Safety Reference Manual Kinetix 6200 and Kinetix 6500 Safe Torque-off Multi-axis Servo Drives Catalog Numbers 2094-SE02F-M00-S0, 2094-EN02D-M01-S0
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.
Summary of Changes This manual contains new and updated information. New and Updated Information This revision includes new material for the 2090-K6CK-D44S0 low-profile connector kit and 2090-CS0DSDS-AAxx interface cable for cascading the safe torque-off signals from drive-to-drive. Section Topic Page Chapter 2 Added a description and connection diagram for the 2090-K6CK-D44S0 connector kit.
Summary of Changes Notes: 4 Rockwell Automation Publication 2094-RM002B-EN-P - May 2012
Table of Contents Preface About This Publication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Chapter 4 Multi-axis Cascaded Systems Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cascaded Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safe Stop Wiring Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2090-K6CK-D44M Connector Kit Examples. . . . . . . . . . . . . . . . . . . 2090-K6CK-D44S0 Connector Kit Examples . . . . .
Preface About This Publication This manual explains how the Kinetix® 6200 and Kinetix 6500 drives can be used in Safety Integrity Level (SIL) CL3, Performance Level [PLe], or Category (CAT) 4 applications. It describes the safety requirements, including PFD and PFH values and application verification information, and provides information on configuring and troubleshooting the Kinetix 6200 and Kinetix 6500 drives with safe torque-off functionality.
Preface Table 1 - Common Safety Terminology (continued) Abbreviation Full Term Definition 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. SS Safe Stop – Additional Resources These documents contain additional information concerning related products from Rockwell Automation.
Chapter 1 Safety Concept Introduction Safety Certification This chapter describes the safety performance level concept and how the Kinetix 6200 and Kinetix 6500 drives can meet the requirements for SIL CL3, CAT 4, or PLe applications.
Chapter 1 Safety Concept Important Safety Considerations You are responsible for the following: • The set-up, 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 • Access control to the system, including password handling IMPORTANT When applying functional safety, restrict
Safety Concept Chapter 1 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.
Chapter 1 Safety Concept Safe State The Safe State encompasses all operation that occurs outside of the other monitoring and stopping behavior defined as part of the drive. While the drive is in the Safe State, all safety control outputs are in their safe state (de-energized). When you cycle power, the drive enters the Safe State for self-testing. If the selftests pass, the drive remains in the Safe State until a successful safe stop reset occurs.
Chapter 2 Installation and Wiring Introduction This chapter provides details on connecting devices and wiring the 2090-K6CK-D44M and 2090-K6CK-D44S0 low-profile connector kits. Topic Page General Safety Information 13 Power Supply Requirements 14 Wiring the Safety Connections 14 Terminal Connections 18 ATTENTION: The drive is intended to be part of the safety-related control system of a machine.
Chapter 2 Installation and Wiring Power Supply Requirements The external power supply must conform to the Directive 2006/95/EC Low Voltage, by applying the requirements of EN61131-2 Programmable Controllers, Part 2 - Equipment Requirements and Tests and one of the following: • EN60950 - SELV (safety extra low voltage) • EN60204 - PELV (protective extra low voltage) • IEC 60536 Safety Class III (SELV or PELV) • UL 508 Limited Voltage Circuit • 21.6…28.
Chapter 2 Installation and Wiring Figure 1 - Making 2090-K6CK-D44M Safety Connections Use tie wraps (4x) for stress relief. Use shield clamps (3x) for high-frequency bonding. S1 ONLY S1 ONLY INPUTS 0 39 41 40 39 42 40 39 43 40 39 44 40 0 38 37 36 35 34 33 32 31 30 29 28 27 28 27 28 27 28 27 Turn clamps over for smaller diameter cables. AUX FEEDBACK 2 1 4 3 7 6 5 Refer to page 18 for safety, auxiliary feedback, and I/O signal descriptions.
Chapter 2 Installation and Wiring Using the 2090-K6CK-D44S0 Low-profile Connector Kit The 2090-K6CK-D44S0 connector kit includes two motion-allowed jumpers. Remove the jumpers to wire the safe torque-off connections. Install the jumper when your application is not using the safe torque-off functionality, but your application requires I/O connections. The 2090-K6CK-D44S0 connector kit lets you cascade the safe torque-off signals from drive-to-drive by using the 2090-CS0DSDS-AAxx interface cable.
Installation and Wiring Chapter 2 Using the Motion-allowed Plug Because the safe torque-off feature of Kinetix 6200 and Kinetix 6500 control modules (catalog numbers 2094-xx02x-M0x-S0) is not configured, the safe torque-off functionality is always operational. If you do not want to use the safe torque-off feature, wiring of the safe stop inputs (SS_IN_CH0/1) are still required to operate the drive. For this reason, the 2094-xx02x-M0x-S0 control modules ship with the motion-allowed plug.
Chapter 2 Installation and Wiring Terminal Connections Prepare wires for termination on the IOD connector with a 5 mm (0.2 in.) strip length. Tighten all terminal screws firmly and recheck them after all connections have been made. Recommended terminal screw torque is 0.4 N•m (3.5 lb•in). Refer to page 37 for the I/O signal electrical specifications.
Chapter 3 Safe Torque-off I/O Signals Introduction Inputs This chapter describes the safe torque-off input and output signals of the Kinetix 6200 and Kinetix 6500 drives. Topic Page Inputs 19 Outputs 23 Safe Stop Wiring Example 26 The Kinetix 6200 and Kinetix 6500 drives have two sets of dual-channel inputs. Each dual-channel input supports the safe stop (SS) function of the drive. The SS_IN_CH0/1 inputs are intended for connection to a non-switching E-stop device (dry contact).
Chapter 3 Safe Torque-off I/O Signals Figure 5 - Cycle Inputs Required Cycle Inputs Required Active Channel 0 Inactive Active Channel 1 Inactive ON Evaluated Status OFF An Input fault occurs if the inputs are discrepant for longer than one second. For SS_IN_CH0/1, use TEST_OUT_0/1 as a reference signal, or a fault occurs. For more information on I/O faults, refer to Troubleshooting the Safe Torque-off Drive on page 33. Discrepancy Time The maximum discrepancy time between two inputs is 1.0 second.
Safe Torque-off I/O Signals Chapter 3 Figure 7 - Reset Behavior SS_IN_CH0 or SS_IN_CH2 SS_IN_CH1 or SS_IN_CH3 RESET_IN Fault 20 ms, max Gate Power and Gate Enable RESET_REQUIRED (waiting for reset) SO_REQUEST_VALUE SO_IN_VALUE IMPORTANT When the inactive ‘OFF’ state of RESET_IN transitions to the active ‘ON’ state, following a successful reset, the time to re-enable gate power and gate enable, and set dual-channel safe-off outputs to active ‘ON’ state will not exceed 20 ms.
Chapter 3 Safe Torque-off I/O Signals Figure 8 - Safety Input Wiring Examples Drive Drive Test_Out_0 (IOD-27) Test_Out_1 (IOD-28) Test_Out_0 (IOD-27) Test_Out_1 (IOD-28) SS_IN_CH0 (IOD-19) SS_IN_CH1 (IOD-20) SS_IN_CH0 (IOD-19) SS_IN_CH1 (IOD-20) 24VPWR (IOD-14) 24VCOM (IOD-15) 24VPWR (IOD-14) 24VCOM (IOD-15) Dual-channel Equivalent Safety Device Light Curtain or Safety Mat SPWR (IOD-17) SS_IN_CH2 (IOD-23) SS_IN_CH3 (IOD-24) 24V DC OSSD1 OSSD2 SCOM (IOD-18) IMPORTANT SPWR (IOD-17) SS_IN_CH2
Safe Torque-off I/O Signals Chapter 3 Reset Input (Reset_In) The Reset input is for reset and monitoring of the safety circuit. RESET_REF provides reference voltage for the RESET_IN input. For automatic reset option, wire the reset input terminal (IOD-26) to the RESET_REF terminal, (IOD-25). Figure 9 - RESET_IN Terminal Example IOD-25 RESET_IN IOD-26 RESET_IN Outputs The drive has safe-stop safety control outputs. See the specifications in Appendix A to verify your power requirements.
Chapter 3 Safe Torque-off I/O Signals Figure 10 - SS_Out to SS_In Connections for Multi-axis Applications Drive 1 SS_OUT_CH0 SS_OUT_CH1 IOD-21 IOD-22 IOD-23 IOD-24 SS_IN_CH2 SS_IN_CH3 Drive 2 For more information on multi-axis configurations, see Cascaded Configurations starting on page 27. Alternately, the first SS_Out output may be used to signal a programmable logic controller (PLC) that a Safe Stop has been requested.
Safe Torque-off I/O Signals Chapter 3 Safe Stop Reset Safe torque-off drives provide a Reset Input (RESET_IN) for resetting the drive after a fault, and for synchronizing restart of several cascading drives. The Reset Input (RESET_IN) is not safety certified and does not have dual-channel capability. Automatic reset functionality, if needed, can be achieved by hardwiring the RESET_REF and RESET_IN terminals together.
Chapter 3 Safe Torque-off I/O Signals Safe Stop Wiring Example This example illustrates safe stop wiring.
Chapter 4 Multi-axis Cascaded Systems This chapter describes cascaded multi-axis drive operation and provides wiring examples for cascaded multi-axis drive systems. Introduction Cascaded Configurations Topic Page Cascaded Configurations 27 Safe Stop Wiring Examples 28 For cascaded drives, connect the safety switches to the safety inputs (SS_In) of only the first axis.
Chapter 4 Multi-axis Cascaded Systems Cascaded configurations can be wired with either the 2090-K6CK-D44M or 2090-K6CK-D44S0 low-profile connector kits. The 2090-K6CK-D44S0 connector is designed specifically for cascading the safe torque-off signals from drive-to-drive. Safe Stop Wiring Examples The examples shown are safe-stop configurations that use a dry-contact safety device.
Multi-axis Cascaded Systems Chapter 4 2090-K6CK-D44S0 Connector Kit Examples The 2090-K6CK-D44S0 connector kit and 2090-CS0DSDS-AAxx safe-off cable are designed specifically for cascading the safe torque-off signals from drive-to-drive.
Chapter 4 Multi-axis Cascaded Systems Figure 16 - Cascading Safe Stop OSSD Device Wiring Example 24V DC Light Curtain or Safety Mat OSSD1 OSSD2 IOD Connector (P5) IOD Connector (P5) 28 27 24 23 22 21 20 19 TEST_OUT_1 TEST_OUT_0 SS_IN_CH3 SS_IN_CH2 SS_OUT_CH1 SS_OUT_CH0 SS_IN_CH1 SS_IN_CH0 28 27 24 23 22 21 20 19 28 27 24 23 22 21 20 19 26 25 18 17 15 14 RESET_IN RESET_REF SCOM SPWR 24VCOM 24VPWR 28 27 24 23 22 21 20 19 28 27 24 23 22 21 20 19 IOD Connector (P6) IOD Connector (P6) Reset TEST_
Multi-axis Cascaded Systems Chapter 4 In this example, three safe torque-off drives are shown using the Bulletin 2090 low-profile connector kit and cables. The right-angled cable connectors are keyed to exit left as shown. Cables loop back and cascade to the next drive or other cascading device.
Chapter 4 Multi-axis Cascaded Systems Notes: 32 Rockwell Automation Publication 2094-RM002B-EN-P - May 2012
Chapter 5 Troubleshooting the Safe Torque-off Drive Introduction Nonrecoverable Faults This chapter provides troubleshooting tables for diagnosing fault conditions associated with the safe torque-off safety functions.
Chapter 5 Troubleshooting the Safe Torque-off Drive Input and Output Faults An input or output fault indication can be caused by several wiring fault conditions during commissioning or normal operation. If an input fault occurs, check for the following: • One of the channels may have shorted to a 24V DC source. • One of the channels may have shorted to a GND source. • Two input channels have shorted together. • One or both output channels have an overcurrent condition.
Troubleshooting the Safe Torque-off Drive Status Attributes Chapter 5 For diagnostic purposes only, you can view status attributes by accessing the AxisServoDrive.GuardStatus tag (Kinetix 6200 systems) and AxisCIPDrive.GuardStatus tag (Kinetix 6500 systems) in RSLogix 5000 software. IMPORTANT AxisServoDrive.GuardStatus tags must be selected as a Real-time attribute in order to receive updated attribute values. This is not required for AxisCIPDrive.GuardStatus tags.
Chapter 5 Troubleshooting the Safe Torque-off Drive Table 8 - Guard Status Bit Values Parameter Name Description Bit Values Axis 1: Guard Status GuardOKStatus GuardConfigLockedStatus GuardGateDriveOutputSatus GuardStopInputStatus GuardStopRequestStatus GuardStopInProgressStatus GuardStopDecelStatus GuardStopStandstillStatus GuardStopOutputStatus GuardLimitedSpeedInputStatus GuardLimitedSpeedRequestStatus GuardLimitedSpeedMonitorInProgressStatus GuardLimitedSpeedOutputStatus GuardMaxSpeedMonitorInProgr
Appendix A Specifications Introduction General Specifications This appendix provides product specifications for the safe torque-off safety functions. Topic Page General Specifications 37 Certifications 38 These specifications apply to the safe torque-off safety functions. Attribute Value Standards IEC/EN60204-1, ISO12100, IEC 61508, IEC 61800-5-2 Safety category Cat. 4 and PLe per EN ISO 13849-1; SIL CL3 per IEC 61508 and EN 62061 Power supply Voltage Current, max 21.6…28.
Appendix A Specifications Certifications See the Product Certification link at http://www.ab.com for Declarations of Conformity, Certificates, and other certifications details. Agency Certification (1) Value c-UL-us (2) UL Listed, certified for US and Canada.
Index Numerics 2090-K6CK-D44M 14 2090-K6CK-D44S0 16 G guard faults 36 guard status 36 A additional resources 8 ADR 12 automatic drive replacement 12 automatic reset 23, 25 C cascaded configurations 27 cascaded connections 24 Cat 4 7, 9 performance definition 10 certification 38 Cat 4 7, 9 ISO 13849-1 9 PLe 7, 9 SIL CL3 7, 9 connector kit wiring 14, 16 cycle inputs 20 D discrepancy time 20 documentation additional resources 8 drive replacement 12 E emergency shutdown systems 9 EN 61508 11 SIL CL3 certif
Index SIL CL3 7, 9, 38 certification, user responsibilities 10 single-channel operation 19 SO Reset 25 specifications general 37 SS_Out output 23 status attributes 35 stop category definition 10 T terminal screws connections 18 strip length 18 torque 18 timing diagrams discrepancy time 20 reset behavior 21 W wiring connector kit 2090-K6CK-D44M 14 2090-K6CK-D44S0 16 motion-allowed plug 17 multi-axis connections 24 safety input examples 22 wiring example Safe Stop mode 26, 28 40 Rockwell Automation Publi
Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products. At http://www.rockwellautomation.com/support, you can find technical manuals, 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. You can also visit our Knowledgebase at http://www.rockwellautomation.
