowerFlex safety option can be used in applications up to and including SIL
209. sioning and operation of safety related systems may configure test and confirm the project Follow these steps to put the safety option into Run mode generate a configuration signature and lock the configuration 1 2 From the Security group choose the P6 Operating Mode parameter Set the P6 Operating Mode parameter value to 1 which equals Run mode configuration signature is generated Choose the P10 Signature ID parameter and record the configuration signature value stored in this parameter Ifyou configured a password choose the P1 Password parameter and type the password 5 Choose the P5 Lock State parameter Set the P5 Lock State parameter value to 1 Lock to lock the configuration Rockwell Automation Publication 750 February 2012 Chapter 12 Troubleshooting the PowerFlex Safety Option Module Introduction This chapter provides troubleshooting tables for diagnosing fault conditions associated with the PowerFlex safety option module Topic Page Status Indicators 151 Nonrecoverable Faults 152 Fault Recovery 157 Fault Codes and Descriptions 152 Fault Reactions 155 Status Attributes 156 Status Indicators The safety option features two indicators to provide status information Indicator Status Description Green On The safety option is operating normally and is in Run mode Red Flashing A recoverable fault has occurred
210. sted 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 safety option 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 51 5 Reset is attempted If the SLS In transitions from OFF to ON and the Reset In input is OFF the safety option 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 515 Reset If at any time the SLS In input transitions back to OFF the 51 5 Reset is aborted Manual Monitored When the SLS In input transitions from OFF to ON the safety option waits for an OFF to ON to OFF transition of the Reset In input before 51 5 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 750 February 2012 77 Chapter7 Safe Limited Speed SLS Modes Safe Limited Speed Parameter List Display Name Full Name Description File Group 21 Safety Mode Safety Mode Defines the prim
211. still Checking Torque Off NoCk 3 Safe Torque Off Without Standstill Checking Stop Mon Delay Stop Monitoring Delay Defines the monitoring delay between the request and the Max Stop Time when the request for a Safe Stop 1 or a Safe Stop 2 is initiated by an 55 In input ON to OFF transition Ifthe Safe Stop Type is Safe Torque Off With or Without Standstill Speed Checking the Stop Monitor Delay must be 0 or a Invalid Configuration Fault occurs Max Stop Time Maximum Stop Time Defines the maximum stop delay time that is used when the Safe Stop function is initiated by a stop type condition Standstill Speed Standstill Speed Defines the speed limit that is used to declare motion as stopped Units are based on rotary or linear configuration defined by P29 Fbk 1 Units Not valid for Safe Torque Off without Standstill Checking Standstill Pos Standstill Position Defines the position limit window in encoder 1 degrees or mm that will be tolerated after a safe stop condition has been detected Degrees 360 1 revolution or mm based on rotary or linear configuration defined by P29 Fbk 1 Units Not valid for Safe Torque Off without Standstill Checking Decel Ref Speed Deceleration Reference Speed Determines deceleration rate to monitor for Safe Stop 1 or Safe Stop 2 Units are based on rotary or linear configuration defined by encoder 1 feedback configuration P29 Fbk 1 Units Stop Decel Tol Stop Deceleration
212. sword Change PW Go to the next section to set the parameters found in the General parameters group Rockwell Automation Publication 750 February 2012 HIM Screen Configuration Examples Chapter 11 Example 1 General Group Settings Figure 47 General Group Parameters Not Enabled 0 000 Hz AUTO FO Port O4 File Group FILE Parameter Groups GROUP General Safety Mode Reset Type Software Screen File Edit Explore Actions Help 5 DSH teess ueste s wee E Devices EtherNet IP Direct E Node 1 PowerFlex 755 Cascaded Config Single H 0 PowerFlex 755 480V 22A 1 4 21 Safety Mode Safe Stop 8 1 20 HIM x6 LCD HIM 1 4 22 Reset Type Monitored ui 24 1 4 24 OverSpd Response 42 msec ed shes ead s 1 4 72 55 Out Mode Pulse Test 1 4 73 515 Out Mode Pulse Test E Parameter Groups Security General Feedback Stop Limited Speed Door Control Max Speed Faults 5 Dual Encoder DENC 1 13 EtherNet IP Embedded 8 14 DeviceLogix Embedded Custom Views Follow these steps to configure the general operation of the safety option From the General group choose the P20 Cascaded Config parameter Set the P20 Cascaded Config parameter to 0 default to configure the safety option as a Single unit Choose the P21 Safety Mode parameter The default setting is 1 which equals Safe Stop Set the P21 Safety Mode parameter value to 4
213. t during Safe Limited Speed monitoring the Door Control output Out is unlocked after the P53 LimSpd Mon Delay if configured has expired ATTENTION Make sure that an unlocked door does not result in a hazardous N situation If a Safe Stop Type is initiated or a fault occurs while the safety option is actively monitoring Safe Limited Speed door control remains unlocked The safe state of theSLS In input may allow the door be unlocked Rockwell Automation Publication 750 February 2012 75 Chapter 7 76 Safe Limited Speed SLS Modes P55 Safe Speed Limit If the measured velocity exceeds the Safe Speed Limit an SLS fault occurs and the configured P45 Safe Stop Type is initiated An optional P53 LimSpd Mon 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 safety option does not monitor for Safe Limited Speed and the measured velocity can be above or below the Safe Speed Limit monitoring is disabled when the 5 5 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 ATTENTION If the Reset is configured as Automatic Safe Limited Speed If you configure a P53 LimSpd Mon Delay the delay
214. t use a single encoder application if they meet the following criteria Motor is a Permanent magnet PM brushless AC motor Motor controller utilizes the single encoder for control of IGBT firing commutation Controller is not configured for auto transition to encoderless commutation in the event of encoder failure Encoder is of the Sin Cos type Motor Encoder coupling is designed so as to exclude shaft slippage as a failure mechanism optional such as tapered fittings Rockwell Automation Publication 750 February 2012 21 Chapter1 Safety Concept 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 rotating magnetic field is created by a number of electromagnets commutated electronically with IGBT at the right speed order and times Movement of the electromagnetic field is achieved by switching the currents in the coils ofthe stator winding This process is called commutation Interaction of the two electromagnetic fields produces magnetic force or torque For example with the PowerFlex 755 drive follow these guidelines to make sure that the incremental encoder or high resolution feedback device is used for commutation e Set P35 Motor Cntl Mode 1 Induction FV
215. tary feedback Enter the value to define the position limit in encoder units that is tolerated after standstill has been reached Choose the P50 Decel Ref Speed parameter The default value is 0 RPM but you can enter a value from 0 65 535 RPM The Decel Ref Speed parameter is used to verify that the speed is decelerating at the desired rate Enter a number greater than the Max Speed 2000 in this example Choose the P51 Stop Decel Tol parameter The Stop Decel Tol parameter determines the total percentage of the Decel Ref Speed that is used as the upper limit of deceleration speed Enter 10096 for this example Go to the next section to set the parameters found in the Limited Speed parameters group 146 Rockwell Automation Publication 750 February 2012 HIM Screen Configuration Examples Chapter 11 Example 2 Limited Speed Group Settings Figure 57 Limited Speed Group Parameters Not Enabled 0 000 Hz AUTO Port 04 Param File Group FILE Parameter Groups GROUP Limited Speed LimSpd Mon Delay Enable SW Input Software Screen se 3DriveExplorer Beta File Edit Explore Actions Help MEER GS RR SO Da kd 5 El Devices EtherNet IP Direct El Node 1 PowerFlex 755 1 Lim Speed Input Not Used 9 0 PowerFlex 755 480 22A 1 4 53 LimSpd Mon Delay 0 0 9 1 20 HIM x6 LCD HIM HM Used 5 4 Safe Speed Montr 51 Bs
216. ted Speed on all axes at the same time Rockwell Automation Publication 750 February 2012 Speed Monitoring 1 0 Signals Chapter 4 Figure 7 5 5 OuttoSLS In Connections for Multi axis Applications Safety Option Master SLS OUT CHO 515 OUT TB2 68 TB2 78 2 552 TB2 S62 SLS_IN_CHO SLS_IN_CH1 Safety Option Slave For more information on multi axis configurations see Cascaded Configurations starting on page 97 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 safety option is ina SLS Monitoring Delay LimSpd Mon 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 safety option is in the safe state See Safe Limited Speed Status Only Mode on page 91 for more information If an error is detected on either channel of the dual channel output a fault occurs I O faults are Stop Category faults which initiate the configured Safe Stop Type The fault is latched until the safety option is successfully reset For more information on faults refer to Chapte
217. the lock state and OFF in the unlock state The first and middle units of a multi axis system must be configured as cascading 2 Lock Mon Enable Lock Monitor Enable Lock Monitoring can only be enabled when the speed monitoring safety option is a single unit or as the first unit in a multi axis system P20 Cascaded Config 0 or 1 Lock Mon Input Lock Monitor Input Configuration for the Lock Monitor input LM In 1 Dual channel equivalent 2NC 3s 2 Dual channel equivalent 3 s 1NC 1NO 3 Dual channel complementary 1NC 1NO 35 4 Dual channel complementary 3 s 2 OSSD 3s 5 Dual channel SS equivalent 6 Single channel equivalent SS Out Mode Defines whether the 55 Out output is pulse tested If pulse testing is turned off for any output the SIL Category and PL rating is reduced for the entire safety system 1 If pulse testing is turned off for any output the SIL Category and PL rating is reduced for the entire safety system 70 Values Units Default Min Max Units Default Min Max Units Default Min Max Default Options Default Options Default Options Default Options Deg mm 10 0 65 535 deg 0 65 535 mm RPM mm s 0 0 65 535 RPM 0 65 535 mm s 96 0 0 100 0 Pwr to Rel 0 Pwr to Rel 1 Pwr to Lock 2 2 Ch Sourcing 0 Disable 0 D
218. the lock state and OFF in the unlock state The first and middle units of a multi axis system must be configured as cascading 2 DM Input Door Monitor Input Configuration for the Door Monitor input DM In 2 OSSD 3s 5 Dual channel SS equivalent 3 s Values Default Options Options 0 Pwr to Rel 0 Pwr to Rel 1 Pwr to Lock 2 2 Ch Sourcing 5 2 0SSD 3s Rockwell Automation Publication 750 February 2012 Read Write RW RW Data Type 8 bit Integer 8 bit Integer Slave Safe Stop Wiring Examples GND 24V DC Slave Modes for Multi axis Cascaded Systems These examples show two different Slave Safe Stop configurations Chapter 8 The first example shows the safety option configured as a cascaded middle unit via the P20 Cascaded Config parameter Multi Mid It has SS In and DM In input connections from the previous upstream safety option as wellas 55 Out and Out output connections to the next downstream safety option 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 74 for an example of a first master unit Figure 30 Slave Safe Stop Middle Unit Previous Upstream Axis Safety Option Terminals TB1 511 S11 511 TEST 0010 511 11 S11 21 521 521 TEST
219. the safety option A technical support representative will use the security code to calculate a Vendor Password value Enter the value provided by your Rockwell Automation Technical Support representative into the P19 Vendor Password parameter Set the P17 Password Command parameter to 2 which equals Reset Password 5 Enter the new password by using the P13 New Password parameter Set the P17 Password Command parameter to 1 which equals Change Password Rockwell Automation Publication 750 February 2012 Basics of Application Development and Testing Safety Configuration and Verification Chapter 10 Resetting the Configuration When the safety option is unlocked and the P6 Operating Mode parameter equals 0 Program you can reset the safety option s configuration parameters to their factory default settings by setting the P7 Reset Defaults parameter to 1 The reset parameters are sent to the safety option when the P6 Operating Mode parameter is changed to 1 Run Configuration for the intended SIL CL3 PL e or Cat 4 system should be carried out by the system integrator or an operator trained and experienced in safety applications developer must follow good design practices Use functional specifications including flow charts timing diagrams and sequence charts Perform a configuration review Perform configuration validation Rockwell Automation Pu
220. tion lt 1 4 10 Signature ID 0 1 4 13 New Password 0 El Parameter Groups 1 417 Password Command No Action Security 1 4 18 Security Code 256 General 1 4 19 Vendor Password Feedback 1 4 70 Config Flt Code No Fault Stop Limited Speed Door Control Max Speed Faults 132 89 5 Dual Encoder DENC 1 9 13 EtherNet IP Embedded 9 14 DeviceLogix Embedded Custom Views Follow these steps to put the safety option into Program mode for configuration 1 11 From the Security group choose the P5 Lock State parameter The default value of the Lock State parameter is 0 or unlocked If the safety option is locked Lock State parameter value equals 1 set the P5 Lock State parameter value to 0 If an error occurs a password has been configured to protect the safety option configuration Choose the P1 Password parameter Type the password Choose the P6 Operating Mode parameter The default value is 0 which equals Program If the safety option is in Run mode Operating Mode parameter equals 1 set the P6 Operating Mode parameter to 0 to enable you to enter a new configuration If you want to configure a password or change the password choose the P13 New Password parameter The default value is 0 Enter a value from 0 4 294 967 295 Type the new password value Choose the P17 Password Command parameter Set the P17 Password Command parameter value to 1 which equals Change Pas
221. to OFF the safety option does not initiate the configured Stop Delay P47 Max Stop Time until after the optional Stop Monitoring Delay 46 Stop Mon 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 P47 Stop Time begins immediately regardless of whether a Stop Monitoring Delay P46 Stop Mon Delay is configured Deceleration monitoring takes place during the Stop Delay P47 Max Stop Time These three configurable parameters define the deceleration profile that is used Deceleration Reference Speed P50 Decel Ref Speed Deceleration Tolerance P51 Stop Decel Tol Stop Delay P47 Max Stop Time If Standstill Speed is detected any time after the Safe Stop has been initiated and before the Stop Delay P47 Max 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 P47 Max Stop Time a Stop Speed fault occurs For Safe Stop 1 motion power is removed when Standstill Speed is reached For Safe Stop 2 motion power is not removed Figure 12 Timing Diagram for Safe Stop 1 Stop Request Stop Monitoring Delay 46 Stop Delay P47 A P51 Stop Decel Tol 4 afe Torque off Active lime SS In Signal SS OutSignal Motion Power 7 Stop Command DC Out Output 0
222. ttings Figure 54 General Group Parameters HIM Screen Software Screen Not Enabied AUTO 0 000 Hz FU Edit Explore Actions Help Port 04 Param File Group FILE Parameter Groups GROUP General Safety Mode Reset Type AA DH E Devices EtherNet IP Direct 5 npp E Node 1 PowerFlex 755 0 PowerFlex 755 480 22A 1 20 HIM x6 LCD HIM 4 Safe Speed Montr 51 Cascaded Config Single 4 21 Safety Mode Safe Stop 14 22 Reset Monitored 4 24 OverSpd Response 42 msec 14 72 55 Out Mode Pulse Test DA m Device Parameters E Parameter Groups Security Feedback Stop Limited Speed Door Control Max Speed Faults 9 5 Dual Encoder DENC 1 13 EtherNet IP Embedded 9 14 DeviceLogix Embedded Custom Views 14 73 SLS Out Mode Pulse Test Follow these steps to configure the general operation of the safety option 1 From the General group choose the P20 Cascaded Config parameter 2 Set the P20 Cascaded Config parameter to 0 default to configure the safety option as a Single unit 3 Choose the P21 Safety Mode parameter The default setting is 1 which equals Safe Stop Rockwell Automation Publication 750 February 2012 Configuration Examples Chapter 11 Set the P21 Safety Mode parameter value to 6 for Master Safe Limited Speed with Door Monitoring and Enabling Switch Monitoring mode Lim Speed DM E
223. ty Option Terminals TB TB 511 511 51 511 TEST OUT O 91 511 TEST OUT 0 91 511 511 sn sn 521 521 521 ST Sot TEST OUT 1 91 531 TEST OUT 1 2 51 521 51 TB2 TB2 534 RESET_IN 534 RESET IN 52 3 Cx 122 DC OUT CHx 51 51 2 179105 188 0 8 78 SLS QUT CHx 68 68 68 M SS OUT CHx 3 3 e ipo LM IN CHx 32 32 2 50 532 532 532 62 IN CH res 52 582 esm IN Cx 282 582 IN CHx 572 572 57 521 ss noa 27 522 SS IN 512 512 512 a2 2 W M M EW Rockwell Automation Publication 750 February 2012 109 Chapter8 Slave Modes for Multi axis Cascaded Systems Multi axis Connections When configuring a multi axis system you need to consider the location of each safety option in the system The type of cascaded connections that can be made are dependent upon the Safety mode configurations of the master and slave safety options and their positions in the system Middle and last units in the cascaded chain m
224. ul 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 safety option s location in the system P20 Cascaded Config and Door Control Output Type P57 Door Out Type determine whether the Door Control output Out is locked or unlocked during normal operation When the Out output has no faults the safety option is configured for Safe Stop and the safety option is monitoring motion the door control logic state is Locked It remains locked while a Safe Stop is being executed For all Safe Stop Types except Safe Torque Off without Standstill Checking door control logic is set to Unlock only when Standstill Speed has been reached Checking door control logic is set to Unlock when the Stop Delay P47 Max Stop ATTENTION If the Safe Stop Type is Safe Torque Off without Standstill Time has elapsed regardless of speed Rockwell Automation Publication 750 February 2012 67 Chapter6 Safe Stop and Safe Stop with Door Monitoring Modes Configuration You configure the type of door control for each Safe Speed Monitor Option module in the system P57 Door Out Type Settings DC Out Status and Lock State Single and Last Units First and Middle Units 0 Power to Release Not valid ON Door is unlocked OFF Door is locked 1 Power to Lock Not valid ON Door is locked OFF Door is unlocked 2 C
225. ult Bit 8 Dual Fbk Pos Dual FB Position Fault Bit 9 SS In 7 55 In Fault Bit 10 SS Out Flt 55 Out Fault Bit 11 Decel Fit Deceleration Fault Bit 12 Stop Spd Stop Speed Fault Bit 13 Mov in Stop Motion After Stopped Fault Bit 14 SLS In Fit SLS_In Fault Bit 15 SLS Out Flt SLS_Out Fault Bit 16 SLS Spd Flt SLS_Speed Fault Bit 17 SMS Spd Fit SMS_ Speed Fault Bit 18 Accel Fit Acceleration Fault Bit 19 Dir Direction Fault Bit 20 DM In Fit Fault Bit 21 Door Mon Fit Door Monitoring Fault Bit 22 DC Out Fit DC Out Fault Bit 23 LM In Fit LM In Fault Bit 24 Lock Mon Lock Monitoring Fault Bit 25 ESM In Fit ESM_In Fault Bit 26 ESM ESM Monitoring Fault Bit 27 Fok 1 V Fit Encoder 1 Voltage Fault Bit 28 Fbk 2 V Fit Encoder 2 Voltage Fault Critical Flt gt Combined Fit gt Dual Fbk Pos Dual Spd gt JFbk 2 Fit gt JEbK 1 Fit gt Reset PwrUp S MP Out Fit lInvalid Cfg N N N N Un A N c N N c w w Safe Speed Monitor Faults Rockwell Automation Publication 750 February 2012 175 Appendix B File Safe Speed Monitor Faults 68 176 Parameter Data Display Name
226. ult Reactions Troubleshooting the Safety Option Module Chapter 12 When a fault occurs the type of fault and the status of the system determine the resulting state of the system Safe State Faults If a Safe State fault occurs in any operational state including the Disabled state the safety option goes to the Safe State In the Safe State all safety outputs are in their safe states Stop Category Faults and Fault While Stopping Faults If a Stop Category fault or Fault While Stopping fault occurs while the safety option is monitoring motion the safety option initiates the configured Safe Stop Type The type of fault detected determines the safety options response when the fault occurs while the safety option is executing the configured Safe Stop Type Type of Fault Detected Fault While Stopping Faults Deceleration fault Decel Stop Speed fault Stop Spd These Stop Category Faults SMS Speed fault when the P63 Max Spd Stop Typ is configured for Use Safe Torque Off with Check for Standstill Torque Off Acceleration fault when the P66 Max Acc Stop Typ is configured for Use Safe Torque Off with Check for Standstill Torque Off e Direction fault Dir Flt if the fault occurred while a safe stop was in progress Response Outputs are placed in a faulted state but door control logic can be set to Unlock if feedback signals indicate that Standstill Speed has been rea
227. ure ID from the contents of the P10 Signature ID parameter Enter the password into the P1 Password parameter if required Set the P5 Lock State parameter to 1 Lock Refer to Appendix B for a complete list of parameters and settings for the safety option 126 Rockwell Automation Publication 750 February 2012 Safety Configuration and Verification Chapter 10 Project Verification Test To check that the safety option s configuration adheres to the application specification you must generate a suitable set of test cases covering the application The set of test cases must be filed and retained as the test specification You must include a set of tests to prove the validity of the safety configuration parameters You must perform a complete functional test of the entire system before the operational startup of a safety related system Confirm the Project You must check each parameter to make sure it is set to the correct value according to your system configuration specification Safety Validation An independent third party review of the safety system may be required before the system is approved for operation An independent third party certification is required for IEC 61508 SIL CL3 Verifying the Signature and Lock in the Safe Speed Monitor Option Module To meet SIL CL3 PL e or Cat 4 requirements you must verify that the correct configuration is locked in the safety option To
228. used when the Safe Stop function is initiated by a stop type condition Standstill Speed Standstill Speed Defines the speed limit that is used to declare motion as stopped Units are based on rotary or linear configuration defined by P29 Fbk 1 Units Not valid for Safe Torque Off without Standstill Checking Safe Stop and Safe Stop with Door Monitoring Modes Chapter 6 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 Out is in the Lock state except for the 5 seconds following Out output 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 Lock Monitoring fault is Stop Category fault which initiates the configured Safe Stop Type To configure the safety option for Safe Stop mode set these parameters in addition to the General and Feedback parameters listed on page 53 and page 58 E E Bis amp 18 Setting 1 SafeStop 8 bit Integer Default 1 2 RW 8 bit Options 10 Not used Integer 12 2 2NC3s 3 1NC 1N0 4 1NC 1N0 35 5 2 0550 35 6 Default 0 Torque Off RW 8 bit Options 10 Torque Off Integer 1 Safe Stop 1 2 Safe Stop 2 3 Torque Off NoCk Units
229. verify the configuration Signature ID view the contents of the P10 Signature ID parameter and make sure that it matches the configuration Signature ID you recorded as part of the configuration process on page 126 To verify the lock status you can view the P5 Lock State parameter You can also view the status of the Configuration Lock bit bit 1 of the P68 Guard Status parameter If the bit equals 1 the configuration is locked If the bit equals 0 the configuration is unlocked Rockwell Automation Publication 750 February 2012 127 Chapter 10 Safety Configuration and Verification Configure ADC and the Safe Speed Monitor Option Module Automatic Device Configuration ADC is a Logix feature present in version 20 or later ADC can be used to download a configuration stored in a controller into a device and uses an ADC Configuration Signature value to determine if the configuration of a device has changed since the controller last configured the device The controller can also be configured to flash update the firmware in a device with the revision that the controller requires to be present in the device Follow these steps to configure ADC using RSLogix 5000 version 20 or later 1 10 11 12 If the safety option configuration is locked you can unlock the configuration by setting the P5 Lock State parameter to 0 Unlock If an error occurs you need to enter the password by us
230. well Automation Publication 750 February 2012 HIM Screen Configuration Examples Chapter 11 Example 1 Limited Speed Group Settings Figure 50 Limited Speed Group Parameters Not Enabled 0 000 Hz AUTO FO Port O4 File Group FILE Parameter Groups GROUP Limited Speed Lim Speed Input LimSpd Mon Delay Enable SW Input Software Screen 5 Beta File Edit Explore Actions Help 5 5 mss El Devices EtherNet IP Direct El Node 1 PowerFlex 755 1 Lim Speed Input Not Used 9 0 PowerFlex 755 480V 224 1 4 53 LimSpd Mon Delay 0 0 8 1 20 HIM x6 LCD HIM 1 4 54 Enable SW Input Not Used 1 4 55 Safe Speed Limit 0 0 5 4 Safe 4 Montr 51 E eae 1 4 56 Speed Hysteresis 0 Device Parameters E Parameter Groups Security General Feedback Stop Limited Speed Door Control Max Speed Faults 5 Dual Encoder DENC 1 13 EtherNet IP Embedded 14 DeviceLogix Embedded Custom Views H A E Follow these steps to configure the Safe Limited Speed operation 1 From the Limited Speed group choose the P52 Lim Speed Input parameter The default value is 0 Disabled for applications without Safe Limited Speed control Set the P52 Lim Speed Input parameter value to 1 for 2NC dual channel equivalent operation In this example application the Safe Limited Speed input 51 5 In monitors a
231. x Speed group choose the P61 Max Speed Enable parameter The default value is 0 Disabled for no maximum speed limitation Set the P61 Max Speed Enable parameter value to 1 Enabled which monitors that the encoder feedback signal does not exceed the velocity configured by using the Safe Max Speed parameter Choose the P62 Safe Max Speed parameter The default value is 0 rpm or mm s Enter a value from 0 6553 5 Type the maximum allowable rpm value for velocity The speed is calculated in rpm based on the Fbk 1 Units parameter setting 0 Rotary feedback entered previously Choose the P63 Max Spd Stop Typ parameter Rockwell Automation Publication 750 February 2012 139 11 Configuration Examples 6 Set the P63 Max Spd Stop Typ parameter value to 0 default which equals Use Safe Torque Off with Standstill Checking Torque Off With this configuration if speed exceeds the configured Safe Max Speed the safety option initiates a Safe Torque Off with Standstill Checking type of Safe Stop regardless of the configured Safe Stop Type the next section to put the safety option into Run mode and lock the configuration Example 1 Final Security Group Settings This example includes only the steps for entering a configuration by using the HIM module or software program You must also follow the requirements described in Chapter 10 Safety Configuration and Ve
232. xis Applications Safety Option Master SS OUT CHO 55 OUT TB2 34 TB2 44 2 512 and 2 522 are 2 512 2 522 configured as 2 OSSD 3s inputs SS IN CHO SS IN Safety Option Slave For more information on multi axis configurations see Cascaded Configurations starting on page 97 Alternately the first 55 Out output may be used to signal a programmable logic controller PLC that a Safe Stop has been requested If the 55 In is ON closed and a successful Safe Stop Reset is performed the 55 Out output is turned ON If Lock Monitoring is not enabled or the door control logic state is Unlock the 55 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 55 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 Rockwell Automation Publication 750 February 2012 41 Chapter 4 42 Speed Monitoring 1 0 Signals If the Safe Stop Type 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 which initiate the configured Safe Stop Type The fault is latched until the safety option is successfully reset For mo
233. y Option Module Chapter 12 These tables list the faults fault codes and display text for each fault You can view these faults by accessing the P67 Fault Status parameter Description A combined fault is indicated if any error has occurred 1 Critical Fit A nonrecoverable microprocessor error has occurred 2 Invalid Cfg An Invalid Configuration fault occurs if a configuration parameter is set to an illegal value or combination of values See the Configuration Fault Codes on page 159 MP Out Fit An MP Output fault occurs if an error is detected in the Motion Power command to the drive If you are not using the 010 digital input on the drive s main control board as a hardware enable verify that J1 ENABLE jumper also on the drive main control board is installed Reset PwrUp A Reset Powerup fault occurs if the reset type is configured for Manual or Manual Monitored and the Reset In input is detected as ON when power is cycled Fbk 1 Fit A Feedback 1 fault occurs if any of these conditions are detected at encoder 1 Anopen wire is detected A short circuit is detected Asine cosine fault exists that is the amplitude of the sine signal squared plus the amplitude of the cosine signal squared is not equal to a constant value The feedback signals indicate a frequency greater than or equal to 100 kHz for a Sine cosine encoder or 200 kHz for a incremental encoder Illegal encoder si
234. y lock status of the system configuration Though optional you can configure a password to help protect the system configuration from unauthorized modifications Configuration Signature ID The configuration Signature ID is an identification number that uniquely identifies a specific configuration for a safety option Each time the system is configured or reconfigured a new configuration signature is generated to identify that specific configuration You can view the configuration Signature ID by accessing the P10 Signature ID parameter Safety lock When you have verified the operation of the system and recorded the configuration Signature ID you must lock the configuration to protect it from modification IMPORTANT Ifyou notsafety lock the configuration untested or unintentional changes can be made to the safety option configuration which could result in unexpected system behavior You can lock the configuration by using the P5 Lock State parameter You can check the safety lock status of the system by viewing the Configuration Lock bit bit 1 in the P68 Guard Status parameter If the bit equals 1 the configuration is locked If it equals 0 the configuration is unlocked Rockwell Automation Publication 750 February 2012 121 Chapter 10 File HOST GROUPS 122 Group Security 13 17 Safety Configuration and Verification Display Name Full Name Description

750-RM001 - Rockwell Automation

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