Allen-Bradley Kinetix 5700 Reference Manual
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Allen-Bradley Kinetix 5700 Reference Manual

Safe monitor functions
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See also: User Manual , Instruction and Installation Manual
Safety Reference Manual
Original Instructions
Kinetix 5700 Safe Monitor Functions
Catalog Numbers 2198-D006-ERS3, 2198-D012-ERS3, 2198-D020-ERS3, 2198-D032-ERS3, 2198-D057-ERS3
2198-S086-ERS3, 2198-S130-ERS3, 2198-S160-ERS3, 2198-D006-ERS4, 2198-D012-ERS4, 2198-D020-ERS4,
2198-D032-ERS4, 2198-D057-ERS4, 2198-S086-ERS4, 2198-S130-ERS4, 2198-S160-ERS4

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  • Page 1 Safety Reference Manual Original Instructions Kinetix 5700 Safe Monitor Functions Catalog Numbers 2198-D006-ERS3, 2198-D012-ERS3, 2198-D020-ERS3, 2198-D032-ERS3, 2198-D057-ERS3 2198-S086-ERS3, 2198-S130-ERS3, 2198-S160-ERS3, 2198-D006-ERS4, 2198-D012-ERS4, 2198-D020-ERS4, 2198-D032-ERS4, 2198-D057-ERS4, 2198-S086-ERS4, 2198-S130-ERS4, 2198-S160-ERS4...
  • Page 2 Important User Information Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.

  • Page 3: Table Of Contents

    Table of Contents Preface Summary of Changes ......... . . 5 Conventions .
  • Page 4 Table of Contents Motion Safety>STO Category......57 Motion Safety>SS1 Category ....... 58 Primary Safety Feedback Example (SIL 2 encoder) .

  • Page 5: Preface

    Kinetix 5700 drives with safe-stopping and safe-monitoring functions. Use this publication if you are responsible for designing, configuring, or troubleshooting safety applications that use the Kinetix 5700 drives. You must have a basic understanding of electrical circuitry and familiarity with Kinetix 5700 drives.

  • Page 6: Conventions

    Preface Conventions These conventions are used throughout this publication: • Bulleted lists such as this one provide information, not procedural steps • Numbered lists provide sequential steps or hierarchical information • When the phrase ‘GuardLogix® controller’ is used in this publication it refers to either of the following controller families: –...

  • Page 7: Terminology

    Preface Terminology This table defines common safety terms used throughout this publication. Abbreviation Full Term Definition Timed SS1 Timed Safe Stop 1 Timed SS1 and Safe Stop 1 time-controlled (SS1-t) are synonymous. Both mean safe stop where the motor speed is decelerated to zero and once the maximum stop-time elapses, torque is removed from the motor.

  • Page 8: Additional Resources

    Kinetix Servo Drives Specifications Technical Data, publication KNX-TD003 Motion over sercos interface, EtherNet/IP networking, and component servo drive families. Provides information to install, configure, startup, and troubleshoot your Kinetix 5700 servo Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 drive system.
  • Page 9 Safety Concept Kinetix Safe Motion-monitoring Operation Out of Box State The Kinetix 5700 dual-axis and single-axis inverters are equipped for integrated (drive-based) Monitored SS1 and Timed SS1 stopping functions over the EtherNet/IP™ network. Drive-based safety functions operate in the drive and are activated through the network safety connection.

  • Page 10: Safety Concept

    GuardLogix safety controller for use in controller-based monitoring functions. The Kinetix 5700 dual-axis and single-axis inverters are also equipped for hardwired and integrated safe torque-off (STO). These STO modes apply to 2198-xxxx-ERS3 and 2198-xxxx-ERS4 dual-axis and single-axis inverters.

  • Page 11: Important Safety Considerations

    About Safe Stop and Safe Monitor Functions Chapter 1 TÜV Rheinland 2198-xxxx-ERS4 certification applies to only STO, drive- based Monitored SS1, and drive-based Timed SS1 safety functions. Refer to the GuardLogix Safety Application Instruction Set Reference Manual, publication 1756-RM095, for more information on safe motion-monitoring instructions.

  • Page 12: Average Frequency Of A Dangerous Failure

    Table 4 - Safe Motion-monitoring System Components Safety System Component Bulletin/Cat. No. Description Dual-axis inverter with safe-motion 2198-Dxxx-ERS4 monitoring support. Kinetix 5700 servo drives Single-axis inverter with safe-motion 2198-Sxxx-ERS4 monitoring support. Compact GuardLogix controller Bulletin 5380 Safety controllers required for use in safe...
  • Page 13 Studio 5000 Logix Designer 1585J-M8CBJM-x Application Ethernet (shielded) Cable (version 31.00 or later) 1734-AENTR POINT Guard I/O™ EtherNet/IP Adapter Kinetix 5700 Servo Drive System with Integrated Safety Functions Safety Device I/O-A I/O-B DSL feedback connector kit with primary UFB-A UFB-B...

  • Page 14: Compatible Safety Controllers

    EtherNet/IP network. See Motion Task in Figure 3 page • The Kinetix 5700 (2198-xxxx-ERS4) drives contain 1 or 2 inverters for the control of 1 or 2 motors, each associated with an axis controlled by the motion task. • Feedback from position encoders, supplied to the motion tasks, is also associated with the axis.

  • Page 15: Motion Safety Instances

    About Safe Stop and Safe Monitor Functions Chapter 1 Motion Safety Instances The Kinetix 5700 (2198-xxxx-ERS4) drives also contain 1 or 2 motion safety instances to provide integrated safety functions. The safety instances operate independently of the inverters and feedback used for motion.
  • Page 16 Chapter 1 About Safe Stop and Safe Monitor Functions 4. The motion core communicates with the motion controller running the motion task by updating the motion axis tag axis.SS1ActiveStatus. 5. The motion task controls the axis to bring the motor to a stop within the Monitored SS1 limits for speed and time.

  • Page 17: Safe Monitor Network Communication

    About Safe Stop and Safe Monitor Functions Chapter 1 This figure shows how the safety task and motion tasks communicate with the drive. Figure 2 - Safe Monitor System Communication Kinetix 5700 Single-axis or Dual-axis Inverter CIP Motion™ Motion Protocol...
  • Page 18 Data is exchanged at a periodic rate over the connection. To configure the drive-module motion connection Axis Properties in the Logix Designer application, see the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002. Some of the axis tags are updated from fault and safety status provided by the safety instance in the drive module.
  • Page 19 About Safe Stop and Safe Monitor Functions Chapter 1 IMPORTANT Axis tags are for status only and are not used by the safety function. For more information on pass-through data, see Pass-through Data page Safety Connection The safety controller communicates with the safety instances in the drive module over the safety connection.

  • Page 20: Explicit Messages

    Chapter 1 About Safe Stop and Safe Monitor Functions Explicit Messages Use explicit messages to communicate with a drive and obtain additional fault, status, or configuration information that is not be available in the Safety I/O Tag structure. Attribute data is useful for additional diagnostic information. An explicit message can be sent by any controller on the network and used to read any drive module attribute.
  • Page 21 Figure 4 - Explicit Message Example Safe Torque-off Mode You can use the attribute STO Mode to check if the Kinetix 5700 inverter is in STO Bypass mode. STO Bypass mode is used to allow motion while commissioning or troubleshooting a system when Motion Direct Commands (MDC) are needed.

  • Page 22: Out Of Box State

    2198-UM002 for a wiring example. Out of the box, you can use Kinetix 5700 servo drives in Integrated STO mode only after a Motion and Safety or Safety-only connection has been established at least once in the Logix Designer application.

  • Page 23: Restore Hardwired Sto Mode By Using The Drive Display

    Restore Hardwired STO mode by Using the Drive Display After the integrated safety connection configuration is applied to the Kinetix 5700 servo drive at least once, you can restore the drive to Hardwired STO mode by using the drive display and navigation buttons.
  • Page 24 Chapter 1 About Safe Stop and Safe Monitor Functions Notes: Rockwell Automation Publication 2198-RM001B-EN-P - May 2018...

  • Page 25: Timed Ss1 (Drive-Based) Stopping Function

    Chapter Safe Stop Functions Use this chapter to learn more about the Monitored SS1 and Timed SS1 stopping functions that are built into Kinetix® 5700 dual-axis and single-axis inverters. Topic Page Timed SS1 (drive-based) Stopping Function Monitored SS1 (drive-based) Stopping Function Safe Torque-off Function Safe Stop Functions (drive-based) Assembly Tags Drive-based Safe Stopping Application Requirements...
  • Page 26 Chapter 2 Safe Stop Functions Figure 5 - Timed SS1 Normal Operation Stop Time, max Axis Speed SS1 Request SS1 Active SS1 Complete STO Active Torque Disabled SS1 Start STO Delay (1) For more information on STO Delay, see Motion Safety>STO Category page Attribute Name Tag Name...

  • Page 27: Monitored Ss1 (Drive-Based) Stopping Function

    Safe Stop Functions Chapter 2 Monitored SS1 (drive-based) Monitored SS1 is a ramped safe-stop where the motion safety instance monitors the speed ramp to standstill speed, while either the motion task or Stopping Function the drive itself controls the deceleration to standstill speed. When standstill is reached, then the motion safety instance removes torque from the motor.

  • Page 28: Ramp Monitored Function

    Chapter 2 Safe Stop Functions Ramp Monitored Function The Monitored SS1 (ramp monitored) function is the ramped deceleration of the axis. A ramp function represents the maximum speed while the axis is stopping as a function of time (t). The ramp function depends on several variables as stated in this equation: •...
  • Page 29 Safe Stop Functions Chapter 2 Monitored SS1 Example In this example, an axis is running at 1200 rpm when SS1 Request goes high (1), which sets SS1 Active high (1). SS1 Active is read by the Main task and prepares to decelerate the axis. At the end of Stop Monitor Delay, the axis speed is 1200 rpm.

  • Page 30: Monitored Ss1 With Fault

    Chapter 2 Safe Stop Functions Monitored SS1 With Fault This figure shows how the Monitored SS1 behaves when the axis speed does not stay below the ramp function limit. Figure 9 - Deceleration Rate Fault Stop Time, max Stop Monitor Stop Delay, x Delay Decel...
  • Page 31 Safe Stop Functions Chapter 2 Series of events when a Monitored SS1 fault occurs. 1. If an SS1 fault occurs, STO Active goes high (1), and Torque Disabled goes high (1) immediately and ignores STO Delay. The safety instance detects a fault and activates the STO function within 6.0 ms of when the fault condition occurred.

  • Page 32: Monitored Ss1 Request Removed

    Chapter 2 Safe Stop Functions Monitored SS1 Request Removed This figure shows what happens when SS1 Request goes low (0) before completion. Figure 10 - Monitored SS1 Request Removed Before Completion Stop Time, max Stop Monitor Stop Delay, x Delay Speed Decel Limit...

  • Page 33: Safe Torque-Off Function

    These conditions must be met for integrated control of the STO function: • The Kinetix 5700 drive module must be added to the GuardLogix 5570 or Compact GuardLogix 5370 controller I/O Configuration.

  • Page 34: Safe Stop Functions (Drive-Based) Assembly Tags

    Kinetix 5700 safety output assembly to control the safe torque-off function. The SI.Status tags are sent from the Kinetix 5700 inverter to the GuardLogix safety input assembly and indicate the Kinetix 5700 safety control status. Table 15 - Safety Input Assembly Tag Name Description...
  • Page 35 95 list the safety tags added to the controller tags when a Kinetix 5700 servo drive is added to a GuardLogix I/O configuration and the connection is configured for Safety Only. In this example, the SO.STOOutput bit permits torque when the bit is high.

  • Page 36: Drive-Based Safe Stopping Application Requirements

    Chapter 2 Safe Stop Functions Drive-based Safe Stopping This section describes some of the safety information required to design your safety application. Application Requirements Table 16 - Achievable Safety Ratings Safety Function Achievable Functional Safety Rating SIL 3, PL e (independently if hardwired or integrated option is used) Timed SS1 SIL 3, PL e •...

  • Page 37: System Safety Reaction Time

    IMPORTANT You must read, understand, and fulfill the requirements detailed in the GuardLogix controller systems safety reference manual prior to operating a safety system that uses a GuardLogix controller and Kinetix 5700 drive. System Safety Reaction Time System safety reaction time is the sum of sensor reaction time, GuardLogix controller system reaction time and actuator reaction time.
  • Page 38 Chapter 2 Safe Stop Functions Notes: Rockwell Automation Publication 2198-RM001B-EN-P - May 2018...

  • Page 39: Understand Module Properties Categories

    Chapter Configure the Motion Safety Instances Use this chapter to configure Kinetix® 5700 dual-axis and single-axis inverters for safety applications with Allen-Bradley® servo motors. Topic Page Understand Module Properties Categories Primary Safety Feedback Example (SIL 2 encoder) Dual Feedback Monitoring Example (SIL 2 encoder)
  • Page 40 Chapter 3 Configure the Motion Safety Instances Right-click your Kinetix 5700 single-axis or dual-axis inverter and choose Properties. The Module Properties dialog box appears. Figure 12 - Module Definition Configured With Dual Feedback Monitoring Module properties categories are listed along the left side panel.

  • Page 41: Module Properties>General Category

    Configure the Motion Safety Instances Chapter 3 In this 2198-Dxxx-ERS4 (dual-axis inverter) example, the Connection mode is Motion and Safety and the Motion Safety instances are configured as Dual Feedback Monitoring. Module Properties Category Page General page 41 Connection and Safety page 44 Motion Safety Actions...
  • Page 42 Chapter 3 Configure the Motion Safety Instances Table 17 - Safety Application Definitions Minimum Drive Module Drive Module Connection Safety Application Mode Safety Functions Minimum Controller Required Required Options Hardwired Safe Torque-off (STO) 2198-xxxx-ERS3 (series A) Motion Only • ControlLogix® 5570 •...
  • Page 43 Configure the Motion Safety Instances Chapter 3 If a Motion and Safety connection is configured, the Motion Safety categories appear and can be configured for feedback options (see Table 19 page 43). In this example, the Motion Safety categories are configured for Single Feedback Monitoring, so only Primary Feedback appears.

  • Page 44: Module Properties>Connection And Safety Categories

    Chapter 3 Configure the Motion Safety Instances Figure 14 - Configure Motion Safety • If Motion Safety is configured for Safe Stop Only - No Feedback, the feedback options do not appear. • If Motion Safety is configured for Dual Feedback Monitoring, the Primary Feedback and Secondary Feedback categories appear.
  • Page 45 Configure the Motion Safety Instances Chapter 3 2. To set the Safety Output value, right-click SafetyTask in the Controller Organizer and click Properties. 3. Click the Configuration tab. The default safety task Period value (and output RPI) is 20 ms. IMPORTANT The period is the interval at which the safety task executes.

  • Page 46: Motion Safety>Actions Category

    Automatic Automatic is the only choice. operation immediately after the controller enters run mode. (1) Kinetix 5700 drives do not support the manual option. 2. From the Connection Loss Action and Connection Idle Action pull- down menus, choose SS1 or STO as required for your application.

  • Page 47: Motion Safety>Primary Feedback Category

    Configure the Motion Safety Instances Chapter 3 Motion Safety>Primary Feedback Category Configure primary feedback if you intend to use any drive-based or controller- based safety function that monitors motion. There are many different combinations of feedback for motion control and safety that can be configured.
  • Page 48 Based on encoder rotation and evaluation requirements. Choose between Normal (default) or Polarity Inverted as appropriate for your application. Allen-Bradley motors with -Q or -W encoder types are SIL 2 capable and 2 is shown. For non SIL-rated motor or encoder, this SIL Capability field indicates Unknown.
  • Page 49 Configure the Motion Safety Instances Chapter 3 Velocity Average Time Parameter The Velocity Average Time parameter sets the time period for a moving average filter that is applied to velocity samples reported in Velocity Feedback. The motion safety instance of the drive calculates velocity by taking the differences in position count samples that are divided by the sample period.
  • Page 50 Chapter 3 Configure the Motion Safety Instances Figure 15 - Velocity Average Time Encoder Cycle Clockwise Counter Clockwise   Sine Cosine … Position Sample Times 3 ms Incremental Position Instantaneous Velocity Average Velocity (18 ms average time) Average Velocity (36 ms average time) This table shows different values of velocity resolution based on the encoder cycle count and the velocity average time.

  • Page 51: Motion Safety>Secondary Feedback Category

    Configure the Motion Safety Instances Chapter 3 Motion Safety>Secondary Feedback Category Configure secondary feedback for your motion monitoring application that requires SIL 3 or PL e for drive-based or controller-based safety functions. There are different combinations of feedback for motion control and safety that can be configured.

  • Page 52: Motion Safety>Scaling Category

    Chapter 3 Configure the Motion Safety Instances Motion Safety>Scaling Category The Primary Feedback category set safety resolution in terms of counts per revolution. The Scaling category configures the position and time to be used in terms of counts per position unit in the safe monitoring functions. Figure 16 - Scaling Category (default settings) Table 22 - Scaling Category Attributes Attribute...
  • Page 53 Configure the Motion Safety Instances Chapter 3 Scaling Example 1 In the following example, a rotary knife with one blade is directly coupled to the motor. The servo motor is a VPC-Bxxxx-Q with SIL 2 encoder that generates 4096 counts per revolution. Figure 17 - Rotary Knife with One Blade Unwind Rotary Knife...
  • Page 54 Chapter 3 Configure the Motion Safety Instances Scaling Example 2 In this example, a rotary knife with two blades is driven by a 10:1 gear reduction and servo motor. The servo motor is a VPC-Bxxxx-Q with SIL 2 encoder that generates 4096 counts per revolution. Figure 19 - Rotary Knife with Two Blades Unwind Rotary Knife...

  • Page 55: Motion Safety>Discrepancy Checking Category

    Configure the Motion Safety Instances Chapter 3 Motion Safety>Discrepancy Checking Category Discrepancy checking is only used in applications where the Module Definition>Safety Instance is configured for Dual Feedback Monitoring. Its purpose is to perform an evaluation of the speed discrepancy between primary and secondary feedback.
  • Page 56 Chapter 3 Configure the Motion Safety Instances 2. Set the remaining Discrepancy Checking attributes. Attribute Description The amount of time (ms) specified for velocity deadband to be evaluated and trigger a Time safety fault condition. The gear ratio of one primary feedback revolution to one secondary feedback Ratio revolution.

  • Page 57: Motion Safety>Sto Category

    Configure the Motion Safety Instances Chapter 3 Motion Safety>STO Category The STO category provides a disable and coast fault action. However, if a torque disable delay is needed following STO Active, you can enter a value in the Delay field. TIP The STO Delay feature is also available with 2198-xxxx-ERS3 (series B) drives when the Module Definition is configured for Safe Stop Only - No Feedback.

  • Page 58: Motion Safety>Ss1 Category

    Chapter 3 Configure the Motion Safety Instances Motion Safety>SS1 Category The Motion Safety>SS1 category is configured when a Timed or Monitored Safe Stop 1 (SS1) function is desired. TIP Timed SS1 is also available with 2198-xxxx-ERS3 (series B) drives when the Module Definition is configured for Safe Stop Only - No Feedback.

  • Page 59: Primary Safety Feedback Example (Sil 2 Encoder)

    Configure the Motion Safety Instances Chapter 3 Primary Safety Feedback This example applies to any Kinetix 5700 (2198-xxxx-ERS4) inverter that is paired with Kinetix VP (Bulletin VPL, VPF, or VPC) motors that are Example (SIL 2 encoder) equipped with -Q or -W (SIL 2, PL d rated) encoders.
  • Page 60 In this example, SS1 settings are used. IMPORTANT The SS1 action only occurs with a connection loss or connection idle fault. If a safety or other motion fault occurs, consult the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 determine the appropriate action to take.
  • Page 61 Configure the Motion Safety Instances Chapter 3 The Change Catalog Number dialog box appears. 8. Select the motor catalog number appropriate for your SIL 2 application. To verify the motor catalog number, refer to the motor name plate. 9. Click OK to close the Change Catalog Number dialog box. 10.
  • Page 62 Chapter 3 Configure the Motion Safety Instances 13. Select the Motion Safety 1>Scaling category. 14. In the Position Units field, type revolutions. In this application, the position units are in revolutions. 1 motor revolution = 1 revolution. 15. Select the Axis Properties>Scaling category. Both the Motion Safety and Axis Properties>Scaling (motion) categories match as shown.

  • Page 63: Dual Feedback Monitoring Example (Sil 2 Encoder)

    1 through step This example applies to any Kinetix 5700 (2198-xxxx-ERS4) inverter that is Dual Feedback Monitoring paired with Kinetix VP (Bulletin VPL, VPF, or VPC) motors that are Example (SIL 2 encoder) equipped with -Q or -W (SIL 2, PL d rated) encoders. In this example, the application has an external Bulletin 842HR sin/cos encoder for dual feedback monitoring.
  • Page 64 In this example, SS1 settings are used. IMPORTANT The SS1 action only occurs with a connection loss or connection idle fault. If a safety or other motion fault occurs, consult the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 determine the appropriate action to take.
  • Page 65 Configure the Motion Safety Instances Chapter 3 6. From the Device pull-down menu, choose DSL Feedback Port because the motion connection is associated with a VPC-Bxxxx-Q motor. IMPORTANT Because this safety configuration is using the DSL Feedback Port, the motion configuration (if used with this port) must use the same device with this port.
  • Page 66 Chapter 3 Configure the Motion Safety Instances 12. Click Apply. 13. Select the Motion Safety 1>Secondary Feedback category. 14. From the Device pull-down menu, choose Universal Feedback Port. In this example, the Bulletin 842HR sine/cosine encoder is used, which requires the 15-pin UFB connector. IMPORTANT Because this safety configuration is using the Universal Feedback Port, the motion configuration (if used with this port) must use the same device with this port.
  • Page 67 Configure the Motion Safety Instances Chapter 3 18. Select the Motion Safety 1>Scaling category. 19. In the Position Units field, type revolutions. In this application, the position units are in revolutions. 1 motor revolution = 1 revolution. 20. Select the Axis Properties>Scaling category. Both the Motion Safety and Axis Properties>Scaling (motion) categories match as shown.
  • Page 68 Chapter 3 Configure the Motion Safety Instances 22. Select the Motion Safety 1>SS1 category. 23. From the Mode pull-down menu, choose the SS1 - Safe Stop 1 mode. In this example, Monitored SS1 is used to control the deceleration rate and tolerance.

  • Page 69: Primary Safety Feedback Example (Sin/Cos Encoder)

    Motion Only connection is controlled by one Logix 5000 controller and Example (sin/cos encoder) the Safety Only connection is controlled by another GuardLogix controller. In this example, the Kinetix 5700 inverter is paired with an MP-Series™ Bulletin MPL-Bxxxx-M (multi-turn) motor. This procedure assumes you have already configured the 2198-xxxx-ERS4 drive with a Motion Only connection and configured the motion associated axis for specific motion functions.
  • Page 70 In this example, the SS1 setting is used. IMPORTANT The SS1 action only occurs with a connection loss or connection idle fault. If a safety or other motion fault occurs, consult the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 determine the appropriate action to take.
  • Page 71 Configure the Motion Safety Instances Chapter 3 8. Enter a value in the Cycle Resolution field. 1024 Cycles/rev is the default value when Hiperface is the encoder type. 9. Set the Velocity Average Time and Standstill Speed attributes. In this example, the Velocity Average Time is set to 100 ms and the Standstill Speed is set to 1.000 rev/s (default setting).
  • Page 72 Chapter 3 Configure the Motion Safety Instances 16. Select the Motion Safety 1>SS1 category. 17. From the Mode pull-down menu, choose the SS1 - Safe Stop 1 mode. In this example, a Monitored SS1 is used to control the deceleration rate and tolerance.

  • Page 73: Encoder Feedback Types And Sil Ratings

    Configure the Motion Safety Instances Chapter 3 Encoder Feedback Types and Encoder feedback is used for motion control, safety motion monitoring, or both. The drive must be configured to use a feedback device for motion and/or SIL Ratings for safety. The motion and safety functions in the drive are independent with respect to the encoder feedback.
  • Page 74 Chapter 3 Configure the Motion Safety Instances Table 24 - Feedback Types Assigned to Feedback Ports for SIL 3/PL e Applications Motor Feedback (MF) Connector Universal Feedback (UFB) Connector Achievable System Encoder Safety Encoder Motion Encoder Safety Encoder Motion Safety Rating Encoder Source Encoder Source Function...

  • Page 75: Drive Safety Instructions

    GuardLogix 5380 controllers and use the EtherNet/IP™ network to communicate with the safety I/O. Drive Safety instructions use safety feedback, provided by Kinetix 5700 drives in the Safety Task of the controller, to preform safe monitoring functions. Rockwell Automation Publication 2198-RM001B-EN-P - May 2018...
  • Page 76 Chapter 4 Controller-based Safety Functions Table 25 - Drive Safety Instructions Safety Instruction Description The SFX function scales feedback position into position units and feedback velocity into position units per time unit. SFX is used with Safety Feedback Interface other Drive Safety instructions.SFX also provides unwind for rotary applications and position homing.

  • Page 77: Before Adding The Safety Instructions

    3. Add and configure an axis in the Motion Group. For help with these Logix Designer configuration examples (steps 1, 2, and 3), see the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002. 4. Add Drive Safety instructions to your Safety Task safety program.

  • Page 78: Drive Safety Instruction Example

    Chapter 4 Controller-based Safety Functions Drive Safety Instruction Example Drive Safety instructions provide the following information. In this example, the Safely Limited Speed (SLS) instruction is shown. Figure 30 - SLS Drive Safety Instruction Outputs Configurable Inputs Inputs Pass Through Outputs Table 26 - Drive Safety Instruction Definitions Instruction...

  • Page 79: Pass-Through Data

    SLS instruction. IMPORTANT Pass-through data is for status information only and does not impact configured safety functions. Figure 31 - Pass Through Data Path Kinetix 5700 Servo Drive System with Integrated Safety Functions Safety Task Programming I/O-A...

  • Page 80: Sfx Instruction

    Chapter 4 Controller-based Safety Functions The following steps correspond to the activity in Figure 1. Safety device reports a request to the safety zone. Initiates monitoring by the SLS instruction (Safety Task). 2. SLS Active status is passed to the motion program (Safety Task to Standard Task via the drive).

  • Page 81: Sfx Instruction Example

    Controller-based Safety Functions Chapter 4 SFX Instruction Example In this SFX example, a VPL-B0631T-W motor is used in the safety function. The motor has 512 feedback counts per motor revolution and is scaled for position to have 512 counts per motor revolution. The SFX instruction scales the applicable safety instructions with feedback position units from the safety encoder/motor, into position feedback units used in applicable safety instructions.
  • Page 82 Chapter 4 Controller-based Safety Functions The VPL-B0631T-W motor is used in a rotary application where the unwind is set to rollover each motor revolution. Therefore, the unwind of 512 counts/ rev was added in the SFX instruction appropriately. Figure 35 - Scaling Homing Setting the Actual Position output to the Home Position input (homing) of the instruction is required if using a position-based drive safety instruction like...

  • Page 83: Safety Fault Names

    Chapter Troubleshoot Safety Faults This chapter provides troubleshooting tables and related information for Kinetix® 5700 drive systems that include 2198-Dxxx-ERS4 (dual-axis) and 2198-Sxxx-ERS4 (single-axis) inverters. Topic Page Safety Fault Names Understand Safety Faults Safety Fault Names The Motion Safety instance in the 2198-xxxx-ERS4 drive reports faults to the drive through the AxisSafetyFaults and AxisSafetyFaultsRA tags.

  • Page 84: Understand Safety Faults

    Chapter 5 Troubleshoot Safety Faults The safety faults named in Table 27 appear as Safety Faults when they occur. In addition, if any of these faults are present, a safety fault appears under the axis fault. Corresponding axis tags are set with any of the faults. Table 27 - Safety Fault Names Fault Name Description...

  • Page 85: Safe Torque-Off Fault

    Troubleshoot Safety Faults Chapter 5 Safe Torque-off Fault The safe torque-off (STO) function detected a fault. The safe stop function in the Motion Safety instance records the specific fault type in the attribute. Explicit messaging can be used to read the fault type information from the drive.

  • Page 86: Ss2, Sos, Sbc, Sls, Slp, And Sdi Faults

    Chapter 5 Troubleshoot Safety Faults Table 30 - SS1 Fault Types SS1 Fault SS1 Fault Type Name Description Type Value Reserved Not used No Fault No Fault is present The SS1 function has been requested when it has been Invalid Configuration configured as ‘not used’...
  • Page 87 Troubleshoot Safety Faults Chapter 5 Table 31 - Safety Feedback Faults Safe Feedback Safe Feedback Fault Type Duplicated to Fault Type Description Name Other Axis? Value Reserved Not used – No Fault No Fault is present – The DSL safety feedback diagnostics have detected that the actual resolution of the connected DSL Invalid Configuration feedback device does not match the configured resolution of the corresponding Motion Safety instance.

  • Page 88: Troubleshoot The Safety Function

    Chapter 5 Troubleshoot Safety Faults Troubleshoot the Safety Function Table 32 - Safe FLT Sxx Fault Codes Fault Message Exception Code on Drive Display Problem Possible Solutions Logix Designer • Cycle control power Drive safety diagnostic detected SAFE FLT S01 - Safety Core Internal Fault SafetyFault internal STO design failure.

  • Page 89: Safety Fault Reset

    IMPORTANT Transition of the SO.STOOutput tag to logic 1 must always be executed prior to transition of the SO.ResetRequest tag to logic 1. IMPORTANT All Kinetix 5700 inverter axes enter the faulted state if any STO function fault is detected. Refer to...
  • Page 90 Chapter 5 Troubleshoot Safety Faults Figure 38 - Reset Safe Stop Fault Diagram Safety Fault Occurs Drv:SO.STOOutput Disable Torque Permit Torque Drv:SO.ResetRequest Drv:SI.TorqueDisabled Torque Permited Torque Disabled Drv:SI.SafetyFault No Fault Drv:SI.RestartRequired Restart Not Required Restart Required Axis.SafetyFault Faulted (cleared by MAFR) No Fault Axis.SafeTorqueOffActiveInhibit Start Permitted...
  • Page 91 Appendix Controller Tags and Safety Attributes Controller axis tags are used by the motion controller motion task to read the status of safety functions and coordinator motion. This appendix lists the motion controller tags that are associated with the safety instances and with safety functions operating in the safety task of the controller.

  • Page 92: Motion Connection Axis Tags

    Appendix A Controller Tags and Safety Attributes Motion Connection Axis Tags This table provides motion-connection axis tag names that are updated to show safety instance status or controller-based safety function status. TIP The words module, instance, and axis (italic) in these tag names represent the module, instance, and axis name assigned in the Logix Designer application.
  • Page 93 Controller Tags and Safety Attributes Appendix A Table 33 - Motion Connection Axis Tags (continued) Axis Tag Name Motion Connection Safety Output Assembly Tag Name Data Type Description Attribute Number (safety controller) (motion controller) Axis.SOSStandstillStatus [10] BOOL Indicates that the controller-based SOS function has detected module:SO.SOSLimit[instance] standstill according to the function configuration.
  • Page 94 Appendix A Controller Tags and Safety Attributes Table 33 - Motion Connection Axis Tags (continued) Axis Tag Name Motion Connection Safety Output Assembly Tag Name Data Type Description Attribute Number (safety controller) (motion controller) Axis.SafetyCoreFault BOOL Indicates an internal fault occurred within the drive-module None (use explicit message) safety instance.

  • Page 95: Safety Assembly Tags

    Controller Tags and Safety Attributes Appendix A Safety Assembly Tags Safety assembly tags are associated with a safety connection from a safety controller to a drive module. The data in these tags are communicated at the configured connection rate. TIP The words module and instance (italic) in these tag names represent the module and instance name assigned in the Logix Designer application.
  • Page 96 Appendix A Controller Tags and Safety Attributes Table 35 - Safety Output Assembly Tags Safety Output Assembly Tag Name Type/[bit] Description (output to safety controller) module:SO.PassThruDataA[instance] DINT 32-bit data container holding general purpose safety data passed from the safety controller. module:SO.PassThruDataB[instance] DINT 32-bit data container holding general purpose safety data passed from the safety controller.
  • Page 97 Controller Tags and Safety Attributes Appendix A Table 35 - Safety Output Assembly Tags (continued) Safety Output Assembly Tag Name Type/[bit] Description (output to safety controller) module:SO.SFXFault[instance] Indicates that a fault occurred with the controller-based SFX function. 0 = Normal Operation 1 = Fault module:SO.SBCFault[instance] Indicates that a fault occurred with the controller-based SBC function.

  • Page 98: Safety Feedback Attributes

    Attributes that can be written are indicated in Table 37. Configuration attributes can only be read using explicit messages. Table 36 - Safety Feedback Instance Numbers Safety Feedback Kinetix 5700 Drive Motion Safety Category Feedback Instance Single-axis inverters...
  • Page 99 0 = Normal (default) 18 (0x12) Feedback Polarity specifications. For feedback devices internal to Allen-Bradley® motors, the 1 = Inverted Normal direction is clockwise rotation of the shaft when facing the end of the motor shaft.

  • Page 100: Safe Stop Function Attributes

    Attributes that can be written are indicated in the table. Configuration attributes can be read but cannot be written using an explicit message. Table 38 - Safe Stop Function Instance Numbers Safe Stop Instance Kinetix 5700 Drive Motion Safety Category Single-axis inverters Motion Safety Dual-axis inverters...
  • Page 101 Controller Tags and Safety Attributes Appendix A Table 39 - Safe Stop Function Attributes (Class 0x5A) (continued) Attribute ID Attribute Name Attribute Description Values Decimal (Hex) 0 = Reserved 1 = No Fault 2 = Invalid Configuration 1 3 = Exceeded Max Speed 1 5 = Sin +Cos Error 1...
  • Page 102 Appendix A Controller Tags and Safety Attributes Table 39 - Safe Stop Function Attributes (Class 0x5A) (continued) Attribute ID Attribute Name Attribute Description Values Decimal (Hex) 0 = STO (default) Safety Output Connection’s Run/Idle bit transitions from Run to Idle and 51 (0x33) Connection Idle Action Optional Connection Idle Action is Set to STO (default).
  • Page 103 Controller Tags and Safety Attributes Appendix A Table 39 - Safe Stop Function Attributes (Class 0x5A) (continued) Attribute ID Attribute Name Attribute Description Values Decimal (Hex) Bit: 0 = STO Output Active 1 = SS1 Complete 2 = Safety Stop Fault 265 (0x109) STO Activation Bit string showing status of all inputs to the STO Activation block.

  • Page 104: Dual Channel Feedback Attributes

    Appendix A Controller Tags and Safety Attributes Table 39 - Safe Stop Function Attributes (Class 0x5A) (continued) Attribute ID Attribute Name Attribute Description Values Decimal (Hex) 1 = No Fault 304 (0x130) SS2 Fault Type Detailed information about a fault. 2 = Invalid Configuration SS2 Function Not Supported 0 = No Fault...
  • Page 105 Appendix Safety Function Validation Checklist Use this appendix to validate your Drive Safety instructions. Each instruction has a checklist with test commands and results to verify for normal operation and abnormal operation scenarios. Topic Page Safe Stop 1 (SS1) Safe Stop 2 (SS2) Safe Operating Speed (SOS) Safely Limited Speed (SLS) Safely Limited Position (SLP)

  • Page 106: Safe Stop 1 (Ss1)

    Appendix B Safety Function Validation Checklist Safe Stop 1 (SS1) Use this SS1 instruction checklist to verify normal operation and the abnormal operation scenarios. IMPORTANT Perform I/O verification and validation before validating your safety ladder program. SFX instruction must be verified within your application. When possible, use immediate operands for instructions to reduce the possibility of systematic errors in your ladder program.
  • Page 107 Safety Function Validation Checklist Appendix B Table 41 - SS1 Instruction Checklist (continued) Test Type Test Description Test Status Change the motion deceleration rate within the motion task associated with this SS1 function so that the stop delay time is exceeded without triggering a deceleration fault.

  • Page 108: Safe Stop 2 (Ss2)

    Appendix B Safety Function Validation Checklist Safe Stop 2 (SS2) Use this SS2 instruction checklist to verify normal operation and the abnormal operation scenarios. IMPORTANT Perform I/O verification and validation before validating your safety ladder program. SFX instruction must be verified within your application. When possible, use immediate operands for instructions to reduce the possibility of systematic errors in your ladder program.
  • Page 109 Safety Function Validation Checklist Appendix B Table 42 - SS2 Instruction Checklist (continued) Test Type Test Description Test Status Change the motion deceleration rate within the motion task associated with this SS2 function so that the stop delay time is exceeded without triggering a deceleration fault.
  • Page 110 Appendix B Safety Function Validation Checklist Table 42 - SS2 Instruction Checklist (continued) Test Type Test Description Test Status Initiate a Start command. • Verify that the machine is in a normal machine run condition • Verify proper machine status and safety application program status Operate the machine at maximum (normal) operating system speed.

  • Page 111: Safe Operating Speed (Sos)

    Safety Function Validation Checklist Appendix B Safe Operating Speed (SOS) Use this SOS instruction checklist to verify normal operation and the abnormal operation scenarios. IMPORTANT Perform I/O verification and validation before validating your safety ladder program. SFX instruction must be verified within your application. When possible, use immediate operands for instructions to reduce the possibility of systematic errors in your ladder program.
  • Page 112 Appendix B Safety Function Validation Checklist Table 43 - SOS Instruction Checklist (continued) Test Type Test Description Test Status Initiate a Start command. • Verify that the machine is in a normal machine run condition • Verify proper machine status and safety application program status Operate the machine at maximum (normal) operating system speed.

  • Page 113: Safely Limited Speed (Sls)

    Safety Function Validation Checklist Appendix B Safely Limited Speed (SLS) Use this SLS instruction checklist to verify normal operation and the abnormal operation scenarios. IMPORTANT Perform I/O verification and validation before validating your safety ladder program. SFX instruction must be verified within your application. When possible, use immediate operands for instructions to reduce the possibility of systematic errors in your ladder program.

  • Page 114: Safely Limited Position (Slp)

    Appendix B Safety Function Validation Checklist Safely Limited Position (SLP) Use this SLP instruction checklist to verify normal operation and the abnormal operation scenarios. IMPORTANT Perform I/O verification and validation before validating your safety ladder program. SFX instruction must be verified within your application. When possible, use immediate operands for instructions to reduce the possibility of systematic errors in your ladder program.
  • Page 115 Safety Function Validation Checklist Appendix B Table 45 - SLP Instruction Checklist (continued) Test Type Test Description Test Status Initiate a Start command. • Verify that the machine is in a normal machine run condition • Verify proper machine status and safety application program status Operate the machine within the desired position range.

  • Page 116: Safe Direction (Sdi)

    Appendix B Safety Function Validation Checklist Safe Direction (SDI) Use this SDI instruction checklist to verify normal operation and the abnormal operation scenarios. IMPORTANT Perform I/O verification and validation before validating your safety ladder program. SFX instruction must be verified within your application. When possible, use immediate operands for instructions to reduce the possibility of systematic errors in your ladder program.

  • Page 117: Safe Feedback Interface (Sfx)

    Safety Function Validation Checklist Appendix B Safe Feedback Interface Use this SFX instruction checklist to verify normal operation and the abnormal operation scenarios. (SFX) IMPORTANT Perform I/O verification and validation before validating your safety ladder program. SFX instruction must be verified within your application. When possible, use immediate operands for instructions to reduce the possibility of systematic errors in your ladder program.
  • Page 118 Appendix B Safety Function Validation Checklist Table 47 - SFX Instruction Checklist (continued) Test Type Test Description Test Status Initiate a Start command. • Verify that the machine is in a normal machine run condition • Verify proper machine status and safety application program status Operate the machine within the normal operating range.

  • Page 119: Safe Brake Control (Sbc)

    Safety Function Validation Checklist Appendix B Safe Brake Control (SBC) Use this SBC instruction checklist to verify normal operation and the abnormal operation scenarios. IMPORTANT Perform I/O verification and validation before validating your safety ladder program. When possible, use immediate operands for instructions to reduce the possibility of systematic errors in your ladder program.
  • Page 120 Appendix B Safety Function Validation Checklist Notes: Rockwell Automation Publication 2198-RM001B-EN-P - May 2018...

  • Page 121: Index

    Index Numerics controller-based instructions 75 1oo2 monitoring functions 9 definition 7 stopping functions 9 actions 46 decel rate fault 30 additional resources 8 discrepancy application requirements 36 checking 55 assembly tags 34 checking example 56 downloads 37 input 95 output 96 drive safety instructions 75 associated axes 40 adding instruction 77...

  • Page 122: Rockwell Automation Publication 2198-Rm001B-En-P - May

    Index definition 7 proof test interval 12 definition 7 PFH definition 12 IEC 60204-1 27 IEC 61508 11 definition 7 IEC 61800-5-2 11 PLe 5 IEC 62061 11 primary IGBT encoder 17 definition 7 feedback 47 input assembly tags 19 feedback example 59 proof test interval 12 integrated...
  • Page 123 Index SFX 16 instruction 80 website scaling 81 product downloads 37 validation checklist 117 SIL rating definition 7 feedback types 73 monitored SS1 36 timed SS1 36 SLP 114 fault 86 validation checklist 114 SLS 113 fault 86 validation checklist 113 SOS 111 fault 86 validation checklist 111...
  • Page 124 Index Notes: Rockwell Automation Publication 2198-RM001B-EN-P - May 2018...
  • Page 126 Rockwell Automation maintains current product environmental information on its website at http://www.rockwellautomation.com/rockwellautomation/about-us/sustainability-ethics/product-environmental-compliance.page. Allen-Bradley, CompactLogix, ControlLogix, GuardLogix, HPK-Series, Integrated Architecture, Kinetix, Logix 5000, MP-Series, POINT Guard I/O, Rockwell Automation, Rockwell Software, Stratix, and Studio 5000 Logix Designer are trademarks of Rockwell Automation, Inc.

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