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Copley Controls Xenus Plus Compact Manual

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Xenus Plus Compact
STO Manual
P/N 16-01553 Rev 00
September 12, 2016

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Summary of Contents for Copley Controls Xenus Plus Compact

  • Page 1 Xenus Plus Compact STO Manual P/N 16-01553 Rev 00 September 12, 2016...

  • Page 2: Table Of Contents

    Risk of electric shock .............................. 8 Disclaimer ................................8 Installation Overview ............................... 9 Definitions ................................9 Introduction to the Xenus Plus COMPACT ......................10 Product Description ............................... 10 Model Overview & Numbering ..........................10 Specifications Overview ............................11 Control Modes ............................... 11 Command Sources..............................
  • Page 3 AC Mains Over-Voltage Category ......................... 17 6.6.9 Wiring to the STO Inputs ..........................17 6.6.10 Periodic Test Requirements ......................... 17 Installation Using STO for Xenus Plus Compact ....................18 STO Wiring Overview ............................18 7.1.1 STO Power Requirements ..........................18 7.1.2 STO Wiring Requirements ..........................

  • Page 4: About This Manual

    Xenus Plus Compact STO Manual 16-01553 Rev 00 About This Manual Title, Number, Revision Title Xenus Plus Compact STO Manual Table 1 Document Number 16-01553 Current Revision Revision History Revision Date ECO # Comments 9/12/2016 ECO-063895 Originated Table 2 EC Declaration of Conformity The products covered by this manual comply with the EC Directives 2014/30/EU (EMC Directive), 2014/35/EU (Low Voltage Directive), 2006/42/EC (Machinery Directive) and 2011/65/EU (RoHS Directive).

  • Page 5: Purpose And Scope Of This Document

    Purpose and Scope of This Document This document is intended to inform the reader about the Functional Safety features of the Xenus Plus Compact servo drive models and to provide information on the steps required to install it into systems so that a target level of Functional Safety performance can be achieved.

  • Page 6: Related Documentation

    Xenus Plus Compact STO Manual 16-01553 Rev 00 Related Documentation These documents have additional information on the Xenus Plus Compact and are required for proper installation and commissioning of the drives. Available upon request from Copley Controls: User Guide Xenus Plus Compact User Guide (Document No. 16-01552) Datasheet Xenus Plus XEC Datasheet (Document No.
  • Page 7 Xenus Plus Compact STO Manual 16-01553 Rev 00 1.10 Abbreviations and Acronyms Acronym Description Safety-Related a,b,c,d,e Denotation of performance level (PL) Cat. Category Common Cause Failure Diagnostic Coverage, Average Functional Safety Hardware Fault Tolerance MTTF Mean Time to Failure MTTFd...

  • Page 8: Risk Assessment & Responsibility Of The Installer

    The information in this manual is specific to the functional safety features of the Xenus Plus Compact servo drives. The user must use this manual along with the Xenus Plus Compact User Guide and the datasheets for the Xenus Plus Compact models for proper and safe installation and overall commissioning of the drives.

  • Page 9: Installation Overview

    16-01553 Rev 00 Installation Overview This graphic shows all of the elements in a complete Xenus Plus Compact installation. The STO feature and interface to the machine-level functional safety equipment are highlighted in red to emphasize the aspects of the installation that are addressed in this manual.

  • Page 10: Introduction To The Xenus Plus Compact

    Introduction to the Xenus Plus Compact Product Description The Xenus Plus Compact models are intended to be operated from single or three phase power in the 100 Vac to 240 Vac range and can drive motor currents up to 15 Adc. These drives have a Safe Torque Off (STO) function.

  • Page 11: Specifications Overview

    Over-Voltage Category: OVC III (An SPD or isolation transformer is required to limit overvoltages to OVC II levels) Model dependent – see the Xenus Plus Compact User Guide Maximum Mains Current: Control Power +24 Vdc typical, +20 to +32 Vdc The 24V is required for operation and powers the control core and communications in the drive.

  • Page 12: Sto Architecture And Function

    STO Architecture and Function The Xenus Plus Compact STO function is suitable for use in safety loops up to SIL 3 and/or Cat. 3 PL d performance. The circuit concept uses a quasi three-channel architecture so that the safety function will continue to operate even in the event of two failures.

  • Page 13: Sto Channel Operation

    Xenus Plus Compact STO Manual 16-01553 Rev 00 STO Channel 3 is ANDed with Channel 2 to disable the drive by disabling both the high and low side MOSFET gate drives. Any of the three channels by itself is therefore sufficient to prevent the initiation of motion or halt drive induced acceleration when the STO function is activated.

  • Page 14: Sto Function Specifications

    Xenus Plus Compact STO Manual 16-01553 Rev 00 STO Function Specifications Specification Requirement When STO is active, motor current that can cause rotation (or motion in the case of a linear motor) is not applied. The PWM outputs are disabled and Operation cannot source or sink current.

  • Page 15: Safety Related Parameters

    Xenus Plus Compact STO Manual 16-01553 Rev 00 Safety Related Parameters IEC 61508: 2010 ISO 13849-1: 2015 Category Table 8 6.5 x 10 < 60% MTTF 5.7 x 10 20 yrs Regulatory Specifications Specification Requirement Approvals UL recognized component to UL 61800-5-1...

  • Page 16: Limitations And Necessary Risk Reductions

    180 Degree Electrical Movement In the event of IGBT failures in the Xenus Plus Compact output stage, unexpected motor movement of up to 180 electrical degrees can occur. It is the responsibility of the designer of the larger system to assess and address any hazards that this unexpected movement could create.

  • Page 17: Dc Power Supply

    Xenus Plus Compact STO Manual 16-01553 Rev 00 6.6.7 24V DC Power Supply A constraint on the larger system is that the power supply used to provide the 24V control power to the drive must be a SELV or PELV type.

  • Page 18: Installation Using Sto For Xenus Plus Compact

    Xenus Plus Compact STO Manual 16-01553 Rev 00 Installation Using STO for Xenus Plus Compact STO Wiring Overview This diagram gives detail on the physical cabling, shielding, and grounding of the wiring between the drive STO inputs and the machine level safety circuits.

  • Page 19: Sto (Safety) Cable Connector

    7.1.3 STO (Safety) Cable Connector The Xenus Plus Compact STO connector J4 is a Kycon K22X-E9S-N. It is a Dsub-9F receptacle with gold-flash plating on the pins and #4-40 standoffs which can receive male jack-screws on the cable connector. The mating cable connector must have crimp and poke contacts with gold flash or plating and jack-screws.

  • Page 20: Wiring Example:sil 3/Cat. 3 Pl D Emergency Stop - Stopping Category 1

    IN7 is an opto-isolated input that is programmed to Enable the drive. The INCOM signal for IN7 connects to ground. When 24V is applied to IN7 it will enable the Xenus Plus Compact if no other inputs are configured as Enables and no Enable inputs are inactive.

  • Page 21: Example Sto Timing

    Xenus Plus Compact STO Manual 16-01553 Rev 00 7.1.6 Example STO Timing Fig. 6 Power +24 VDC supplied to the safety relay Reset/Start Momentary push-button that causes the K1~K2 relay contacts to close, supplying power to the STO inputs of the drive, and de-activating the STO function.

  • Page 22: Start-Up Checklist

    Before powering the drive, and commencing with the functional safety tests, check: • That the installation requirements given in the Xenus Plus Compact User Guide and this manual have been adhered to. Specifically ensure that proper grounding, shielding, overcurrent, and overvoltage protection measures are in place in regards to electrical safety and electromagnetic compatibility.

  • Page 23: Start-Up Checklist

    Xenus Plus Compact STO Manual 16-01553 Rev 00 7.2.2 Start-Up Checklist Requirement Comments Initials Ensure that the drive can be run and stopped freely during the commissioning. Stop the drive (if running), and safely remove AC power from the drive.

  • Page 24: Sto Status Indications

    STO Circuit Status Data Objects The Xenus Plus Compact has a variety of data objects that can be read by the end user via CANopen, EtherCAT, or serial communications. The status of the STO circuit is available in ASCII parameter 0x139 and DS-402 parameter 0x219D.

  • Page 25: Cme2 Control Panel

    Xenus Plus Compact STO Manual 16-01553 Rev 00 7.3.3 CME2 Control Panel CME2 is the PC based software tool used for configuring, commissioning, and troubleshooting Copley Control digital servo drives. A graphic LED labeled “Safety” on the CME2 Control Panel screen gives the status of the STO function.

  • Page 26: Troubleshooting

    16-01553 Rev 00 Troubleshooting The status of the STO function in the Xenus Plus Compact drive can be viewed via LED indicators on the drive, data objects accessible over CANopen, EtherCAT, and the configuration software CME2. Other Copley software products such as CMO (Copley Motion Objects), CML (Copley Motion Libraries), CPL (Copley Programming Language) and ASCII communications can read the status of the STO function.

  • Page 27: Maintenance

    Accessibility and Replacement of Internal Parts There are no user-replaceable parts in the Xenus Plus Compact. The warranty will be void if the user removes the cover or attempts any repairs. For safety and to assure compliance with documented system data, only Copley Controls shall perform repairs to the Xenus Plus Compact.

  • Page 28: Periodic Testing Checklist

    Xenus Plus Compact STO Manual 16-01553 Rev 00 Periodic Testing Checklist Table 12 Requirement Comments Initials Ensure that the drive can be run and stopped freely during the commissioning. Stop the drive (if running), and safely remove AC power from the drive.

  • Page 29: Muting & Suspension Of Safety Functions

    Xenus Plus Compact STO Manual 16-01553 Rev 00 Muting & Suspension of Safety Functions STO Muting Muting means de-activating the STO function. A convenient method for muting the STO function is provided for those applications not using the STO function.

  • Page 30: 10.0 Decommissioning

    Xenus Plus Compact STO Manual 16-01553 Rev 00 10.0 Decommissioning Before decommissioning any safety system from active service:  Evaluate the impact of decommissioning on adjacent operating units and facilities or other field services.  Conduct a proper review and obtain required authorization.

  • Page 31: Xenus Plus Compact Sto Manual 16-01553 Rev

    Xenus Plus Compact STO Manual 16-01553 Rev 00 Xenus Plus Compact STO Manual P/N 16-01553 Revision 00 September 12, 2016  2016 Copley Controls Analogic Motion Controls 20 Dan Road Canton, MA 02021 USA All rights reserved Page 31 of 31...

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