Safe Limited Speed Wiring Example

Guardmaster MSR57P Speed

Monitoring Safety Relay

User Manual

(Catalog Number

440R-S845AER-NNL

)

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://literature.rockwellautomation.com

) 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 of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell

Automation, Inc., is prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

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.

IMPORTANT

ATTENTION

Identifies information that is critical for successful application and understanding of the product.

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.

Rockwell Automation, Allen-Bradley, TechConnect, Guardmaster, Kinetix, PowerFlex, SCANport, RSLinx, DriveExplorer, and DriveExecutive are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

Table of Contents

Safety Concept

About the MSR57P Speed

Monitoring Safety Relay

Installation and Wiring

3 Publication 440R-UM004A-EN-P - December 2008

Preface

About This Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . 9

Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Additional Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Chapter 1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Safety Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Important Safety Considerations . . . . . . . . . . . . . . . . . . . 14

Safety Category 4 Performance Definition . . . . . . . . . . . . 15

Stop Category Definitions. . . . . . . . . . . . . . . . . . . . . . . . 15

Performance Level and Safety Integrity Level (SIL) 3 . . . . 16

Functional Proof Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

PFD and PFH Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . 16

PFD and PFH Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Safe State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Safety Reaction Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Considerations for Safety Ratings . . . . . . . . . . . . . . . . . . . . . 18

Output Pulse Test Considerations . . . . . . . . . . . . . . . . . . 19

Considerations for Single-encoder Applications . . . . . . . . 19

Contact Information if Device Failure Occurs . . . . . . . . . . . . 22

Chapter 2

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Safety Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Safety Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Disabled Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Lock Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Safe Maximum Speed, Safe Maximum Acceleration, and

Safe Direction Monitoring. . . . . . . . . . . . . . . . . . . . . . . . 25

Hardware Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Chapter 3

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

General Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . 30

Environment and Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . 31

Considerations for Reducing Noise. . . . . . . . . . . . . . . . . . . . 31

Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Spacing Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Mount the MSR57P Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Power Supply Requirements . . . . . . . . . . . . . . . . . . . . . . . . 32

Removable Terminal Blocks . . . . . . . . . . . . . . . . . . . . . . . . 33

3

Table of Contents

4

Speed Monitoring I/O Signals

General Relay and Feedback

Monitoring Configuration

Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Terminal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Compatible Encoders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Connect an Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Encoder Cable Specifications . . . . . . . . . . . . . . . . . . . . . . . . 42

Feedback Cable Connections for Kinetix 2000, Kinetix 6000,

Kinetix 7000 and Ultra3000 Drives . . . . . . . . . . . . . . . . . . . . 42

Flying-lead Feedback Cable Pin-outs. . . . . . . . . . . . . . . . 44

Wiring Low-profile Connector Kits . . . . . . . . . . . . . . . . . 51

Feedback Connections for PowerFlex 70 Drives . . . . . . . . . . 52

Safe Off Board Terminal Block

(Enhanced Control Only) . . . . . . . . . . . . . . . . . . . . . . . . 53

Encoder Interface Terminal Block

(Enhanced Control Only) . . . . . . . . . . . . . . . . . . . . . . . . 53

Feedback Connections for PowerFlex 700S Drives . . . . . . . . 55

Connect a Configuration Device . . . . . . . . . . . . . . . . . . . . . 55

Chapter 4

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Safe Stop Input (SS_In) . . . . . . . . . . . . . . . . . . . . . . . . . 60

Safe Limited Speed Input (SLS_In) . . . . . . . . . . . . . . . . . 60

Door Monitor Input (DM_In) . . . . . . . . . . . . . . . . . . . . . 60

Enabling Switch Monitor Input (ESM_In). . . . . . . . . . . . . 61

Lock Monitor Input (LM_In) . . . . . . . . . . . . . . . . . . . . . . 61

Reset Input (Reset_In) . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Reset Loop Input (RL_In) . . . . . . . . . . . . . . . . . . . . . . . . 63

Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Safety Control Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Diagnostic Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Chapter 5

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Cascaded Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Safety Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Reset Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Reset Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Overspeed Response Time . . . . . . . . . . . . . . . . . . . . . . . . . 75

Speed Resolution Accuracy for Rotary Systems . . . . . . . . 76

Speed Resolution Accuracy for Linear Systems . . . . . . . . 78

Language Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Max Display Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

General Parameter List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Feedback Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Feedback Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Publication 440R-UM004A-EN-P - December 2008

Table of Contents

Single Encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Dual Encoders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Feedback Voltage Monitor Range . . . . . . . . . . . . . . . . . . 85

Feedback Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Feedback Parameter List . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Safe Stop and Safe Stop with Door

Monitoring Modes

Chapter 6

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Safe Stop Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Safe Stop Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Standstill Speed and Position Tolerance . . . . . . . . . . . . . 93

Deceleration Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . 94

Safe Stop Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Door Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Lock Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Safe Stop Parameter List . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Safe Stop Wiring Example . . . . . . . . . . . . . . . . . . . . . . . . . 102

Safe Stop with Door Monitoring Mode . . . . . . . . . . . . . . . . 102

Lock Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

SS Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Safe Stop with Door Monitoring Parameter List. . . . . . . . . . 103

Safe Stop with Door Monitoring Wiring Example . . . . . . . . 104

Chapter 7

Safe Limited Speed (SLS) Modes

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Safe Limited Speed (SLS) Mode . . . . . . . . . . . . . . . . . . . . . 105

Safe Limited Speed Reset . . . . . . . . . . . . . . . . . . . . . . . 107

Safe Limited Speed Parameter List . . . . . . . . . . . . . . . . . . . 108

Safe Limited Speed Wiring Example . . . . . . . . . . . . . . . . . . 109

Safe Limited Speed with Door Monitoring Mode. . . . . . . . . 110

Safe Limited Speed Reset . . . . . . . . . . . . . . . . . . . . . . . 111

SLS with Door Monitoring Parameter List . . . . . . . . . . . . . . 111

SLS with Door Monitoring Wiring Example. . . . . . . . . . . . . 112

Safe Limited Speed with Enabling Switch Monitoring Mode. 112

Safe Stop Reset (SS Reset) and Safe Limited Speed Reset

(SLS Reset) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

SLS with Enabling Switch Monitoring Parameter List . . . . . . 114

SLS with Enabling Switch Monitoring Wiring Example . . . . 115

Safe Limited Speed with Door Monitoring and Enabling

Switch Monitoring Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Behavior During SLS Monitoring. . . . . . . . . . . . . . . . . . 117

Behavior While SLS Monitoring is Inactive . . . . . . . . . . 117

Behavior During SLS Monitoring Delay . . . . . . . . . . . . . 117

Safe Stop Reset (SS Reset) and Safe Limited Speed Reset

(SLS Reset) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118


5

Table of Contents

6

Slave Modes for Multi-axis

Cascaded Systems

Safe Maximum Speed and

Direction Monitoring

Safety Configuration and

Verification

SLS with Door Monitoring and Enabling Switch Monitoring

Parameter List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118


Wiring Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Safe Limited Speed Status Only Mode . . . . . . . . . . . . . . . . 119

Speed Hysteresis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

SLS Status Only Parameter List . . . . . . . . . . . . . . . . . . . . . . 121

SLS Status Only Wiring Examples. . . . . . . . . . . . . . . . . . . . 122

Chapter 8

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Cascaded Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Slave, Safe Stop Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Slave, Safe Stop Parameter List. . . . . . . . . . . . . . . . . . . . . . 127

Slave, Safe Stop Wiring Examples . . . . . . . . . . . . . . . . . . . 129

Slave, Safe Limited Speed Mode. . . . . . . . . . . . . . . . . . . . . 132

Slave, Safe Limited Speed Parameters. . . . . . . . . . . . . . . . . 132

Slave, Safe Limited Speed Wiring Examples . . . . . . . . . . . . 133

Slave, Safe Limited Speed Status Only Mode. . . . . . . . . . . . 135

Slave, Safe Limited Speed Status Only Parameter List . . . . . 135

Slave, Safe Limited Speed Status Only Wiring Examples . . . 135

Multi-axis Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Cascaded System Examples . . . . . . . . . . . . . . . . . . . . . . . . 139

Chapter 9

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Safe Maximum Speed (SMS) Monitoring . . . . . . . . . . . . . . . 145

Safe Maximum Acceleration (SMA) Monitoring . . . . . . . . . . 148

Safe Direction Monitoring (SDM) . . . . . . . . . . . . . . . . . . . . 150

Max Speed, Max Accel, and Direction Monitoring

Parameter List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Chapter 10

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Safety Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Configuration Signature ID . . . . . . . . . . . . . . . . . . . . . . 153

Safety-lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Set a Password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Reset the Password . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Reset the Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Basics of Application Development and Testing . . . . . . . . . 156

Commissioning the System . . . . . . . . . . . . . . . . . . . . . . . . 156

Specify the Safety Configuration . . . . . . . . . . . . . . . . . . 157

Configure the Speed Monitoring Relay . . . . . . . . . . . . . 158

Project Verification Test . . . . . . . . . . . . . . . . . . . . . . . . 159


Table of Contents

Configuration Examples

Confirm the Project . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Safety Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Verify the Signature and Lock at the Speed Monitoring

Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Editing the Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . 160

Chapter 11

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Example Application 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Example 1: Initial Security Group Settings . . . . . . . . . . . 162

Example 1: General Group Settings . . . . . . . . . . . . . . . 163

Example 1: Feedback Group Settings . . . . . . . . . . . . . . 164

Example 1: Stop Group Settings . . . . . . . . . . . . . . . . . . 166

Example 1: Limited Speed Group Settings . . . . . . . . . . . 168

Example 1: Door Control Group Settings . . . . . . . . . . . 169

Example 1: Max Speed Group . . . . . . . . . . . . . . . . . . . 170

Example 1: Final Security Group Settings . . . . . . . . . . . 171

Example Application 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Example 2: Initial Security Group Settings . . . . . . . . . . . 173

Example 2: General Group Settings . . . . . . . . . . . . . . . 174

Example 2: Feedback Group Settings . . . . . . . . . . . . . . 175

Example 2: Stop Group Settings . . . . . . . . . . . . . . . . . . 177

Example 2: Limited Speed Group Settings . . . . . . . . . . . 179

Example 2: Door Control Group Settings . . . . . . . . . . . 181

Example 2: Max Speed Group . . . . . . . . . . . . . . . . . . . 182

Example 2: Final Security Group Settings . . . . . . . . . . . 183

Chapter 12

Troubleshoot the MSR57P Relay

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

Nonrecoverable Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

Fault Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Input and Output Faults . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Fault Codes and Descriptions . . . . . . . . . . . . . . . . . . . . . . 187

Fault Reactions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

Safe State Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

Stop Category Faults and Fault While Stopping Faults . . 191

Status Attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

Guard Status Attributes. . . . . . . . . . . . . . . . . . . . . . . . . 192

I/O Diagnostic Status Attributes . . . . . . . . . . . . . . . . . . 195

Configuration Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . 196


7

8

Table of Contents

Specifications

Parameter Data

Using a HIM

Use DriveExplorer or

DriveExecutive Software

Application Examples

Appendix A

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . 198

Certifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

Encoder Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

Appendix B

Parameter Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

Parameters and Settings in a Linear List . . . . . . . . . . . . . . . 202

Appendix C

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

Connect a HIM Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

Setting Parameters with a HIM Module. . . . . . . . . . . . . . . . 214

Accessing the Fault History Queue. . . . . . . . . . . . . . . . . . . 215

Appendix D

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

Connect a Personal Computer . . . . . . . . . . . . . . . . . . . . . . 217

Using DriveExplorer Software . . . . . . . . . . . . . . . . . . . . . . 218

Configure Serial Communication. . . . . . . . . . . . . . . . . . 218

Edit Parameters in DriveExplorer Software . . . . . . . . . . 219

Access the Fault History Queue . . . . . . . . . . . . . . . . . . 220

Using DriveExecutive Software . . . . . . . . . . . . . . . . . . . . . 221

Configure Serial Communication. . . . . . . . . . . . . . . . . . 221

Edit Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

Appendix E

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

PowerFlex 70 Drive with Safe-Off Application Example . . . 228

PowerFlex 700 Drive without Safe-Off . . . . . . . . . . . . . . . . 231

Kinetix 6000 or Kinetix 7000 Drives with Safe-off Example . 233

Kinetix 2000 Drive without Safe-off Example . . . . . . . . . . . 235

Index


Preface

About This Publication

Who Should Use This

Manual

This manual explains how the Guardmaster MSR57P Speed Monitoring

Safety Relay can be used in Safety Integrity Level (SIL) 3, 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 relay.

Use this manual if you are responsible for designing, installing, configuring, or troubleshooting safety applications that use the

MSR57P Speed Monitoring Safety Relay.

You must have a basic understanding of electrical circuitry and familiarity with relay logic. You must also be trained and experienced in the creation, operation, and maintenance of safety systems.

Conventions

In this manual, configuration parameters are listed by number followed by the name in brackets. For example,

P24 [OverSpd Response].

Terminology

Terminology

Abbreviation

1oo2

CAT

DC

DM

EN

ESM

ESPE

Full Term

One out of Two

Category

Door Control

Door Monitoring

European Norm

Enabling Switch Monitoring

Electro-sensitive Protective

Equipment

FMEA

IEC

The following table defines terms used in this manual.

Failure Mode and Effects Analysis

International Electrotechnical

Commission

Definition

Refers to the behavioral design of a dual-channel safety system.

—

—

The official European Standard.

—

An assembly of devices and/or components working together for protective tripping or presence-sensing purposes and comprising as a minimum:

• a sensing device.

• controlling/monitoring devices.

• output signal-switching devices (OSSD).

Analysis of potential failure modes to determine the effect upon the system and identify ways to mitigate those effects.

—


9

Preface

PC

PFD

PFH

PL

RL

SDM

SFF

SIL

SLS

SMA

SMS

SS

Terminology

Abbreviation

IGBT

HFT

HIM

LM

MP

OSSD

Full Term

Insulated Gate Bi-polar Transistor

Hardware Fault Tolerance

Human Interface Module

Lock Monitoring

Motion Power

Output Signal Switching Device

Personal Computer

Probability of Failure on Demand

Probability of Failure per Hour

Performance Level

Reset Loop

Safe Direction Monitoring

Safe Failure Fraction

Safety Integrity Level

Safe Limited Speed

Safe Maximum Acceleration

Safe Maximum Speed

Safe Stop

Definition

—

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.

A module used to configure a device.

—

—

The component of the electro-sensitive protective equipment (ESPE) connected to the control system of a machine, which, when the sensing device is actuated during normal operation, responds by going to the OFF-state.

—

—

—

—

Computer used to interface with and program your safety system.

The average probability of a system to fail to perform its design function on demand.

The probability of a system to have a dangerous failure occur per hour.

ISO 13849-1 safety rating

—

—

The sum of safe failures plus the sum of dangerous detected failures divided by the sum of all failures.

A measure of a products ability to lower the risk that a dangerous failure could occur.

10


Preface

Additional Resources

This table lists publications that contain important information about safety systems that can use the speed monitoring safety functions of the MSR57P relay.

Resource Description

Guardmaster MSR57P Speed Monitoring Safety Relay Installation

Instructions, publication 440R-IN016

Provides information on installing the MSR57P relay.

HIM Quick Reference, publication 20HIM-QR001

DriveExplorer Online Help

PowerFlex USB Converter User Manual, publication

DRIVES-UM001

A quick reference for using the HIM keypad.

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.

Provides detailed information on installing, configuring, and troubleshooting the 1203-USB converter.

PowerFlex Smart Self-powered Serial Converter User Manual, publication 20COMM-UM001

PowerFlex 700S Phase II Drive User Manual, publication

20D-UM006

PowerFlex 700 Series A User Manual, publication 20B-UM001

PowerFlex 700 Series B User Manual, publication 20B-UM002

Provides detailed information on installing, configuring, and troubleshooting the 1203-SSS series B serial converter.

Provides detailed information on installing, wiring, programming, and troubleshooting PowerFlex 700S Phase II drives.

Provides detailed information on installing, wiring, programming, and troubleshooting PowerFlex 700 Series A drives.

Provides detailed information on installing, wiring, programming, and troubleshooting PowerFlex 700 Series B drives.

PowerFlex 70 User Manual, publication 20A-UM001

PowerFlex Reference Manual, publication PFLEX-RM001

Provides detailed information on installing, wiring, programming, and troubleshooting PowerFlex 70 drives.

Provides specifications and dimensions, as well as detailed information about drive operation.

DriveGuard Safe-Off Option (Series B) for PowerFlex 40P and 70

AC Drives User Manual, publication

Kinetix 6000 Multi-axis Servo Drive User Manual, publication

2094-UM001

PFLEX-UM003

Provides detailed information installing, wiring, and operating

PowerFlex 70 AC drives with the Safe-Off option. The manual also includes certification information for the Safe-Off option.

Provides detailed information on installing, connecting, configuring, and troubleshooting a Kinetix 6000 drive. The manual also includes specifications and dimensions.

Kinetix Safe-off Feature Safety Reference Manual, publication

GMC-RM002

Provides detailed information on the safety requirements, as well as connector and wiring diagrams for the Safe-off feature.

Kinetix Motion Control Selection Guide, publication GMC-SG001 Provides features, specifications, and dimensions for selecting Kinetix

Motion Control servo drives, motors, actuators, and accessory components.

Ultra3000 Digital Servo Drives Installation Manual, publication

2098-IN003

Provides information on installing and wiring for the Ultra3000 Digital

Servo Drives.

Ultra3000 Digital Servo Drives Integration Manual, publication

2098-IN005

Safety Guidelines for the Application, Installation and

Maintenance of Solid State Control, publication SGI-1.1

Provides power-up procedures, system integration, and troubleshooting tables for the Ultra3000 Digital Servo Drives.

Describes important differences between solid state control and hard-wired electromechanical devices.

You can view or download publications at: http://literature.rockwellautomation.com

. To order paper copies of technical documentation, contact your local Rockwell Automation distributor or sales representative.


11

Preface

12


Chapter

1

Safety Concept

Introduction

Safety Certification

This chapter describes the safety performance level concept and how the MSR57P Speed Monitoring Safety Relay can meet the requirements for SIL CL3, PL(e), or CAT 4 applications.

Topic

Safety Certification

Functional Proof Tests

PFD and PFH Definitions

PFD and PFH Data

Safe State

Safety Reaction Time

Considerations for Safety Ratings

Contact Information if Device Failure Occurs

Page

13

16

16

17

17

18

18

22

The MSR57P Speed Monitoring Safety Relay is certified for use in safety applications up to and including SIL CL3 according to IEC 61508 and EN 62061, Performance Level PL(e) and CAT 4 according to

ISO 13849-1. Safety requirements are based on the standards current at the time of certification.

The TÜV Rheinland group has approved the MSR57P Speed

Monitoring Safety Relay 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.


13

Chapter 1 Safety Concept

Important Safety Considerations

The system user is responsible for:

• 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.

• programming the application software and the device 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.

ATTENTION

When designing your system, consider how personnel will exit the machine if the door locks while they are in the machine.

Additional safeguarding devices may be required for your specific application.

ATTENTION

A HIM module may be used to configure and monitor the

MSR57P speed monitoring safety relay. However, the stop button on the HIM does not have safety integrity and must not be used to execute a safe stop.

The stop button setting is not maintained through a power cycle. Do not use the stop button in conjunction with an

Automatic Reset configuration. Unintended motion could result.

14



Safety Concept Chapter 1

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.

• a single fault in any of its parts does not lead to a loss of safety function.

• a single fault is detected at or before the next demand of the safety function, or, if this detection is not possible, then an accumulation of faults shall not lead to a loss of the safety function.

• the average diagnostic coverage of the safety-related parts of the control system shall be high, including the accumulation of faults.

• the mean time to dangerous failure of each of the redundant channels shall be high.

• measures against common cause failure shall be applied.

Stop Category Definitions

The selection of a stop category for each stop function must be determined by a risk assessment.

•

Stop Category 0 is achieved with immediate removal of power to the actuator, resulting in an uncontrolled coast to stop. Safe

Torque Off accomplishes a Stop Category 0 stop.

•

Stop Category 1 is achieved with power available to the machine actuators to achieve the stop. Power is removed from the actuators when the stop is achieved.

•

Stop Category 2 is a controlled stop with power available to the machine actuators. The stop is followed by a holding position under power.

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.

15


Functional Proof Tests

Performance Level and Safety Integrity Level (SIL) 3

For safety-related control systems, Performance Level (PL), according to ISO 13849-1, and SIL levels, according to IEC 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.

See

Chapter 10

,

Safety Configuration and Verification , for more

information on the requirements for configuration and verification of a safety-related system containing the MSR57P Speed Monitoring Safety

Relay.

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.

PFD and PFH Definitions

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).

16


PFD and PFH Data

Safe State


These PFD and PFH calculations are based on the equations from

Part6 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.

PFD and PFH for 20-year Proof Test Interval

Attribute

PFD

PFH

SFF

Pulse Test ON

Single Encoder

1.23E - 04

Dual Encoder

5.93E-04

7.04E-09

99.3%

3.38E-09

99.2%

Pulse Test OFF

25.9E-04

14.8E-09

97.9%

(1)

(1) Pulse testing for outputs is configured using the following parameters: P71 [MP Out Mode], P72 [SS Out Mode],

P73 [SLS Out Mode], P74 [Door Out Mode]. If you disable pulse-testing on any of these outputs, the achievable

SIL, Category, and PL ratings of your entire MSR57P safety system are reduced. See

Outputs beginning on page

63 for more information.

The Safe State encompasses all operation that occurs outside of the other monitoring and stopping behavior defined as part of the speed monitoring safety relay. In addition, configuration takes place in the

Safe State. While the relay is in the Safe State, all safety control outputs, except the Door Control (DC_Out) output, are in their safe state (de-energized). The Door Control (DC_Out) output will be in either the locked state or in the de-energized state depending upon the condition that resulted in the safe state.

The diagnostic Fault_Status output may be on in the safe state.

When you cycle power, the relay enters the Safe State for self-testing.

If the self-tests pass and there is a valid configuration, the relay remains in the Safe State until a successful request for safe speed monitoring occurs.

If a Safe State Fault is detected, the relay goes to the Safe State. This includes faults related to integrity of hardware or firmware.

For more information on faults, see

Chapter 12

,

Troubleshoot the

MSR57P Relay

.


17


Safety Reaction Time

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 Safe Stop Type, is 20 ms

(maximum).

The safety reaction time from an overspeed event that triggers a safe stop, to the actual initiation of the configured Safe 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

75 .

Considerations for Safety

Ratings

The achievable safety rating of an application using the MSR57 relay 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 MSR57P relay can be used in applications up to and including

SIL CL3, PL(e), and CAT 4.

When using a drive with the Safe-Off option and one external contactor, or when using two external contactors, the MSR57P relay can be used in applications up to and including SIL CL3, PL(e), and

CAT 4.

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.

18




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 MSR57P relay.

IMPORTANT

Setting any of the P71 [MP_Out Mode], 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 SS_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.

Considerations for Single-encoder Applications

When configured correctly, the MSR57P relay performs these diagnostics on the encoder:

•

Sin

2

+ Cos

2

diagnostic.

• detection of open or short-circuit.

• encoder supply voltage monitoring.

• detection of illegal quadrature transitions of the sine and cosine signals.

A safety rating up to and including SIL CL3, PL(e), and CAT 4 can be achieved in a single-encoder application with these requirements:

•

The motor is a permanent magnet (PM) brushless AC motor.

•

The motor controller must be configured as a closed-loop application with field-oriented control using the single-encoder for commutation.

•

The motor-to-encoder coupling is designed to exclude shaft slippage as a dangerous failure mechanism.

•

The MSR57P relay is configured for Sin/Cos encoder type.

19


•

The encoder is of the Sin/Cos type and is suitable for the desired safety rating of the application.

An encoder that is suitable for SIL CL3 applications must:

– use independent Sine/Cosine signals.

– be incapable of producing simulated signals when under an error condition.

– use simple or discreet circuitry with no complex or programmable internal devices.

•

The controller is not configured for auto transition to encoderless commutation in the event of encoder failure.

•

The motor controller must use the same encoder signals as

MSR57P relay.

•

Encoder voltage monitoring in MSR57P relay must be enabled.

•

The system design of the motor/encoder-to-load coupling excludes shaft slippage and breakage as a dangerous failure mechanism.

Single-encoder with Kinetix Drive

A safety rating up to and including SIL CL3, PL(e), and CAT 4 can be achieved in an MSR57P relay single-encoder application when the relay is used in conjunction with a properly-configured Kinetix Servo

Drive with Safe-Off and any motor/encoder combination that meets the single-encoder application requirements on page

19

.

Single-encoder with PowerFlex Drive

A safety rating up to and including SIL CL3, PL(e), and CAT 4 can be achieved in an MSR57P relay single-encoder application when the relay is used in conjunction with a properly-configured

PowerFlex 700S or PowerFlex 755 drive and any motor/encoder combination that meets the single-encoder application requirements on page

19 .

20




For example, to properly configure a PowerFlex 700S drive to meet the single-encoder application requirements listed on page

19

, make these parameter settings.

Parameter

Number

P485

P222

Parameter

Name

Required Drive

Parameter Setting

Motor Ctrl Mode 2 = Pmag Motor

Mtr Fdbk Sel Pri 5 = FB Opt Port0

Addresses Single-encoder

Requirement

The motor controller must be configured as a closed-loop application with field-oriented control using the single-encoder for commutation.

P153, bit 16 Control Options OFF = Auto Tach Sw The controller is not configured for auto transition to encoderless commutation in the event of encoder failure.

You must make sure that a Sin/Cos feedback option is installed in the drive. The drive must be commissioned according to the normal startup procedure for proper operation in your system.

The MSR57P is suitable for SIL CL3, Cat 4 applications when connected to drives which also support Cat 4 applications. Some applications may require an external contactor to meet Cat 4 requirements. Refer to your drive manual for details on safety requirements.

Refer to the PowerFlex 700S Phase II Drive User Manual, publication

20D-UM006 for detailed information on installing, configuring, and operating a PowerFlex 700S drive.

Understanding Commutation

Permanent magnet (PM), brushless AC motors, like those listed above, are a class of synchronous motor that depend on electronic brushless commutation to generate torque and motion. In PM brushless motors, an electromagnetic field is created by the permanent magnets on the rotor. A rotating magnetic field is created by a number of electromagnets commutated electronically with insulated-gate bipolar transistors (IGBT’s) at the right speed, order, and times. Movement of the electromagnetic field is achieved by switching the currents in the coils of the stator winding. This process is called commutation.

Interaction of the two electromagnetic fields produces magnetic force or torque.

Excessive noise, broken encoder wires, and loss of the encoder power supply are factors that can affect commutation while the motor is running. To prevent the motor from spinning, these conditions can be detected by the drive with the use of safety monitoring circuits.

21


Contact Information if

Device Failure Occurs

If you experience a failure with any safety-certified device, contact your local 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.

22


Introduction

Safety Functions

Chapter

2

About the MSR57P Speed Monitoring Safety

Relay

This chapter describes the features of the MSR57P Speed Monitoring

Safety Relay.

Topic

Safety Functions

Hardware Features

Configuration

Page

23

26

27

The MSR57P Speed Monitoring Safety Relay features five inputs, three sets of safety outputs, and one bipolar safety output. Each of the inputs supports a specific safety function.

•

Safe Stop (SS)

•

Safe Limited Speed Monitoring (SLS)

•

Door Monitoring (DM)

•

Enabling Switch Monitoring (ESM)

•

Lock Monitoring (LM)

An additional reset input provides for reset and monitoring of the safety circuit.

The relay can be used in single-axis or multi-axis applications, and the relay is configurable as a master or slave based on its location in the system.


23

Chapter 2 About the MSR57P Speed Monitoring Safety Relay

Safety Modes

The relay can be configured to operate in one of 11 user-selectable safety modes, based on combinations of the safety functions listed on the previous page. The relay monitors motion for Safe Stop in every mode except Disabled.

Safety Mode

Disabled – In this mode, all safety functions are disabled.

Safe Stop – The relay activates the configured Safe Stop Type upon deactivation of the Safe Stop input or the occurrence of a Stop Category Fault.

Safe Stop with Door Monitoring – In addition to monitoring for Safe Stop, the relay monitors the status of the door.

Safe Limited Speed – In addition to monitoring for Safe Stop, the relay monitors the feedback velocity and compares it to a configurable Safe Speed Limit. If the velocity exceeds the limit, the relay initiates the configured Safe Stop Type.

Safe Limited Speed with Door Monitoring – In addition to monitoring for Safe Stop and Safe Limited Speed, the relay monitors the status of the door.

Safe Limited Speed with Enabling Switch Control – In addition to monitoring for

Safe Stop and Safe Limited Speed, the relay monitors the status of the Enabling

Switch input.

Safe Limited Speed with Door Monitor and Enabling Switch – In addition to monitoring for Safe Stop and Safe Limited Speed, the relay monitors the status of the door and the Enabling Switch input.

Safe Limited Speed (status only) – In addition to monitoring for Safe Stop, the relay 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.

Slave, Safe Stop – The relay performs the same functions as Safe Stop. However, it regards the Door Monitor input as a Door Control output from an upstream axis, and performs a logical AND with its internal Door Control signal to form the cascaded Door Control output.

Slave, Safe Limited Speed – The relay performs the same functions as Safe

Limited Speed mode. However, it regards the Door Monitor input as a Door Control output from an upstream axis, and performs a logical AND with its internal Door

Control signal to form the cascaded Door Control output.

Slave, Safe Limited Speed (status only) – The relay performs the same functions as Safe Limited Speed Status Only mode. However, it regards the Door Monitor input as a Door Control output from an upstream axis, and performs a logical AND with its internal Door Control signal to form the cascaded Door Control output.

Page

24

89

102

105

110

112

115

119

125

132

135

Disabled Mode

In Disabled mode, all safety functions are disabled. Input, output, or speed monitoring diagnostics do not take place and all outputs are in their safe state.

24



About the MSR57P Speed Monitoring Safety Relay Chapter 2

Lock Monitoring

Lock monitoring helps prevent access to the hazard during motion. In many applications, it is not sufficient for the machine to initiate a stop command once the door has been opened because a high inertia machine 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 (DC_Out) is in the locked state, or if the Lock Monitor input indicates locked when the Door Monitor input (DM_In) transitions from closed to open, the configured 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 relay 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 relay 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 relay is actively monitoring motion, the configured Safe Stop type is initiated.

Safe Direction Monitoring is also activated via device configuration.

The relay monitors the feedback direction and executes the configured Safe Stop type when motion in the illegal direction is detected.

See Chapter 9

,

Safe Maximum Speed and Direction Monitoring , for

detailed information on these functions.

25


Hardware Features

The MSR57P relay features five dual-channel inputs, three sets of sourcing safety outputs, and one bipolar safety output. You can configure dual-channel inputs to accept contact devices 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. Two RJ-45 connectors support encoder inputs. The MSR57P relay features status indicators and status data for troubleshooting.

26


Configuration

About the MSR57P Speed Monitoring Safety Relay Chapter 2

Configure the MSR57P relay by setting the configuration parameters using a HIM module (catalog number 20-HIM-A3). You can also use

DriveExplorer software, version 5.02 or later, or DriveExecutive software

(1)

, version 4.01 or later. All of these configuration tools let you save the configuration and download it to another MSR57P relay.

Only DriveExecutive software lets you edit the configuration offline.

When the relay configuration is complete, it can be safety-locked to prevent unauthorized changes to the safety configuration. If you set a password to protect the safety configuration, you must enter the password before you can lock or unlock the configuration.

If you are using a HIM to configure the relay, see Appendix C

for information on connecting a HIM and setting parameters with the keypad. If you are using software to configure the relay, see

Appendix

D for information on connecting to a personal computer and using the

software.


(1)

RSLinx software, version 2.50.00 or later, is required for DriveExecutive software.

27


28


Introduction

Chapter

3

Installation and Wiring

This chapter provides details on connecting devices and wiring the

MSR57P relay.

Topic

Environment and Enclosure

General Safety Information

Dimensions

Spacing Requirements

Mount the MSR57P Relay

Power Supply Requirements

Removable Terminal Blocks

Circuit Diagram

Terminal Connections

Compatible Encoders

Connect an Encoder

Encoder Cable Specifications

Feedback Cable Connections for Kinetix 2000, Kinetix 6000, Kinetix 7000 and Ultra3000 Drives

Feedback Connections for PowerFlex 70 Drives

Feedback Connections for PowerFlex 700S Drives

Connect a Configuration Device

52

55

55

32

32

33

33

34

35

Page

31

30

31

32

36

42

42

ATTENTION

This device is intended to be part of the safety-related control system of a machine. Before installation, a risk assessment should be performed to determine whether the specifications of this device are suitable for all foreseeable operational and environmental characteristics for the system to which it is to be installed.


29

Chapter 3 Installation and Wiring

General Safety Information

WARNING

Use this product for its intended applications.

This equipment must not be used for unintended applications, nor in ways that do not conform to appropriate safety standards and good practices. The safety functions may not operate properly, or at all, if this equipment is not used for the intended purposes.

Use within specified operating limits.

This product and the equipment on which it is installed, persons handling the product and the equipment, and/or the immediate environment can be harmed if this equipment is operated outside the specified limits of any of its technical specifications.

Installation and operation must be performed only by qualified technical personnel.

This equipment is to be installed, started up, and operated only by technical personnel who have been trained and understand:

• the products covered by this publication.

• directives, regulations, and good practices relating to machine safety.

• instrumentation and automation components, equipment, and systems.

• industrial electrical practices.

Up-to-date user documentation must be readily accessible by technical personnel.

The latest version of user documentation that includes instructions for installation, operation, and maintenance of this product must be readily available to personnel involved in any of these tasks.

Identify hazardous areas and dangerous operating modes before using the product.

Machine safety applications make it necessary for hazardous areas and dangerous operating modes to be carefully identified, and adequate measures taken to be sure that failure or tampering does not allow automated equipment to be of risk to personnel.

Observe electrical safety regulations and good practices.

Electrical safety regulations stipulated by the appropriate technical authorities must be observed.

Do not use the product if it is damaged or diminished in any way.

Carefully inspect the product before it is installed, or reinstalled. If, at any time, the condition of the product is observed to be diminished in any way so that there is even the slightest possibility of incorrect functioning, you should assume that safe operation is no longer possible, and the equipment should be removed from the system immediately so that unintentional operation is impossible. Examples of such conditions are:

• visible damage to the equipment.

• loss of electrical functions.

• exposure to temperatures higher than the specified operating limit.

• visible indication of burning.

• physical damage due to impact or excessive mechanical shock.

Observe all electrical safety regulations stipulated by the appropriate technical authorities.

ATTENTION

Make sure that electrical power supply to the MSR57P relay is switched off before making or removing any electrical connections.

30


Installation and Wiring Chapter 3

Environment and Enclosure

IMPORTANT

This product must be installed inside protected control panels or cabinets appropriate for the environmental conditions of the industrial location. The protection class of the panel or cabinet should be IP54 or higher.

See the specifications in

Appendix A

.

Considerations for

Reducing Noise

To reduce the affects of electromagnetic interference (EMI), follow these guidelines when connecting your system:

•

Keep wire lengths as short as possible.

•

Route signal cables away from motor and power wiring.

•

Ground all equipment, following the manufacturers instructions.

Additional noise reduction techniques may be necessary.

Refer to the System Design for Control of Electrical Noise Reference

Manual, publication GMC-RM001 for more information.

Dimensions


31


Spacing Requirements

Adequate air space must be provided around the system (module cluster). Minimum recommended clearances:

•

15 mm (0.6 in.) above

•

15 mm (0.6 in.) below

•

2…3 mm (0.08…0.12 in.) between modules at ambient temperatures higher than 40 °C (104 °F).

Mount the MSR57P Relay

Follow these steps to mount the MSR57P relay to an EN50022 -35 x 7.5

DIN rail.

1. Hook the top slot over the DIN rail.

2. Snap the bottom of the relay into position while pressing the relay down against the top of the rail.

Power Supply

Requirements

32

Slot

DIN Rail

Latch

3. Attach end plates on each end of the DIN rail.

To remove the relay from the DIN rail, use a flathead screwdriver to pull down the latch and lift the relay from the rail.

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

To meet EN60204 - PELV, 24V DC + 10% - 20% has to be supplied by a power supply that complies with IEC/EN60204 and IEC/EN 61558-1.


Removable Terminal

Blocks


Such a power supply meets the electrical safety requirements and maintains minimum power of 19.2V DC during 20 ms even in the event of voltage dips.

For planning information, refer to the guidelines in Industrial

Automation Wiring and Grounding Guidelines, Allen-Bradley publication 1770-4.1

.

To remove an upper terminal block, insert a screwdriver into the slot

(a) as shown and push down (b) to disconnect the terminal block. For the lower terminal blocks, reverse the direction of the action.

a b

Circuit Diagram

HIM

S11 S21 S12 S22 S52 S62 S72 S82 S32 S42 X32 X42

A1

13

DPI

Monitor

Encoder

PS

Pulse

Test

Outputs

Safe

Stop

(SS_In)

Isolated Outputs

Safe

Limited

Speed

(SLS_In)

Enabling

Switch

(ESM_In)

Door

Monitor

(DM_In)

Lock

Monitor

(LM_In)

Diag.

Out

SS_Out

(Cascade)

SLS_Out

(Cascade)

Door Lock

Control

(DC_Out)

Bipolar

2 OSSD 2 OSSD

Motion

Power

(MP_Out)

2 OSSD

Door Lock

Control

(DC_Out)

Cascade

Y1 S34 Y2 Y31 Y32 Y33 Y30 Y35 Y37 34 44 68 78 51 52 A2 14 24 51 52


33


Terminal Connections

Tighten all terminal screws firmly and recheck them after all connections have been made. Recommended terminal screw torque is

0.6…0.8 Nm (5…7 lb-in).

52

34, 44

Y31

Y32

Y33

Y30

Y35

Y37

13

14, 24

68, 78

51

Terminal Function

A1

+24V dc, user supply

(1)

A2 Common, user supply

S11, S21 Test_Out_0, Test_Out_1, pulse test output for Safe Stop (SS), Safe Limited Speed (SLS), Enabling Switch Monitor (ESM),

Door Monitor (DM), and Lock Monitor (LM)

S12, S22 SS_In_Ch0, SS_In_Ch1, Safe Stop (SS) dual-channel input

S72, S82 ESM_In_Ch0, ESM_In_Ch1, Enabling Switch Monitoring (ESM) dual-channel input

S52, S62 SLS_In_Ch0, SLS_In_Ch1, Safe Limited Speed (SLS) dual-channel input

S32, S42 DM_In_Ch0, DM_In_Ch1, Door Monitoring (DM) dual-channel input

X32, X42 LM_In_Ch0, LM_In_Ch1, Lock Monitor (LM) dual-channel input, solenoid position

Y1

S34

Y2

24V dc output; RL Feed for reset (S34) and for feedback (Y2)

Reset_In

RL_In, feedback input

SLS_Status output

Fault_Status output

Supply power for SS safety output 14 and Motion Power (MP) safety output 24

MP_Out_Ch0, MP_Out_Ch1, Motion Power (MP) outputs

SLS_Out_Ch0, SLS_Out_Ch1, Safe Limited Speed (SLS) outputs

DC_Out_Ch0 (High Side), Door Control output (door switch solenoid, bipolar or 2 Channel Source)

DC_Out_Ch1 (Low Side), Door Control output (door switch solenoid, bipolar or 2 Channel Source)

SS_Out_Ch0, SS_Out_Ch1, Safe Stop (SS) outputs

24V dc power for isolated outputs

Stop_Command, isolated output

SLS_Command, isolated output

GND for isolated outputs

(1) The MSR57P may be powered when +24V power is removed from terminal A1 and a sourcing safety output is shorted to +24V. If A1 power must be removed, also remove any power that could be shorted to a safety sourcing output.

34



Compatible Encoders

Supported Feedback Devices

Cat. No. and Description

842HR-xJxxx15FWYx

Sin/Cos Encoders

(1)

Incremental

Encoders

(1)

These feedback devices 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 C115 , for catalog number, dimensions, and specifications for

Bulletin 845T and 845H Incremental Encoders.

Rotary Motors

Linear Actuators

845T-xx12xxx-x and 845T-xx13xxx-x

845T-xx42xxx and 845T-xx43xxx-x

845T-xx52xxx and 845T-xx53xxx-x

845H-SJxxx4xxYxx

1326AB-Bxxxx-M2L/-S2L

HPK-Series Asynchronous Servo Motor

MP-Series Motors with embedded Sin/Cos or incremental encoders

TL-Series (TLY-Axxxxx-H) Motors with incremental encoders

Any motor with SHS-170 Stegmann encoder

Any motor with SCS-60 Stegmann encoder

Any motor with SRS-60 Stegmann encoder

Any motor with SRM-60 Stegmann encoder

Any motor with SCS-Kit 101 Stegmann encoder

Any motor with SRS660 Stegmann encoder

MP-Series Integrated Linear Stages

Refer to the Kinetix Motion Control Selection Guide, publication GMC-SG001 , for more information on these motors.

Refer to the product documentation for your specific motor to determine the encoder type.

Refer to the Kinetix Motion Control Selection Guide, publication GMC-SG001 , for more information on these actuators.

(1) Maximum cable length for encoders is 90 m (295 ft).


35


Connect an Encoder

Use twisted-pair, individually-shielded cable to connect encoders and drives. Refer to your encoder or drive manual for proper cable type and maximum length.

IMPORTANT

The drive or encoder and the MSR57P power supply reference must be the same.

IMPORTANT

The MSR57P relay has an internal resistance of 600

Ω

on each of the encoder signals to achieve an equivalent load resistance of 100

Ω

if used with a drive that has 120

Ω

internal terminating resistors. Your encoder may require that the equivalent load resistance be 100

Ω

or greater. Refer to your encoder user manual to make sure the equivalent termination resistance does not exceed the encoder signal loading specification.

ATTENTION

Do not use external terminating resistors with PowerFlex or

Kinetix drives. Doing so may cause permanent damage to the drive.

The following illustrations show simple examples of how to connect an MSR57P relay with an encoder, with or without a drive.

Single Encoder without a Drive

Encoder Power Supply

(1)

1 9

Encoder 1

Sin/Cos or Incremental

Terminal Blocks

Encoder Cable

1585J-M8RB-2M5

RJ45

Encoder 1

Encoder 2

S32

S11

S42

S21

S52 S62

S12 S22

P

DPI

13

34

14

44

24 A1

51 52

PWR/Fault

Stop

Config

Lock

Limited Speed

Standstill

Safe Speed

Motion Power Door

S72

Y31

S82

Y32

X32 X42

Y33 Y30

Y1

68

Y2

78

S34 Y37

Y35 A2

(1) Refer to your encoder specifications to determine power supply requirements (5V, 9V, 12V, or 24V).

36



Two Encoders without a Drive


(1)

Terminal Blocks

Encoder 2

Sin/Cos or

Incremental


(1)

Encoder Cables

1585J-M8RB-2M5

Encoder 1

Sin/Cos or

Incremental

Terminal Blocks


Single Encoder with PowerFlex Drive

PowerFlex Drive

Encoder 1

Incremental

(1)

Encoder Cable

1585J-M8RB-2M5

(1) Terminate shield to functional earth at drive end. See page

53 .

Encoder power (5V or 12V) sourced from the drive.


37


Two Encoders with PowerFlex Drive

PowerFlex Drive

Encoder 1

Incremental

(2)

Encoder 2

Incremental


(1)

Encoder Cables

1585J-M8RB-2M5

Terminal Blocks


(2) Terminate shield to functional earth at drive end. See page 53 .

Encoder power (5V or 12V) sourced from the drive.

38




Single Encoder with a Kinetix 6000 or Kinetix 7000 Drive

Kinetix 6000 or

Kinetix 7000

Drive

Logix Platform

(ControlLogix Controller Shown)

Motor Feedback

Connector Kit

2090-K6CK-D15M

(1)

Encoder Cable

1585J-M8RB-2M5

Motor with Embedded

Encoder 1

Sin/Cos

Customer-provided I/O cable for standard I/O connections such as Start, Stop, SLS Request.

(1) Terminate shield to functional earth at drive end. See page

52

.

39


Two Encoders with a Kinetix 6000 or Kinetix 7000 Drive

Kinetix 6000 or

Kinetix 7000

Drive

Encoder 2


Motor Feedback

Connector Kit

2090-K6CK-D15M

(2)


(1)

Logix Platform

(ControlLogix Controller Shown)

Motor with Embedded

Encoder 1

Sin/Cos

Encoder Cables

1585J-M8RB-2M5

Customer-provided I/O cable for standard I/O connections such as Start, Stop, SLS Request

(1) Refer to your encoder specifications to determine power supply requirements (5V or 9V).


In this example, only the feedback from Encoder 1 is monitored by the drive.

40




Monitoring Feedback from Two Encoders with a Kinetix 6000 or Kinetix 7000 Drive

Kinetix 6000 or

Kinetix 7000

Drive

Motor Feedback

Connector Kit

2090-K6CK-D15M

Auxiliary Feedback

Connector Kit

2090-K6CK-D15F

Encoder Cables

1585J-M8RB-2M5

(1)

Encoder 2


Motor with Embedded

Encoder 1

Sin/Cos


In this example, feedback from both encoders is monitored by the drive.

41


Encoder Cable

Specifications

To connect the MSR57P, use the 1585J-M8RB-2M5 cable available from

Rockwell Automation.

1585J-M8RB-2M5 Cable

2.5 m Cable

Catalog Number

1585J-M8RB-2M5

Connection to

MSR57P Relay

7

8

9

5

6

3

4

1585J-M8RB-2M5 Flying-Lead Wires

Pin Number Wire Color

1

2

White/Orange

Orange

White/Blue

Blue

Green

White/Brown

White/Green

Brown

Bare

(1) Terminate encoder shield to functional earth at the drive.

Connection to

Encoder

Connection to Drive or Power Supply

Signal

GND

Vcc

A1-/SIN1-REF

A1+/SIN1+

NC

B1-/COS1-REF

NC

B1+/COS1+

Shield (case)

(1)

Feedback Cable

Connections for Kinetix

2000, Kinetix 6000, Kinetix

7000 and Ultra3000 Drives

To connect your MSR57P relay to a Kinetix drive, review the connector options and compatible cable and motor types listed in the following tables.

Connector Options for Connecting Motor and Auxiliary Feedback

Connection Option

Low-profile connectors for

Kinetix 6000 and

Kinetix 7000 Drives

Low-profile connectors for

Kinetix 2000 Drives

Flying lead cable at

Ultra3000 drive end with one of these three kits.

Connector Kit

Catalog Number

2090-K6CK-D15M

2090-UXBK-D15xx

2090-K6CK-D15F

2090-K2CK-D15M

Description

Motor feedback connector kit

15-pin panel-mounted breakout board kit

Auxiliary feedback connector kit

Motor feedback connector kit

2090-K2CK-COMBO Motor, auxiliary, and I/O feedback connector kit

2090-UXBK-D15xx 15-pin panel-mounted breakout board kit

2090-UXBB-DM15

2090-UXBK-D15xx

2090-UXCK-D15

15-pin drive-mounted breakout board

15-pin panel-mounted breakout board kit

15-pin (high-density D-shell) drive connector kit

Using this Type of Cable

Refer to the table of Motor Feedback Cables for

Specific Motor/Feedback Combinations .

User-supplied flying-lead cable.





42



Motor Feedback Cables for Specific Motor/Feedback Combinations

Ultra3000

2098-DSD-xxx

2098-DSD-HVxxx

2098-DSD-HVxxx

—

2098-DSD-xxx

2098-DSD-xxx

2098-DSD-HVxxx

2098-DSD-xxx

2098-DSD-HVxxx

Compatible Drives

(1)

Kinetix 2000 Kinetix 6000 Kinetix 7000

2093-AC05-MPx

2093-AMxx

2094-ACxx-Mxx-S

2094-AMxx-S

—

—

2094-BCxx-Mxx-S

2094-BMxx-S

—

—

2094-BCxx-Mxx-S

2094-BMxx-S

—

Motor Series

MPL-Axxxx-M/S

MPL-Bxxxx-M/S

—

2093-AC05-MPx

2093-AMxx

2093-AC05-MPx

2093-AMxx

—

2093-AC05-MPx

2093-AMxx

—

—

2094-ACxx-Mxx-S

2094-AMxx-S

2094-ACxx-Mxx-S

2094-AMxx-S

2094-BCxx-Mxx-S

2094-BMxx-S

2094-ACxx-Mxx-S

2094-AMxx-S

2094-BCxx-Mxx-S

2094-BMxx-S

2099-BMxx-S

—

—

—

—

—

1326AB-Bxxxx-M2L

1326AB-Bxxxx-S2L

MPL-B5xxx-M/S,

MPL-B6xxx-M/S,

MPL-B8xxx-M/S,

MPL-B9xxx-M/S

MPL-A3xxx-H

MPL-A4xxx-H

MPL-A45xxx-H

MPL-Axxxx-V/E

MPF-Axxxx-M/S

MPS-Axxxx-M/S

MPL-Bxxxx-V/E

MPF-Bxxxx-M/S

MPS-Bxxxx-M/S

MPL-A15xxx-H

MPL-A2xxx-H

MPL-B15xxx-H

MPL-B2xxx-H

Feedback Type

Multi-turn high-resolution absolute or single-turn high-resolution encoder

Incremental encoder


Incremental encoder or

Flying-Lead

Feedback Cable

2090-XXxFMP-Sxx

(2) or

(3)

2090-XXNFMF-Sxx

(non-flex)

(4) or

2090-CFBM4DF-CDAFxx

(continuous-flex)

(4)

2090-XXNFMF-Sxx

(non-flex)

(4)

2090-CFBM4DF-CDAFxx

(continuous-flex)

(4)

Pinout

Page 44

Page 47

Page 49

— — — 2099-BMxx-S

HPK-series

High-resolution encoder

2098-DSD-xxx

2098-DSD-xxx

2098-DSD-HVxxx

2093-AC05-MPx

2093-AMxx

2093-AC05-MPx

2093-AMxx

—

2094-ACxx-Mxx-S

2094-AMxx-S

2094-ACxx-Mxx-S

2094-AMxx-S

2094-BCxx-Mxx-S

2094-BMxx-S

—

—

—

TLY-Axxxx-H

MPAS-Axxxx-V/A

MPAS-Bxxxx-V/A

Incremental encoder


2090-

CFBM6DF-CBAAxx

2090-XXNFMF-Sxx

(non-flex)

(4)

or

2090-CFBM4DF-CDAFxx

(continuous-flex)

(4)

Page 50

Page 47

Page 49

(1) Refer to the Kinetix Motion Control Selection Guide, publication GMC-SG001 for detailed information on the compatibility of specific drive and motor combinations.

(2) For Bulletin MPL motors equipped with bayonet-style connectors.

(3) These cables are available as non-flex (catalog number 2090-XXNFMP-Sxx) and continuous-flex (catalog number 2090-XXTFMP-Sxx).

(4) For Bulletin MPL motors equipped with DIN-style connectors.


43


Flying-lead Feedback Cable Pin-outs

Motors Using 2090-XXxFMP-Sxx Feedback Cable

MPL-Bxxx-M/-S, MPL-A5xxx-M/-S, and 1326AB-Bxxx-M2L/-S2L Motors

N

R

T

U

V

Motor Connector

Pin

(1)

A Black

B White/Black

C Red

D White/Red

E Green

F White/Green

K Gray

L White/Gray

Orange

Drive Side

Sine+

Sine-

Cos+

Cos-

Data+

Data-

EPWR_5V

ECOM

EPWR_9V

TS+

S1

S2

S3

Signal

8

Drive MF

Connector Pin

1

2

3

4

5

10

14

6

7

11

12

13

NC

NC

NC

NC

MSR57P Relay Side


Pin Wire Color

—> 4 Blue

—> White/Blue

—> 8 Brown

—>

—>

3

6

NC

NC

NC

1

White/Brown

White/Orange

—> 2 Orange

Signal

A1+/SIN1+

A1-/SIN1-REF

B1+/COS1+

B1-/COS1-REF

GND

Vcc

5 Green NC

7 White/Green NC

9

(2)

Bare Shield (case)

(1) Bayonet-style connector

(2) Make sure you ground the shield properly to the low profile connector along with the feedback cable. See the

diagram on page 52 .

44




MPL-A3xxx-M/-S, MPL-A4xxx-M/-S, and MPL-A45xxx-M/-S Motors

Motor Connector

Pin

(1)

A Black

Drive Side

Signal

B White/Black Sine-

C Red

U

V

D White/Red

E Green

Sine+

Cos+

Cos-

Data+

F White/Green Data-

K Gray

L White/Gray

EPWR_5V

ECOM

N Orange

R

T

EPWR_9V

TS+

S1

S2

S3

7

11

12

10

14

6

13

8

3

4

5

1

2

Drive MF

Connector Pin



Pin Wire Color Signal

—> 4 Blue

—> 3 White/Blue

A1+/SIN1+

A1-/SIN1-REF

—> 8 Brown B1+/COS1+

—> 6 White/Brown B1-/COS1-REF

NC

NC

—> 2 Orange Vcc

—> 1 White/Orange GND

NC

NC

NC

NC

NC

5 Green NC

7 White/Green NC

9

(2)

Bare Shield (case)

(1) Bayonet-style connector



45


MPL-A3xxx-H, MPL-A4xxx-H, and MPL-A45xxx-H Motors

U

V

Motor Connector

Pin

(1)

A Black

C Red

D White/Red

E Green

N Orange

R

T

Drive Side

Signal

AM+

B White/Black AM-

BM+

BM-

IM+

F White/Green IM-

K Gray

L White/Gray

EPWR_5V

ECOM

EPWR_9V

TS+

S1

S2

S3

Drive MF

Connector Pin

1

2

3

4

5

10

14

6

7

11

12

13

8




—> 4 Blue

—> 3 White/Blue

A1+/SIN1+

A1-/SIN1-REF



NC

NC

—> 2 Orange Vcc


NC

NC

NC

NC

NC

5 Green NC

7 White/Green NC

9

(2)

Bare Shield (case)

(1) ITT Cannon connector

(2) Make sure you ground the shield properly to the low profile connector along with the feedback cable. See the diagram on page

52 .

46




Motors Using 2090-XXNFMF-Sxx or 2090-CFBM4DF-CDAFxx Feedback Cable

MPL-B15xxx-V/-E, MPL-B2xxx-V/-E, MPF/MPS-Bxxx-M/-S, MPF-A5xx-M/-S

Motors and MPAS-Bxxxx-VxxSxA Linear Stages

Motor Connector

Pin

(1)

1 Black

9 Gray

Drive Side

10 White/Gray ECOM

11 Orange EPWR_9V

13

15

16

17

Sine+

2 White/Black Sine-

3 Red Cos+

4 White/Red Cos-

5 Green Data+

6 White/Green Data-

EPWR_5V

TS+

S1

S2

S3

Signal

11

12

13

14

6

7

8

4

5

10

1

2

3

Drive MF

Connector Pin

—>




4 Blue

—> 3 White/Blue

—> 8 Brown

—> 6 White/Brown

NC

NC

A1+/SIN1+

A1-/SIN1-REF

B1+/COS1+

B1-/COS1-REF

NC


—> 2 Orange

NC

NC

NC

NC

5 Green

7 White/Green

9

(2)

Bare

Vcc

NC

NC

Shield (case)

(1) DIN Connector



47


MPL-A15xxx-V/-E, MPL-A2xxx-V/-E, MPF/MPS-A3xx-M/-S, MPF/MPS-A4xx-M/-S,

MPF/MPS-A45xx-M/-S, MPS-A5xx-M/-S Motors and MPAS-Axxxx-VxxSxA Linear

Stages

Motor Connector Pin

(DIN Connector)

Signal

1 Black

Drive Side

2 White/Black Sine-

5 Green

10 White/Gray

11 Orange

13

15

16

17

3 Red

4 White/Red

Sine+

Cos+

Cos-

Data+

6 White/Green Data-

9 Gray EPWR_5V

ECOM

EPWR_9V

TS+

S1

S2

S3

Drive MF

Connector Pin




—> 4 Blue A1+/SIN1+ 1

2

3

4

5

10

14

6

7

11

12

13

8

—>

—> 8 Brown

A1-/SIN1-REF

B1+/COS1+


NC

NC

—> 2 Orange

—>

3

1

NC

NC

NC

NC

NC

White/Blue

White/Orange

Vcc

GND

5 Green NC

7 White/Green NC

9

(1)

Bare Shield (case)



48




MPL-A15xxx-H, MPL-A2xxx-H, MPL-B15xxx-H, MPL-B2xxx-H Motors and

MPAS-A/Bxxxx-ALMx2C Linear Stages

Drive Side

Motor Connector

Pin (DIN

Connector)

Signal

1 Black AM+

2 White/Black AM-

3 Red

4 White/Red

5 Green

BM+

BM-

IM+

6 White/Green IM-

9 Gray EPWR_5V

10 White/Gray ECOM

11 Orange

13

15

16

17

EPWR_9V

TS+

S1

S2

S3

7

11

12

10

14

6

13

8

3

4

5

1

2

Drive MF

Connector Pin




—> 4 Blue

—> 3 White/Blue

—> 8 Brown

—> 6 White/Brown

NC

NC

—> 2 Orange Vcc


NC

NC

NC

A1+/SIN1+

A1-/SIN1-REF

B1+/COS1+

B1-/COS1-REF

NC

NC

5 Green

7 White/Green

9

(1)

Bare

NC

NC

Shield (case)


52

.

49


Motors Using 2090-CFBM6DF-CBAAxx Cables

TLY-Axxxx-H Motors

Motor Connector

Pin

9

10 White/Black AM-

11 Red

12 White/Red

13 Green

14 White/Green IM-

22 Gray EPWR_5V

23 White/Gray ECOM

15

17

19

24

Black

Drive Side

Signal

AM+

BM+

BM-

IM+

S1

S2

S3

Shield

Drive CN2

Connector

Pin

1

2

3

4

5

10

14

6

12

13

8



Pin Wire Color

—> 4 Blue

Signal

A1+/SIN1+

—> 3 White/Blue A1-/SIN1-REF



NC

NC

—> 2 Orange Vcc


NC

NC

NC


NC

NC

NC

5 Green NC

7 White/Green NC

9

(1)

Bare Shield (case)


52 .

50



Integrated Axis Module, Front View

(2094-BC02-M02-S is shown)

Wiring Low-profile Connector Kits

Low-profile connector kits (2090-K6CK-D

xxx) are suitable for motor feedback (MF), auxiliary feedback (AF), and I/O (IOD) connections on any Kinetix 6000 IAM or AM module or on a Kinetix 7000 Drive when used with an MSR57P relay.

Use Low-profile connector kit 2090-K2CK-D15M or

2090-K2CK-COMBO for Kinetix 2000 drives.

Kinetix 6000 Integrated Axis Module/Axis Module (MF connector) Example

Integrated Axis Module, Side View

(2094-BC02-M02-S is shown)


Bulletin 2090 (flying lead)

Feedback Cable with

K6CK-DM15Mxx Low-profile

Connector Kit

IMPORTANT

Motor Feedback (MF) Connector

Tightening the mounting screws is essential to ensure shield integrity of the low-profile connector covers with the drive feedback connector D-shells. Use 0.4 Nm (3.5 lb-in) torque.

For detailed information on connections and important wiring requirements regarding Kinetix 2000, Kinetix 6000, Kinetix 7000, and

Ultra3000 drives, please refer to these publications:

•


2093-UM001 .

•


2094-UM001 .

•

Kinetix 7000 High Power Servo Drive User Manual, publication

2099-UM001 .

•

Ultra3000 Digital Servo Drives Integration Manual, publication

2098-IN005 .

•

Ultra3000 Digital Servo Drives Installation Manual, publication

2098-IN003 .

•

System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001 .

51


Bare Wires

Wire Insulation

Foil Shield

Braided Shield

Outer Insulation

Bulletin 2090

Cable

Wiring (15-Pin) Flying-lead Feedback Cable Connections

15-pin (male) Motor Feedback

Low-profile Connector

15-pin (female) Auxiliary Feedback

Low-profile Connector

Mounting

Screws

Pin 10

Pin 5

Pin 1

Pin 15

Pin 11

Pin 6

Pin 1

Pin 5

Pin 10

Pin 6

Pin 11

Pin 15

Tie Wrap

Shield Clamp

Turn clamp over to hold small wires secure.

Exposed Braid under clamp

Bulletin 2090 Feedback Cable

Secure exposed shield under clamp for proper grounding.

1585J-M8RB-2M5 Cable

Feedback Connections for

PowerFlex 70 Drives

IMPORTANT

For detailed information in installing and connecting

PowerFlex 70 drives, including important wiring requirements, refer to these publications:

•

PowerFlex 70 User Manual, publication 20A-UM001 .

•

DriveGuard Safe-Off Option (Series B) for PowerFlex 40P and 70 AC Drives User Manual, publication PFLEX-UM003 .

•

Wiring and Grounding Guidelines for AC Drives, publication

DRIVES-IN001 .

52



Safe Off Board Terminal Block (Enhanced Control Only)

4 3 2 1

No. Signal

3 +24V dc

4 24V Common

Description

1 Monitor - N.C.

Normally closed contacts for monitoring relay status.

2 Common - N.C.

Maximum Resistive Load: 250V ac / 30V dc / 50 VA / 60 W

Maximum Inductive Load: 250V ac / 30V dc / 25 VA / 30 W

Connections for user supplied power to energize coil.

Encoder Interface Terminal Block (Enhanced Control Only)


1 6

4

5

2

3

PowerFlex 70 Side

Terminal

1

Signal

5-12V Power

(1)

6

CASE

Power Return

—>

Encoder B (NOT) —> 6

Encoder B

Encoder A (NOT) —> 3

Encoder A

Shield

—>

—>

—>

—>

1

8

4

9

Pin

2

(1) Jumper selectable +5/12V is available on 20A-ENC-1 Encoder Boards.


Color

Orange

Signal

Vcc

White/Orange

White/Brown

Brown

White/Blue

Blue

Bare

GND

B1-/COS1-

B1+/COS1+

A1-/SIN1-

A1+/SIN1+

Shield

53


3

4

5

6

1

2

3

4

5

6

1

2

Jumper Settings

Receive Voltage

= 12V

= 5V

= 12V

= 5V

Send Voltage

Set the jumper according to your encoder specifications.

Encoder Wiring Examples

These illustrations show examples of how to connect encoder power and encoder signals.

Encoder Power

Internal (Drive)

12V dc

(250 mA)

Common

External Source

To

Shield

External

Power

Source

To

Shield

Encoder Signal

Single-ended, Dual-channel

To Power Supply

Common

B (NOT)

B

A (NOT)

A

To Shield

3

4

5

6

1

2

Differential, Dual-channel

To Shield

B (NOT)

B

A (NOT)

A

54



Feedback Connections for

PowerFlex 700S Drives

Use the terminal connection information in the table to connect your

MSR57P relay to a PowerFlex 700S drive.

PowerFlex 700S Side

Terminal Signal

12 Power Common

11 POWER

10

9

8

7

6

5

4

3

2

1

REFSIN

+SIN

REFCOS

+COS

Shield

Shield

NC

NC

DATA+ (RS 485)

DATA- (RS 485)

—>

—>

—>

—>

—>

—>

—>

3

4

6

8

9

Pin

1

2

NC

NC

NC

NC


Color Signal

White/Orange GND

Orange Vcc

White/Blue A1-/SIN1-

Blue A1+/SIN1+

White/Brown B1-/COS1-

Brown

Bare

B1+/COS1+

Shield

IMPORTANT

For detailed information in installing and connecting

PowerFlex 700S drives, including important wiring requirements, refer to the PowerFlex 700S Phase II Drive User

Manual, publication 20D-UM006 .

Connect a Configuration

Device

If you are using a HIM to configure the relay, see Appendix C

for information on connecting a HIM and setting parameters with the keypad.

If you are using software to configure the relay, see

Appendix D

for information on connecting to a personal computer and using the software.


55


56


Introduction

Inputs


Chapter

4

Speed Monitoring I/O Signals

This chapter describes the input and output signals of the speed monitoring relay.

Topic

Inputs

Outputs

Page

57

63

The MSR57P relay has five inputs capable of safety-certified dual-channel support. Each dual-channel input supports a specific safety function of the MSR57P relay: 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 (S11) and Test_Out_1 (S21), when not using the OSSD configuration.

The inputs can be configured for one of the following settings:

•

0 = Not used

•

1 = Dual-channel equivalent (2NC)

•

2 = Dual-channel equivalent 3 s (2NC 3s)

•

3 = Dual-channel complementary (1NC + 1NO)

•

4 = Dual-channel complementary 3 s (1NC + 1NO 3s)

•

5 = Dual-channel SS equivalent 3 s (2 OSSD 3s)

•

6 = Single channel (1NC).

IMPORTANT

Single-channel configuration (1NC) is not SIL CL3, 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 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.

57

Chapter 4 Speed Monitoring I/O Signals

When both channels are active, if one channel’s input terminal transitions from active to inactive and back to active, while the other channel’s input terminal remains active, both channel must go inactive at the same time before the evaluated status may return to ON. This condition is called ‘cycle inputs required’.

cycle inputs required

Channel 0

active in active

Channel 1

active in active

ON

Evaluated Status

If inputs are configured with the following dual channel settings, an

Input fault occurs if the inputs are discrepant for longer than 3 seconds or if a ‘cycle inputs required’ condition exists lor longer than

3 seconds.

•


•


•


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.

•


•


For all input settings except Dual-channel SS equivalent 3 s

(2 OSSD 3s), if one or two channels are connected to a 24V DC source other than terminals S11 and S21, a fault occurs.

I/O faults are Stop Category Faults, which initiate the configured Safe

Stop Type. I/O faults are latched until the relay is successfully reset.

For more information on I/O faults, see Chapter 12

,

Troubleshoot the

MSR57P Relay

.

58


Dual-channel

Equivalent

Safety Device

Single

Channel

Safety Device

Speed Monitoring I/O Signals Chapter 4

When using a dual-channel complementary (1NC + 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).

Safety Input Wiring Examples

MSR57P Relay

MSR57P Relay

Test_Out_0 (S11)

Test_Out_1 (S21)

Test_Out_0 (S11)

Test_Out_1 (S21)

Dual-channel

Complementary

Safety Device

Input 0

Input 1

MSR57P Relay

Test_Out_0 (S11)

Test_Out_1 (S21)

Input 0

Input 1

MSR57P Relay

Input 0

Input 1

Solid State

Safety

Device

Not Connected

Not Connected

GND

OSSD1

OSSD2

Test_Out_0 (S11)

Test_Out_1 (S21)

A2, Common

Input 0

Input 1

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.

Function

Input 0 = Channel 0

Input 1 = Channel 1

Safe

Stop

(SS_In)

S12

S22

Safe

Limited

Speed

(SLS_In)

S52

S62

Terminals

Door

Monitoring

(DM_In)

Enabling

Switch

Monitoring

(ESM_In)

Lock

Monitoring

(LM_In)

S32

S42

S72

S82

X32

X42

Short-circuits of the input loop to ground or 24V will be detected. For dual-channel inputs, cross loops will also be detected.


59


Safe Stop Input (SS_In)

The SS_In input is intended for connection to an E-Stop device.

The SS_In input must be active to initiate Safe Stop monitoring. If the

SS_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 SS_In input is connected to the Safe

Stop (SS_Out) output of an upstream MSR57P relay.

Safe Limited Speed Input (SLS_In)

The SLS_In input is used to connect to a switch whose OFF state requests Safe Limited Speed monitoring.

If Safe Limited Speed monitoring is configured, the SLS_In input is monitored from the time of a 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 relay.

In a cascaded configuration, the SLS_In input is connected to the Safe

Stop (SS_Out) output of an upstream MSR57P relay.

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 speed monitoring relay is configured as a master device with door monitoring. When the MSR57P relay is configured as a slave in a cascaded system, its DM_In input is connected to the Door

Control output (DC_Out) of the upstream MSR57P relay.

60




Enabling Switch Monitor Input (ESM_In)

The ESM_In input is intended to be connected to an enabling switch.

The speed monitoring relay uses the ESM_In input as a 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.

See Safe Limited Speed with Enabling Switch Monitoring Mode on page 112

and

Safe Limited Speed with Door Monitoring and Enabling

Switch Monitoring Mode on page 115

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 relay initiates the configured Safe Stop Type.

See Chapter 12 , Troubleshoot the MSR57P Relay

, 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.

61


Reset Input (Reset_In)

The Reset input is for reset and monitoring of the safety circuit. The reset input can be configured for automatic, manual, or manual monitored reset types.

Wire the S34 reset input terminal to the 24V DC output terminal, Y1, depending on the configured reset type, as shown.

Reset

Y1

Manual

S34

Reset_In

Reset

Y1

Manual

Monitored

S34

Reset_In

IMPORTANT

If you configure the relay for automatic reset, wiring of the S34 reset input terminal is not required.

62



Reset Loop Input (RL_In)

The RL_In input is used to monitor the normally-closed contacts of the contactors that are used to remove power or to the feedback contacts from a drive Safe-off circuit. The signal level of the RL_In may be used to qualify a successful reset of the speed monitoring relay. For feedback loop or external device monitoring and reset qualification, wire the reset loop input, Y2 to the 24V dc output terminal Y1, as shown.

Y1 Y2

RL_In

Outputs

The MSR57P relay has four safety control outputs and four diagnostic outputs. The outputs have various output current capabilities, depending on function.

See the specifications in

Appendix A to verify your power

requirements.


Safety Control Outputs

Safe Stop Output (SS_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 to a slave device.

For SS_Out to SS_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

If you disable pulse-testing on this output, the achievable SIL,

Category, and PL ratings of your entire MSR57P safety system are reduced.

63


SS_Out to SS_In Connections for Multi-axis Applications

MSR57P Master

SS_Out_Ch0 SS_Out_Ch1

34 44

S12 S22

SS_In_Ch0 SS_In_Ch1

MSR57P Slave

S12 and S22 are configured as 2

OSSD inputs.

For more information on multi-axis configurations, see Cascaded

Configurations

starting on page

125

.

Alternately, the first SS_Out output may be used to signal a programmable logic controller (PLC) or a drive that a Safe Stop has been requested.

If the SS_In is ON (closed) and a successful Safe Stop Reset is performed, the SS_Out output is turned ON. If Lock Monitoring is not enabled or the door control logic state is Unlock, the SS_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 SS_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.

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 relay is successfully reset.


Chapter 12 , Troubleshoot the

MSR57P Relay

.

64




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 relays in multi-axis applications. For

SLS_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 pulse-tested when the P73

[SLS Out Mode] parameter is configured for pulse-testing.

IMPORTANT



For a single unit system or the last unit in a cascaded system, the

SLS_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 (SS_In).

For the first or middle units in a cascaded system, the SLS_Out is intended to be connected to the Safe Limited Speed input (SLS_In) of the next relay in the cascaded system. This lets one SLS switch enable

Safe Limited Speed on all axes at the same time.

SLS_Out to SLS_In Connections for Multi-axis Applications

MSR57P Master

SLS_Out_Ch0 SLS_Out_Ch1

68 78

S52 S62

SLS_In_Ch0 SLS_In_Ch1

MSR57P Slave

65


For more information on multi-axis configurations, see Cascaded

Configurations

starting on page

125

.

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 relay is in a 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 relay is in the safe state.

See the Safe Limited Speed Status Only Mode on page 119 for more

information.




MSR57P Relay

.

Door Control Output (DC_Out)

You can use this output for door control in single-device and multi-axis systems. This output attempts to maintain last state when a fault occurs. When no faults are present, it can be used in combination with the fault status as a standard status indication to a programmable controller to identify that the system is at Safe Limited

Speed or Standstill Speed.

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 only Unlocked when motion is verified to be at

Standstill Speed or Safe Limited Speed.

66




Door Control, Door Monitoring, and Lock Monitoring

Test_Out_Ch0 Test_Out_Ch1 Test_Out_Ch0 Test_Out_Ch1

S11 S21 S11 S21

DC_Out_Ch0

51

TIP

S32 S42

DM_In_Ch0 DM_In_Ch1

Door Status

X32 X42

LM_In_Ch0 LM_In_Ch1

Locking Mechanism Status

52

DC_Out_Ch1

Check your interlock switch for internal jumpers before installation.



Chapter 12

,

Troubleshoot the

MSR57P Relay

.

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 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 relay 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.

67


Door Control Cascading Outputs

MSR57P Master

DC_Out_Ch0 DC_Out_Ch1

51 52

S32 S42

DM_In_Ch0 DM_In_Ch1

MSR57P Slave

Only these wiring configurations, shown below, are supported for the

Door Control output.

Door Control Output Wiring

No

Load

Bi-polar

Load

Single-ended

Load

+24V DC +

+ +

2 Channel

Source

(1)

+

Door Control Sourcing Output 51 51 51 51

Load

Door Control Sinking Output

+24V DC Common

52

-

52

-

52

-

Load

52

-

(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 I/O.

Input Circuit Input Circuit

(2)

Short-circuits of the output loop to ground or 24V will be detected.

For cascaded outputs, cross loops will also be detected.

The outputs are pulse-tested when the P74 [Door Out Mode] parameter is configured for pulse-testing.

IMPORTANT



68




Motion Power Output (MP_Out)

The MP_Out output is used to remove power from the drive power circuits. It is compatible with Safe-off enabled drives or applications that use standard drives with external contactors.

The safe state for this signal in all cases is OFF.

The MP_Out output is turned OFF during the Safe State and in

Disabled mode.

IMPORTANT

Terminal 13 must be connected to a 24V dc source to provide power to terminals 14 and 24.

The MP_Out output is turned ON by a successful reset to initiate safe speed monitoring. If Lock Monitoring is enabled and the door control logic state is Lock, the MP_Out output does not turn ON until the door has been locked via the Door Control output (DC_Out) and the Lock

Monitor input (LM_In) has been verified as ON. If Lock Monitoring is disabled or the door control logic state is Unlock, the MP_Out signal turns ON immediately when the SS_In turns ON.

This table describes the ON/OFF operation of the MP_Out output based on the configured Safe Stop Type.

Safe Stop Type

Safe Torque Off

Safe Stop 1

Safe Stop 2

(1)

MP_Out Status

The MP_Out output is OFF while the relay is executing the Safe

Stop.

The MP_Out output is ON while the Safe Stop is executing, unless a fault occurs. It is OFF once Standstill Speed is reached.

The MP_Out output remains ON while the Safe Stop is executing and after Standstill Speed has been reached unless a fault occurs during the Safe Stop.

(1) With or without Standstill Checking.

The outputs are pulse-tested when the P71 [MP Out Mode] parameter is configured for pulse-testing.

IMPORTANT



69


For applications using standard drives with external contactors, wire the output as shown.

MP_Out_Ch0 MP_Out_Ch1

Power Supply for

Outputs 14 and 24

14 24 13

K1 K2

+24V dc

GND

If an error is detected on either channel of the dual-channel output, a

Motion Power Out Fault (MP Out Flt) occurs. An MP Out Flt places the relay in the Safe State. The fault is latched until a power cycle.



MSR57P Relay

.

Diagnostic Outputs

These signals are diagnostic status signals and are not safety signals.

Fault_Status Output

The Fault_Status output may be used to signal that a fault has been detected by the speed monitoring relay. The Fault_Status output is turned ON if a fault occurs.

The Fault_Status output is turned OFF by a successful reset to initiate safe speed monitoring.

Stop_Command Output

This signal is OFF when the MSR57P is in the safe state.

The Stop_Command output turns OFF at the start of the Stop Delay

[Max Stop Time] when the relay is executing the configured Safe Stop

Type and the Stop Monitoring Delay [Stop Mon Delay], if configured, has expired.

The Stop_Command output is turned ON by a successful reset to initiate safe speed monitoring.

70




The Stop_Command output is typically connected to the drive or standard PLC input card to request motion to stop. The

Stop_Command output may also be used to signal a PLC or drive that the configured Stop Delay [Max Stop Time] has begun.

SLS_Command Output

The SLS_Command output is used to signal that Safe Limited Speed monitoring operation has been requested.

When Safe Limited Speed monitoring is not configured or the operating mode is Disabled, the SLS_Command is always OFF.

System Status

The relay is in the Safe State.

Safe Limited Speed monitoring is configured but inactive

(SLS_In is closed).

A Safe Limited Speed Monitoring Delay [LimSpd Mon Delay] is in progress.

Safe Limited Speed monitoring is active (SLS_In is open).

The configured Safe Stop Type has been initiated.

Standstill Speed has been reached at the end of a Safe Stop.

SLS_Command State

OFF

OFF

ON

ON

Hold Last State

OFF

The SLS_Command output is turned ON by a successful Safe Stop

Reset to initiate active Safe Limited Speed monitoring or to initiate a

Safe Limited Speed Monitoring Delay [LimSpd Mon Delay].

This output is typically connected to the drive or standard PLC input card to request that the speed of a machine be reduced.

SLS_Status Output

The SLS_Status output is ON when Safe Limited Speed monitoring is active and the Safe Limited Speed Monitoring Delay [LimSpd Mon

Delay], if configured, has expired.

71


72


Chapter

5

General Relay and Feedback Monitoring

Configuration

Introduction

This chapter describes the general and feedback configuration settings that must be configured to operate the speed monitoring relay.

Topic

Cascaded Configuration

Safety Mode

Reset Type

Reset Qualification

Overspeed Response Time

Language Code

Max Display Speed

General Parameter List

Feedback Monitoring

Feedback Parameter List

Page

73

74

74

75

75

79

80

80

81

86

Cascaded Configuration

The speed monitoring relay may be used in single-axis or multi-axis applications. The P20 [Cascaded Config] parameter indicates the relay’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 relays are system masters.

See Chapter 8

,

Slave Modes for Multi-axis Cascaded Systems

for more information on cascaded configurations.


73

Chapter 5 General Relay and Feedback Monitoring Configuration

Safety Mode

The relay can be configured to operate in one of 11 user-selectable

Safety Modes, based on combinations of the safety functions the relay supports. The modes, except for Disabled, are described in detail in subsequent chapters of this manual.

For These Modes

Master, Safe Stop (Safe Stop)

Master, Safe Stop with Door Monitoring (Safe Stop DM)

See

Chapter 6 , Safe Stop and Safe

Stop with Door Monitoring

Modes

Master, Safe Limited Speed (Lim Speed)

Master, Safe Limited Speed with Door Monitoring

(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)

Chapter 7

,

Safe Limited Speed

(SLS) Modes

Master, Safe Limited Speed Status Only (Lim Spd Stat)

Slave, Safe Stop (Slv Safe Stp)

Slave, Safe Limited Speed (Slv Lim Spd)

Slave, Safe Limited Speed Status Only (Slv Spd Stat)

Chapter 8 , Slave Modes for

Multi-axis Cascaded Systems

Reset Type

74

The Reset Type can be configured 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

Reset input does not require wiring for automatic reset configurations.

See

Safe Stop Reset on pages 95 and

103

, and Safe Limited Speed

Reset

on pages

107

,

111 , and

113 for details on how the Reset Type

affects Safe Stop and Safe Limited Speed operation.

ATTENTION

For all types of reset (automatic, manual, or manual monitored), if a 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

The Safe Stop Reset does not provide safety-related restart 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.


Reset Qualification

General Relay and Feedback Monitoring Configuration Chapter 5

Reset qualification can be configured for Safe Stop Resets. If reset qualification is configured, the MSR57P relay checks the feedback path to make sure it is a closed circuit before the reset can occur.

The P23 [Reset Loop] parameter indicates whether the Reset Loop input (RL_In) is used to qualify a successful Safe Stop Reset. If the P23

[Reset Loop] parameter equals Qualified by RL_In, the RL_in input must be ON (closed) if the motion power output (MP_Out) is in the

OFF state. If the RL_In is OFF (open circuit) when the MP_Out output is OFF, a RL Fault is detected. An RL Fault is a Stop Category Fault which will prevent the reset from being successful.

If the MP_Out output is ON, the RL_In input is not required for qualification.

IMPORTANT

Reset Qualification applies only to Safe Stop Reset and not to Safe Limited Speed Reset.

Overspeed Response Time

The P24 [OverSpd Response] parameter setting determines the maximum reaction time from an overspeed event to the initiation of the configured Safe Stop Type. The safety reaction time from an overspeed event that triggers a Safe Stop Type, to the actual initiation of that Safe Stop Type, is equal to the value of the P24 [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.


75


Speed Resolution Accuracy for Rotary Systems

Encoder Resolution 16 lines/rev

OverSpeed Response Time

(OverSpd Response)

Setting

84

132

228

420

42

48

60

1

156.253

78.127

39.063

19.532

9.766

4.883

2.441




Setting

132

228

420

42

48

60

84

1

19.535

9.767

4.884

2.442

1.221

0.610

0.305




Setting

84

132

228

420

42

48

60

1

2.503

1.252

0.626

0.313

0.156

0.078

0.039

10

2.533

1.267

0.633

0.317

0.158

0.079

0.040

10

19.565

9.782

4.891

2.446

1.223

0.611

0.306

10

156.283

78.142

39.071

19.535

9.768

4.884

2.442

Speed Resolution Accuracy (RPM)

Speed (RPM)

100

156.583

1000

159.583

78.292

39.146

19.573

9.786

4.893

2.447

79.792

39.896

19.948

9.974

4.987

2.493

10,000

189.583

94.792

47.396

23.698

11.849

5.924

2.962


Speed (RPM)

100 1000

19.865

9.932

4.966

2.483

22.865

11.432

5.716

2.858

1.242

0.621

0.310

1.429

0.715

0.357


Speed (RPM)

100

2.833

1000

5.833

1.417

0.708

0.354

0.177

0.089

0.044

2.917

1.458

0.729

0.365

0.182

0.091

10,000

35.833

17.917

8.958

4.479

2.240

1.120

0.560

10,000

52.865

26.432

13.216

6.608

3.304

1.652

0.826

100,000

489.583

244.792

122.396

61.198

30.599

15.299

7.650

93,750

332.031

166.016

83.008

41.504

20.752

10.376

5.188

12,000

42.500

21.250

10.625

5.313

2.656

1.328

0.664

76






Setting

84

132

228

420

42

48

60

1

2.445

1.222

0.611

0.306

0.153

0.076

0.038




Setting

132

228

420

42

48

60

84

1

0.837

0.418

0.209

0.105

0.052

0.026

0.013




Setting

84

132

228

420

42

48

60

1

0.503

0.252

0.126

0.063

0.031

0.016

0.008

10

2.475

1.237

0.619

0.309

0.155

0.077

0.039


Speed (RPM)

100

2.775

1000

5.775

1.387

0.694

0.347

0.173

0.087

0.043

2.887

1.444

0.722

0.361

0.180

0.090

0.217

0.108

0.054

0.027

0.014

10

0.867

0.433


Speed (RPM)

100 1000

1.167

0.583

4.167

2.083

0.292

0.146

0.073

0.036

0.018

1.042

0.521

0.260

0.130

0.065

10

0.533


Speed (RPM)

100

0.833

1000

3.833

0.267

0.133

0.067

0.033

0.017

0.008

0.417

0.208

0.104

0.052

0.026

0.013

1.917

0.958

0.479

0.240

0.120

0.060

10,000

35.775

17.887

8.944

4.472

2.236

1.118

0.559

4000

14.167

7.083

3.542

1.771

0.885

0.443

0.221

2400

8.500

4.250

2.125

1.063

0.531

0.266

0.133

11,718.75

41.504

20.752

10.376

5.188

2.594

1.297

0.648


77


Speed Resolution Accuracy for Linear Systems

Encoder Resolution 500 lines/mm

OverSpeed Response

Time (OverSpd

Response) Setting

84

132

228

420

42

48

60

0.01

0.083

0.042

0.021

0.010

0.005

0.003

0.001



Time (OverSpd


132

228

420

42

48

60

84

0.01

0.042

0.021

0.010

0.005

0.003

0.001

0.001



Time (OverSpd


84

132

228

420

42

48

60

0.01

0.008367

0.004183

0.002092

0.001046

0.000523

0.000261

0.000131

0.1

0.084

0.042

0.021

0.010

0.005

0.003

0.001

Speed Resolution Accuracy (lines/mm)

Speed (mm/s)

1

0.087

10

0.117

0.043

0.022

0.011

0.005

0.003

0.001

0.058

0.029

0.015

0.007

0.004

0.002

100

0.417

0.208

0.104

0.052

0.026

0.013

0.007

0.1

0.042

0.021

0.011

0.005

0.003

0.001

0.001


Speed (mm/s)

1 10

0.045

0.023

0.011

0.006

0.075

0.038

0.019

0.009

0.003

0.001

0.001

0.005

0.002

0.001

100

0.375

0.188

0.094

0.047

0.023

0.012

0.006

0.1

0.008667


Speed (mm/s)

1

0.011667

10

0.041667

0.004333

0.002167

0.001083

0.000542

0.000271

0.000135

0.005833

0.002917

0.001458

0.000729

0.000365

0.000182

0.020833

0.010417

0.005208

0.002604

0.001302

0.000651

40

0.141667

0.070833

0.035417

0.017708

0.008854

0.004427

0.002214

400

1.417

0.708

0.354

0.177

0.089

0.044

0.022

200

0.708

0.354

0.177

0.089

0.044

0.022

0.011

78



Encoder Resolution 20,000 lines/mm


Time (OverSpd


84

132

228

420

42

48

60

0.01

0.002117

0.001058

0.000529

0.000265

0.000132

0.000066

0.000033


Speed (mm/s)

0.1

0.002417

1

0.005417

0.011208

0.000604

0.000302

0.000151

0.000076

0.000038

0.002708

0.001354

0.000677

0.000339

0.000169

0.000085

10

0.035417

0.017708

0.008854

0.004427

0.002214

0.001107

0.000553

For example, an encoder resolution 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.

80.135

100

119.865

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:

Speed Resolution =

(RPM)

15000

(OverSpd Response - 36) x Feedback Resolution

+

Speed (RPM) x 0.02

(OverSpd Response - 36)

For linear systems, the conversion from Overspeed Response Time

[OverSpd Response] to mm/s is:

Speed Resolution =

(mm/s)

250

(OverSpd Response - 36) x Feedback Resolution

+

Speed (RPM) x 0.02

(OverSpd Response - 36)

Language Code


The relay can be configured for any one of seven language options:

English, French, Spanish, Italian, German, Portuguese, and Dutch.

79


Max Display Speed

The configuration tool, HIM or software, can display a speed value based on the output speed of encoder 1 [Fbk 1 Speed]. Use the P26

[Max Display Spd] parameter to determine the scaling for the display.

General Parameter List

Set these parameters to configure general relay operation.

Parameter

20 Cascaded

Config

Description

Defines whether the speed monitoring relay is a single unit or if it occupies a first, middle, or last position in a multi-axis cascaded system.

21 Safety Mode Defines the primary operating mode of the speed monitoring safety functions.

22

23

Reset Type

Reset Loop

Defines the type of reset used by the safety relay.

Defines whether the Reset Loop input (RL_In) input is used to qualify a Safe Stop Reset.

Setting

Default: 0 = Single Unit (Single)

Options: 0 = Single Unit (Single)

1 = Cascaded First Unit (Multi First)

2 = Cascaded Middle Unit (Multi Mid)

3 = Cascaded Last Unit (Multi Last)

Default: 1 = Master, Safe Stop (Safe Stop)

Options: 0 = Disabled

1 = Master, Safe Stop (Safe Stop)

2 = Master, Safe Stop with Door Monitoring

(Safe Stop DM)

3 = Master, Safe Limited Speed (Lim Speed)

4 = Master, Safe Limited Speed with

Door Monitoring (Lim Speed DM)

5 = Master, Safe Limited Speed with

Enabling Switch Control (Lim Speed ES)

6 = Master, Safe Limited Speed with Door

Monitor and Enabling Switch (LimSpd DM ES)

7 = Master, Safe Limited Speed Status Only

(Lim Spd Stat)

8 = Slave, Safe Stop (Slv Safe Stp)

9 = Slave, Safe Limited Speed (Slv Lim Spd)

10 = Slave, Safe Limited Speed Status Only

(Slv Spd Stat)

Default: 2 = Manual Monitored (Monitored)

Options: 0 = Automatic

1 = Manual

2 = Manual Monitored (Monitored)

Default: 0 = Always qualified (Disable)

Options: 0 = Always qualified (Disable)

1 = Qualified by RL_In (Enable)

80



Parameter

24 OverSpd

25

Response

Language

Code

26 Max Display

Spd

Description

Configuration for the feedback interface sampling rate.

Setting

Default: 0 = 42 ms

Determines the language of the parameter display.

Options: 0 = 42 ms

1 = 48 ms

2 = 60 ms

3 = 84 ms

4 = 132 ms

5 = 228 ms

6 = 420 ms

Default: 0 = English

Options: 0 = English

1 = French

2 = Spanish

3 = Italian

4 = German

5 = Reserved

6 = Portuguese

7 = Reserved

8 = Reserved

9 = Dutch

Determines scaling for P33 [Fbk 1 Speed] process display value.

Default: 1800

Range: 1

…

65,535 rpm or mm/s

Feedback Monitoring

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 discrepancy checking that is performed between the two encoders.

IMPORTANT

Both feedback devices must be encoders.

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.


81


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 speed monitoring relay are based on encoder 1.

IMPORTANT

The resolution of encoder 1 should always be equal to or higher than the resolution of encoder 2.

Feedback Polarity

Configure the direction of polarity to be the same as the encoder or reversed by using the P30 [Fbk 1Polarity] parameter. The relay 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 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 one encoder, the single encoder input is processed redundantly and crosschecked in a 1oo2 architecture. The speed, direction, and stopped status are derived from the single encoder by the 1oo2 architecture.

Dual Encoders

If the P27 [Fbk Mode] parameter is set to two encoders, each encoder input is processed by a single channel and crosschecked in a 1oo2 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.

82




Speed and direction checks are affected by these parameters:

•

Dual Feedback Speed Ratio, P39 [Fbk Speed Ratio]

•

Dual Feedback Position Tolerance, P41 [Fbk Pos Tol]

•

Dual Feedback Speed Discrepancy Tolerance, P40 [Fbk Speed

Tol]

Dual Feedback Speed Ratio

The Dual Feedback Speed Ratio, P39 [Fbk Speed Ratio], parameter defines the ratio of the expected speed of encoder 2 divided by the expected speed of encoder 1. This parameter configures the anticipated gearing between encoder 1 and encoder 2.

If P27 [Fbk Mode] equals 0 (one 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 1’s 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 could be either rotary (rev) or linear (mm). Any combination of rotary and linear units for the two encoders is allowed.

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

The relative position discrepancy difference is reset to zero at each Safe Stop Reset.

Discrepancy checking is performed only while the Feedback Mode

[Fbk Mode] is equal to one of the following values.

Feedback Mode, P27 [Fbk Mode] Parameter Setting

1 Dual encoder with speed and position discrepancy checking

3 Dual encoder with position discrepancy checking

83


This table defines the legal values for each Feedback Mode value.

Feedback Mode, P27 [Fbk Mode]

Values

0 One encoder

1 Dual encoder with speed and position discrepancy

Dual Feedback Position Discrepancy

Tolerance, P41 [Fbk Pos Tol] Legal Values

0

1…65,535 in degrees (rotary encoders) or mm

(linear encoders) relative to the resolution of encoder 1

0 2 Dual encoder with speed discrepancy checking


1…65,535 in degrees (rotary encoders) or mm

(linear encoders) relative to the resolution of encoder 1

If an illegal value is detected, an Invalid Configuration Fault occurs and the relay remains in the Safe State.

Con

IMPORTANT

When setting discrepancy tolerances, consider that configuring a high gear ratio between encoder 1 and encoder 2 will result in a very small movement of encoder 2 translating into a very large movement from the encoder 1 perspective. This could lead to unexpected dual feedback position faults.

Dual Feedback Speed Discrepancy Tolerance

The Dual Feedback Speed Discrepancy Tolerance,

P40 [Fbk Speed Tol], parameter defines 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 only performed while the Feedback Mode is equal to one of the following values.

Feedback Mode, P27 [Fbk Mode] Parameter Setting

1

2

Dual encoder with speed and position

Dual encoder with speed discrepancy checking

84



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]

Values

0 One encoder

1

2

Dual encoder with speed and position discrepancy checking

Dual encoder with speed discrepancy checking


Dual Feedback Speed Discrepancy

Tolerance, P40 [Fbk Speed Tol]

0

0.1…6553.5 in rev/min (rotary encoders) or mm/s (linear encoders)

0.1…6553.5 in rev/min (rotary encoders) or mm/s (linear encoders)

0

If an illegal value is detected, an Invalid Configuration Fault occurs and the relay remains in the Safe State.

The encoder must be specified to operate across this complete range or larger.

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 Setting

Range

Trip Zone

May Trip

No Trip

May Trip

Trip Zone

5

4.5…5.5V

< 4.5V

4.5…4.75V

4.75…5.25V

5.25…5.5V

>5.5V

9

7…12V

< 7V

7…7.4V

7.4…11.4V

11.4…12.0V

> 12.0V

12

11…14V

< 11V

11…11.6V

11.6…13.3V

13.3…14.0V

>14.0V

Your power supply must stay within the No Trip range.

14

11.5…15V

< 11.5V

11.5…12.25V

12.25…14.75V

14.75…15.5V

>15.5V


85


Feedback Fault

The allowable frequency of feedback input signals is limited. The speed monitoring relay monitors feedback signals whenever the relay configuration is valid and the Safety Mode is not configured as

Disabled.

Maximum Frequency Encoder Type

Sine/cosine

Incremental

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, a Feedback_

x Fault (Safe State Fault) occurs.

Feedback Parameter List

To define the type of feedback used by the relay, set these parameters.

Feedback Parameters

Parameter

27 Fbk Mode

28 Fbk 1 Type

29 Fbk 1 Units

30 Fbk 1 Polarity

31 Fbk 1

Resolution

Description

Selects the number of encoders and the type of discrepancy checking.

Selects the type of feedback for encoder

1.

Selects linear or rotary feedback for encoder 1.

Defines the direction polarity for encoder

1.

Counts/Revolution.

Setting

Default: 0 = 1 encoder (Single Fbk)

Options: 0 = 1 encoder (Single Fbk)

1 = 2 encoders (Dual S/P Chk)

2 = 2 encoders speed discrepancy checking (Dual Spd Chk)

3 = 2 encoders position discrepancy checking (Dual Pos Chk)

Default: 1 = TTL (Incremental)

Options: 0 = Sine/cosine

1 = TTL (Incremental)

Default: 0 = Rotary (Rev)

Options: 0 = Rotary (Rev)

1 = Linear (mm)

Default: 0 = Same as encoder (Normal)

Options: 0 = Same as encoder (Normal)

1 = Reversed

Default: 1024

Range: 1

…

65,535 pulses/revolution or pulses/mm based on rotary or linear configuration defined by the

P29 [Fbk 1 Units] parameter

86



Feedback Parameters

Parameter

33 Fbk 1 Speed

34 Fbk 2 Units

(1)

35 Fbk 2 Polarity

Description

32 Fbk 1 Volt Mon Encoder 1 voltage to be monitored.

Displays the output speed of encoder 1.

Selects rotary or linear feedback system for encoder 2.

Defines the direction polarity for encoder

2.

Setting

Default: 0 = Voltage not monitored

Options: 0 = Voltage not monitored

5 = 5V ±10%

9 = 7

…

12V

12 = 11

…

14V

14 = 11.5

…

15.5V

Range: -214,748,364.8

…

214,748,364.7 rpm or mm/s based on rotary or linear configuration defined by




1 = Linear (mm)



1 = Reversed

36 Fbk 2

Resolution

37 Fbk 2 Volt Mon

38 Fbk 2 Speed

(1)

Counts/Revolution.

Encoder 2 voltage to be monitored.

Not valid when P27 [Fbk Mode] = 0

(1 encoder).


39 Fbk Speed Ratio Dual Feedback Speed Ratio.

Default: 0

Range: 0

…

65,535 pulses/revolution o pulses/mm based on rotary or linear configuration defined by the




5 = 5V ±10%

9 = 7

…

12V

12 = 11

…

14V

14 = 11.5

…

15.5V

Range: -214,748,364.8

…

214,748,364.7 rpm or mm/s

40 Fbk Speed Tol Dual Feedback Speed Discrepancy

Tolerance.

41 Fbk Pos Tol

Defines the ratio of the expected speed of encoder 2 divided by the expected speed of encoder 1


(1 encoder).

Acceptable difference in speed between

[Fbk 1 Speed] and [Fbk 2 Speed].

Acceptable difference in position between encoder 1 and encoder 2.

Default:

Range:

0.0000

0.0001

…

10,000.0

ratio based on rotary or linear configuration defined by the


Default:

Range:

Default:

Range:

0

0

…

6553.5 rpm or mm/s units are based on rotary or linear configuration defined by the P29 [Fbk 1 Units] parameter

0

0

…

65,535 deg or mm units are based on rotary or linear configuration defined by the P29 [Fbk 1 Units] parameter

(1) Read-only.


87


88


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

Safe Stop Mode

Safe Stop Parameter List

Safe Stop Wiring Example

Safe Stop with Door Monitoring Mode

Safe Stop with Door Monitoring Parameter List

Safe Stop with Door Monitoring Wiring Example

Page

89

99

102

102

103

104

When properly configured for Safe Stop, the relay 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 relay recognizes motion as stopped when the encoder 1 feedback signals indicate the system has reached the configured Standstill Speed. Once Standstill Speed has been reached, the Door Control output (DC_Out) is set to Unlock.

In addition to setting the Standstill Speed, you configure both the Stop

Delay [Max Stop Time], the period during which deceleration occurs after a Safe Stop is initiated, and an optional Stop Monitoring Delay

[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

Stop Monitoring Delay can only be configured for Safe Stop 1 or Safe

Stop 2.

When properly configured for Safe Stop mode, the relay also monitors for faults and initiates the appropriate reaction. If the fault is a Safe

State Fault, the relay enters the Safe State. If the fault is a Stop

Category Fault, the relay initiates the configured Safe Stop Type.


89

Chapter 6 Safe Stop and Safe Stop with Door Monitoring Modes

90

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 SS_In input from ON to OFF or by the occurrence of a Stop Category Fault.

While the relay executes the configured Safe Stop Type, it continues to monitor the system. If a Stop Category Fault is detected, the relay sets the outputs to a faulted state, but allows for the door control logic to be set to Unlock if the feedback signals indicate the configured

Standstill Speed has been reached.

Safe Torque Off with Standstill Checking

This Safe Stop Type lets you access the hazard area immediately after motion is detected as stopped rather than waiting until a specific time has elapsed.

When Safe Torque Off with Standstill Checking is initiated, power is removed from the Motion Power output (MP_Out) immediately and the configured Stop Delay [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 [Max Stop

Time], door control logic is set to Unlock.

If the Standstill Speed is not detected by the end of the configured

Stop Delay [Max Stop Time] a Stop Speed Fault occurs and the door control logic remains set to Lock until Standstill Speed is detected. A

Stop Speed Fault removes power from the Motion Power output

(MP_Out) immediately.

Timing Diagram for Safe Torque Off with Standstill Checking

Stop Request

Door Control

Output Unlock

Stop Delay

Safe Torque-off Active

Standstill Speed

SS_In Input

SS_Out Output

MP_Out Output

Stop_Command Output

Time

DC_Out Output

(1)

(1) DC_Out output shown configured as Power to Release. See Door Control on page 97

for more information.



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 SS_In input from ON to OFF, the relay does not initiate the configured Stop Delay

[Max Stop Time] until after the optional Stop Monitoring Delay [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 [Max Stop Time] begins immediately, regardless of whether a

Stop Monitoring Delay [Stop Mon Delay] is configured.

Deceleration monitoring takes place during the Stop Delay [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 [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 [Max Stop Time], a Stop Speed Fault occurs.

For Safe Stop 1, power is removed from the Motion Power output

(MP_Out) when Standstill Speed is reached. For Safe Stop 2, power is not removed.

91


Timing Diagram for Safe Stop 1

Stop

Request

Stop Monitoring

Delay

Stop Delay

Deceleration

Tolerance

Safe Torque-off

Active

Standstill

Speed

SS_In Signal

SS_Out Signal

MP_Out Signal

Stop_Command Signal

Time

DC_Out Output

(1)

(1) DC_Out Output shown configured as Power to Release. See

Door Control on page 97


Timing Diagram for Safe Stop 2

Stop

Request

Stop Monitoring

Delay

Stop Delay

Deceleration

Tolerance

Standstill Position and Standstill

Speed Monitoring

Standstill

Speed

SS_In Input

SS_Out Output

MP_Out Output

Stop_Command Output

Time

DC_Out Output

(1)

(1) DC_Out output shown configured as Power to Release. See Door Control on page 97


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 [Max

Stop Time] begins. Door control logic is set to Unlock when the

Stop Delay [Max Stop Time] expires, regardless of speed.

92



Timing Diagram for Safe Torque Off without Standstill Checking

Stop

Request

Stop Delay

Door Control

Output Unlock

Safe Torque-off

Active

SS_In Input

SS_Out Output

MP_Out Output

Stop_Command Output

DC_Out Output

(1)

(1) DC_Out output shown configured as Power to Release. See

Door Control on page 97


Time

TIP

All Stop Types require an encoder to be connected.

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 relay 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.


93


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, after standstill has been reached and the door is unlocked, a Motion After Stopped Fault occurs. This type of fault results in the MSR57P relay 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

[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 [Max 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.

94



Deceleration Monitoring

(

Δ v) = Deceleration Tolerance% x Deceleration Reference Speed

Stop Delay

Actual speed measured at the start of the Stop Delay [Max Stop Time].


0

Time

TIP

To account for system overshoot and drive delay, choose

Δ v 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 [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, no faults are present, and, if reset qualification (P23 [Reset Loop]) is configured, the qualification is met.

ATTENTION

For all types of reset (automatic, manual, or manual monitored), if a 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

The Safe Stop Reset does not provide safety-related restart 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.

95


When an SS Reset is requested, all diagnostic tests that can be performed prior to outputs being energized are performed prior to a successful SS Reset. If a diagnostic test can only be performed when outputs are energized, the test is performed immediately following the

SS Reset.

IMPORTANT

An SS Reset is not attempted if the Wait No Stop attribute is set (1), indicating that the HIM stop button was pressed or a stop command was issued from DriveExecutive or DriveExplorer software.

The Wait No Stop attribute is bit 26 of the P68 [Guard Status] parameter.

IMPORTANT

An SS Reset is not attempted if the Wait SS Cyc attribute is set

(1), indicating that an error occurred.

The Wait SS Cyc attribute is bit 25 of the P68 [Guard Status] parameter.

Automatic

If the SS Reset is configured as automatic, the relay always attempts a reset if it is in the Safe State or has initiated a Safe Stop Type. The reset is attempted when the SS_In input transitions from OFF to ON or if SS_In is ON at power-up.

Manual

If the SS Reset is configured as manual, the reset occurs when the

SS_In input is ON and the Reset_In input is ON.

Manual Monitored

A manual monitored reset requires an OFF to ON to OFF transition of the Reset_In input.

If at any time before the closing and opening of the Reset_In input, the SS_In input transitions from ON to OFF, the reset is aborted.

96




Faults

If a fault occurs, other than an Invalid Configuration Fault or an ESM

Monitoring Fault, the SS_In input must turn OFF and ON again to reset the Wait SS Cyc bit before a successful 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 relay’s location in the system

[Cascaded Config] and Door Control Output Type [Door Out Type] determine whether the Door Control output (DC_Out) is locked or unlocked during normal operation.

When the DC_Out output has no faults, the relay is configured for

Safe Stop, and the relay 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. If the Safe Stop Type is Safe Torque Off without Standstill Checking, door control logic is set to Unlock when the Stop Delay [Max Stop Time] has elapsed, regardless of speed.

Configuration

You configure the type of door control for each speed monitoring safety relay in the system.

Configure Door Control Output Type

P57 [Door Out Type] Settings

Single and Last Units First and Middle Units

0 = Power to Release Not valid

1 = Power to Lock

2 = Cascading

(2 Ch Sourcing)

Not valid

2 = Cascading

(2 Ch Sourcing)

DC_Out Status and Lock State

ON = Door is unlocked.

OFF = Door is locked.

ON = Door is locked.

OFF = Door is unlocked.

ON = Door is unlocked.

OFF = Door is locked.

97


A single relay or last relay 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. First or middle relays in a cascaded system must be configured as 2 Ch Sourcing.

ATTENTION

When the DC_Out output is configured as Power to Lock (P57

[Door Out Type] = 1), the safe state and faulted state is

Unlocked.

Make sure that this possibility does not create a hazard.

IMPORTANT

When the DC_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 DC_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 DC_Out output, will force the DC_Out output to its safe state (OFF) regardless of the status of door control logic:

•

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 DC_Out output can maintain its integrity, both door control logic and the DC_Out output hold last state. If hold last state cannot be maintained, faults may turn the

DC_Out output OFF.

ATTENTION

If a fault occurs while the door is unlocked, it may remain unlocked. Make sure that this possibility does not create a hazard.

98



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 (DC_Out) is in the Lock state, except for the 5 seconds following the DC_Out output’s 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).

A Lock Monitoring Fault is a Stop Category Fault, which initiates the configured Safe Stop Type.

Safe Stop Parameter List

To configure the relay for Safe Stop mode, set these parameters in addition to the General and Feedback parameters listed on pages

80

and 86 .

Safe Stop Parameters

Parameter

21 Safety Mode

Description

Defines the primary operating mode of the speed monitoring safety functions.

Setting

Setting: 1 = Safe Stop

44 Safe Stop Input Configuration for Safe Stop input (SS_In).

Default: 1 = Dual-channel equivalent

45 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.

Options: 0 = Not used






6 = Single channel (1NC)

Default: 0 = Safe Torque Off with Standstill Checking (Torque Off)

Options: 0 = Safe Torque Off with Standstill Checking (Torque Off)

1 = Safe Stop 1

2 = Safe Stop 2

3 = Safe Torque Off without Standstill Checking

(Trq Off NoChk)

Default: 0 46 Stop Mon Delay Defines the monitoring delay between the request for a Safe Stop and the start of the Stop Delay [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.

Range: 0

…

6553.5 s

If the Safe Stop Type is Safe Torque Off with or without Speed Checking, the Stop

Monitoring Delay must be 0 or a Invalid

Configuration Fault occurs.


99



Parameter Description

47 Max Stop Time Stop Delay

Defines the maximum stop delay time that is used when the Safe Stop function is initiated by a stop type condition.

48 Standstill Speed Defines the speed limit that is used to declare motion as stopped.

Setting

Default: 0

Range: 0

…

6553.5 s

49 Standstill Pos

Not valid for Safe Torque Off without

Standstill Checking.

Standstill Position Window.

Defines the position limit in encoder 1 degrees or mm, that will be tolerated after a Safe Stop condition has been detected.

Default: 0.001

Range: 0.001

…

65.535 rpm or mm/s based on rotary or linear configuration defined by encoder 1 feedback configuration P29 [Fbk 1 Units] parameter

Default: 10

Range: 0

…

65,535 degrees (360° = 1 revolution) or mm based on rotary or linear configuration defined by P29 [Fbk 1 Units] parameter

Not valid for Safe Torque Off without

Standstill Checking.

50 Decel Ref Speed Decel Reference Speed.

Determines deceleration rate to monitor for Safe Stop 1 or Safe Stop 2.

Default: 0

Range: 0

…

65,535 rpm or mm/s based on rotary or linear configuration defined by


Default: 0

Range: 0

…

100% of Decel Ref Speed

51 Stop Decel Tol Decel Tolerance.

This is the acceptable tolerance above the deceleration rate set by the Decel Ref

Speed parameter.

57 Door Out Type Defines the lock and unlock state for the door control output (DC_Out).

59 Lock Mon

Enable

Door Out Type can be 0 or 1 only for a single-axis system or for the last unit in a multi-axis system. The first and middle units of a multi-axis system must be configured as cascading (2).

Lock Monitoring can only be enabled when the speed monitoring safety relay is a single unit or as the first unit in a multi-axis system (P20 [Cascaded Config] equals 0 or 1).

Default: 0 = Power to release (Pwr to Rel)

Options: 0 = Power to release (Pwr to Rel)

1 = Power to lock (Pwr to Lock)

2 = Cascaded (2 Ch Sourcing)

Default: 0 = Disabled


1 = Enabled

100




Parameter

71

72

74

MP Out Mode

SS Out Mode

Door Out Mode

Description

60 Lock Mon Input Configuration for the Lock Monitor input

(LM_In).

Defines whether the MP_Out output is pulse-tested.

(1)

Defines whether the SS_Out output is pulse-tested.

(1)

Defines whether the DC_Out output is pulse-tested.

(1)

Setting

Default: 0 = Not used





4 = Dual-channel complementary 3 s

(1NC + 1NO 3s)



Default: 0 = Pulse Test

Options: 0 = Pulse test

1 = No pulse test



1 = No pulse test



1 = No pulse test

(1) If pulse-testing is turned off for any output, the SIL, Category, and PL rating is reduced for the entire MSR57P safety system.


101


Safe Stop Wiring Example

This example illustrates safe stop wiring.

Master, Safe Stop (First or Single Unit)

SS

Request

E-Stop

800FM-MT44

800F-MX02V

+24V DC

A1 S11 S21

Pulse Test

Outputs

S12

SS

Input

S22 S52

SLS

Input

S62 S72 S82

ESM

Input

51 52

Door Lock

Control

X32

Lock

Monitor

RJ45

Encoder

Input 1

(1)

A2

SLS

Status

Fault

Status

Y35

RJ45

Encoder

Input 2

Y37

SS

Output

34 44

DPI

MSR57P Relay

Isolated Diagnostics and Power

RL

Feed

Reset Feedback

SLS

Cmd

Stop

Cmd

GND

24V

DC

Y1 S34 Y2 Y33 Y32 Y30 Y31

X42

S32 S42

Door

Monitor

Motion

Power Out

14 24

A1

13

SLS

Output

68 78

Reset

800FM-F6MX10

Safe Stop to next module (optional)

Aux. Signals to PLC

(1) For encoder wiring, see


on page

42

.

(2) Digital input 4. Proper configuration is required for inputs 1, 2, 4, and 6 on the PowerFlex 70 Drive.

(3) 24V DC Com must be at the same potential as the drive common because of the encoder signal.

Safe Stop with Door

Monitoring Mode

102

9 24V DC

8 DC Comm

7 Dig Comm

1 Stop

PowerFlex 70

AC Drive with

DriveGuard

1

3

2 Start

4 SLS Input

(2)

Gate Control

Power Supply

Safe Off Option

4

2

6 Enable

Gate

Control

Circuit

Remove jumpers

L1 L2 L3

Motor

24V DC Com

(3)

When properly configured for Safe Stop with Door Monitoring, the relay monitors the Safe Stop input (SS_In) and initiates the configured

Safe Stop Type upon deactivation of the input as described in Safe

Stop Mode on page 89 .

In addition, the speed monitoring relay verifies through monitoring the Door Monitor input (DM_In) that the device controlled by the

Door Control output (DC_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 speed monitoring relay 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 MSR57P relay 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_In) transitions from

ON to OFF.

IMPORTANT

If your application uses Lock Monitoring without Door

Monitoring, you must use some means to make sure that the

Lock Monitor is not stuck at a Lock indication.

SS Reset

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 speed monitoring relay initiates the configured Safe Stop Type.


Monitoring Parameter List

Parameter

21 Safety Mode

To configure the relay for Safe Stop with Door Monitoring, set the DM

Input parameter in addition to the Safe Stop parameters listed on page

99

.

Setting Description


Setting: 2 = Master, Safe Stop with Door Monitoring

(Safe Stop DM)

58 DM Input Configuration for the Door Monitor input

(DM_In).

Default: 0 = Not used (1)








(1) You must configure this parameter with a non-zero value in this mode.


103



Monitoring Wiring Example

This example illustrates wiring for safe stop with door monitoring.

Master, Safe Stop with Door Monitoring (First or Single Unit)

+24V DC

SS

Request

Power to

Release

11 21 33

E-Stop

800FM-MT44

800F-MX02V

A1

A2

41 51

12 22 34

42 52

TLS3-GD2

440G-T27260

Remove two internal jumpers

L1 L2 L3

A1 S11 S21

Pulse Test

Outputs

S12 S22

SS

Input

S52 S62

SLS

Input

S72

ESM

Input

S82 51 52

Door Lock

Control

X32 X42

Lock

Monitor

(3)

RJ45

Encoder

Input 1

(1)

A2

RJ45

Encoder

Input 2

SLS Fault

Status Status

Y35 Y37

SS

Output

34 44

MSR57P Relay

DPI

RL

Feed

Reset

Feedback


SLS

Cmd

Stop

Cmd

GND

24V

DC

Y1 S34 Y2 Y33 Y32 Y30 Y31 14

S32

24

S42

Door

Monitor

Motion

Power Out

A1

SLS

Output

68

13

78

Reset

800FM-F6MX10

9 24V DC

8 DC Comm

7 Dig Comm

1 Stop

PowerFlex 70

AC Drive with

DriveGuard

1

3

2 Start

4 SLS Input

(2)

Gate Control

Power Supply

Safe Off Option

4

2

6 Enable

Gate

Control

Circuit

Remove jumpers


Motor

Aux. Signals to PLC


Encoder Cable Specifications on page 42

.


(3) Lock monitoring connections are not required for Safe Stop with Door Monitoring mode operation.


24V DC Com

(4)

104


Chapter

7

Safe Limited Speed (SLS) Modes

Introduction

This chapter describes the Safe Limited Speed (SLS) modes of safety operation and provides a list of configuration parameters along with wiring examples for each mode.

Topic

Safe Limited Speed (SLS) Mode

Safe Limited Speed Parameter List

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


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

112

112

114

115

115

Page

105

108

109

110

111

118

119

119

121

122

Safe Limited Speed (SLS)

Mode

When properly configured for Safe Limited Speed, the relay performs

Safe Limited Speed (SLS) monitoring functions in addition to the Safe

Stop function described in Safe Stop Mode on page 89 . When the Safe

Limited Speed input (SLS_In) is OFF, feedback velocity is monitored and compared against a configurable Safe Speed Limit.


105

Chapter 7 Safe Limited Speed (SLS) Modes

If the feedback velocity is below the Safe Speed Limit during Safe

Limited Speed monitoring, the Door Control output (DC_Out) is unlocked after the Safe Limited Speed Monitoring Delay [Lim Spd Mon

Delay], if configured, has expired.

ATTENTION

Make sure that an unlocked door does not result in a hazardous situation.

If a Safe Stop Type is initiated or a fault occurs while the relay is actively monitoring Safe Limited Speed, door control remains unlocked. The safe state of the SLS_In input may allow the door be unlocked.

If the measured velocity exceeds the Safe Speed Limit, an SLS Fault occurs and the configured Safe Stop Type is initiated. An optional Safe

Limited Speed Monitoring Delay [Lim Spd 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 relay does not monitor for Safe Limited Speed and the measured velocity can be above or below the Safe Speed Limit.

ATTENTION

If the Reset Type is configured as Automatic, Safe Limited

Speed monitoring is disabled when the SLS_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.

Safe Speed

Limit

If you configure a Safe Limited Speed Monitoring Delay [Lim Spd Mon

Delay], the delay begins when Safe Limited Speed monitoring is requested by the SLS_In transition from ON to OFF. The relay 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 relay initiates the configured Safe Stop Type.

Timing Diagram for Safe Limited Speed (SLS)

Safe Limited Speed

Request

SLS Monitoring

Delay

Safe Limited Speed

Active

SLS Fault

Acceptable

Speed Range

Time

106



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 Safe Limited

Speed Monitoring Delay [Lim Spd Mon Delay], if one is configured.

When an SLS Reset occurs, the relay 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 relay checks that no faults are present and verifies that the SLS_In input is ON (closed circuit) before the reset is performed.

When the input is OFF, Safe Limited Speed monitoring takes place, after the SLS Monitoring Delay [Lim Spd Mon Delay], if one is configured. An SLS Reset can be requested 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 relay 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 ON, an SLS_Reset is attempted.

If the SLS_In transitions from OFF to ON and the Reset_In input is

OFF, the relay 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 SLS_Reset. If at any time, the SLS_In input transitions back to OFF, the SLS_Reset is aborted.

Manual Monitored

When the SLS_In input transitions from OFF to ON, the relay waits for an OFF to ON to OFF transition of the Reset_In input before an

SLS_Reset is attempted. If at any time during this period, the SLS_In input transitions back to OFF, the SLS_Reset is aborted.

107


Safe Limited Speed

Parameter List

To configure the relay for Safe Limited Speed monitoring, set these parameters in addition to the Safe Stop parameters listed beginning on page

99

.

Parameter

21 Safety Mode

Description


52 Lim Speed Input Configuration for the Safe Limited Speed input

(SLS_In).

53

55

LimSpd Mon

Delay

Safe Speed

Limit

Defines the Safe Limited Speed Monitoring

Delay between the SLS_In ON to OFF transition and the initiation of the Safe Limited Speed

(SLS) monitoring.

Defines the speed limit that will be monitored in Safe Limited Speed (SLS) mode.

Setting

Setting: 3 = Master, Safe Limited Speed (Lim Speed)









Default: 0

Range: 0

…

6553.5 s

73 SLS Out Mode Defines whether the SLS_Out output is pulse-tested.

(1)

Default: 0

Range: 0

…

6553.5 rpm or mm/s based on rotary or linear configuration defined by the encoder 1 feedback configuration




1 = No pulse test



108



Safe Limited Speed Wiring

Example

This example illustrates safe limited speed wiring.

Master, Safe Limited Speed (First or Single Unit)

SS

Request

E-Stop

800FM-MT44

800F-MX02V

SLS Request

800FM-KM23

800F-MX02V

+24V DC

A1 S11 S21

Pulse Test

Outputs

S12 S22

SS

Input

S52

SLS

Input

S62 S72 S82

ESM

Input

51 52

Door Lock

Control

X32

RJ45

Encoder

Input 1

(1)

A2

SLS Fault

Status Status

Y35 Y37

RJ45

Encoder

Input 2

SS

Output

34 44

DPI

MSR57P Relay


RL

Feed

Reset Feedback

SLS

Cmd

Stop

Cmd

GND

24V

DC

Y1 S34 Y2 Y33 Y32 Y30 Y31

X42

Lock

Monitor

S32 S42

Door

Monitor

Motion

Power Out

14 24

A1

SLS

Output

13

68 78

Reset

800FM-F6MX10


Aux. Signals to PLC

(1) For encoder wiring, see Encoder Cable Specifications on page 42

.



9 24V DC

8 DC Comm

7 Dig Comm

1 Stop

PowerFlex 70

AC Drive with

DriveGuard

1

3

2 Start

4 SLS Input

(2)

Gate Control

Power Supply

Safe Off Option

4

2

6 Enable

Gate

Control

Circuit

Remove jumpers

L1 L2 L3

Motor

24V DC Com

(3)


109


Safe Limited Speed with

Door Monitoring Mode

When properly configured for Safe Limited Speed with Door

Monitoring, the relay performs Safe Limited Speed (SLS) monitoring functions as described in

Safe Limited Speed (SLS) Mode on page 105

in addition to the Safe Stop functions as described in

Safe Stop Mode

on page

89 .

In addition, the speed monitoring relay verifies through monitoring the Door Monitor input (DM_In) that the device controlled by the

Door Control output (DC_Out) is in the expected state. If the door is monitored as opened when it should be closed, the speed monitoring relay 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 (SLS_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 Stop Category Fault, which initiates the configured Safe Stop Type.

If Safe Limited Speed Monitoring is active (SLS_In input is OFF) and the relay has verified a safe speed condition, the door can be unlocked and opened.

ATTENTION

Make sure that an unlocked door does not result in a hazardous situation.

If a Safe Stop Type is initiated or a fault occurs while the relay 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.

110





Monitoring, the relay must be monitoring motion (SLS_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 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

Parameter List

To configure the relay for Safe Limited Speed with Door Monitoring, set the DM Input parameter in addition to the Safe Stop parameters

listed on page 99 and the Safe Limited Speed parameters listed on

page 108

.

Parameter

21

58

Safety Mode

DM Input

Description


Configuration for the Door Monitor input

(DM_In).

Setting

Setting: 4 = Master, Safe Limited Speed with Door

Monitoring (Lim Speed DM)








6 = Single-channel equivalent (1NC)



111


SLS with Door Monitoring

Wiring Example

This example illustrates wiring for SLS with door monitoring.

Master, Safe Limited Speed with Door Monitoring (First or Single Unit)

+24V DC

SS

Request

E-Stop

800FM-MT44

800F-MX02V

SLS Request

800FM-KM23

800F-MX02V

Power to

Release

11 21 33

A1

A2

41 51

12 22 34

42 52

TLS3-GD2

440G-T27260


L1 L2 L3

A1 S11 S21

Pulse Test

Outputs

S12

SS

Input

S22 S52

SLS

Input

S62 S72 S82

ESM

Input

51 52

Door Lock

Control

X32 X42

Lock

Monitor

(3)

RJ45

Encoder

Input 1

(1)

A2

SLS Fault

Status Status

Y35

RJ45

Encoder

Input 2

Y37

SS

Output

34 44

DPI

MSR57P Relay

RL

Feed

Reset Feedback


SLS

Cmd

Stop

Cmd

GND

24V

DC

Y1 S34 Y2 Y33 Y32 Y30 Y31

S32 S42

Door

Monitor

Motion

Power Out

14 24

A1

13

SLS

Output

68 78

Reset

800FM-F6MX10


Aux. Signals to PLC



on page

42 .


(3) Lock monitoring connections are not required for Safe Limited Speed with Door Monitoring mode operation.


9 24V DC

8 DC Comm

7 Dig Comm

1 Stop

PowerFlex 70

AC Drive with

DriveGuard

1

3

2 Start

4 SLS Input

(2)

Gate Control

Power Supply

Safe Off Option

4

2

6 Enable

Gate

Control

Circuit

Remove jumpers

Motor

24V DC Com

(4)


Enabling Switch

Monitoring Mode

112

When properly configured for Safe Limited Speed with Enabling

Switch Monitoring, the relay performs Safe Limited Speed (SLS) monitoring functions as described in

Safe Limited Speed (SLS) Mode on page 105

in addition to the Safe Stop functions as described in Safe

Stop Mode on page 89 .

In addition, the relay monitors the Enabling Switch Monitor input

(ESM_In) after the Safe Limited Speed Monitoring Delay [LimSpd Mon

Delay] times out. The ESM_In input must be ON when the delay times out and Safe Limited Speed monitoring begins, or an ESM Monitoring




Fault occurs. An ESM Monitoring Fault is a Stop Category Fault, which initiates the configured Safe Stop Type.

IMPORTANT

When Safe Limited Speed Monitoring is inactive, the ESM_In input is not monitored.

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), perform an SLS Reset (cycle the

SS_In input) to reset the relay and begin monitoring for Safe Limited

Speed again. This is the only case where the SS_In input does not need to be cycled to reset the relay following a fault.

While Safe Limited Speed is being monitored after the SLS Monitoring

Delay [LimSpd Mon Delay] times out, if the SLS_In input is ON and an

SLS Reset occurs, the ESM_In is not monitored.

ATTENTION

Make sure that the SLS_In input cannot transition to ON while 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 an SS Reset when the SLS_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.

113


SLS with Enabling Switch


To configure the relay 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

99 and the Safe Limited Speed

parameters listed on page 108 .



54 Enable SW Input Configuration for the Enabling Switch input

(ESM_In).

Setting

Setting: 5 = Master, Safe Limited Speed with Enabling

Switch Control (Lim Speed ES)


(1)









114



SLS with Enabling Switch


SS

Request

This example illustrates wiring for SLS with enabling switch monitoring.

Master, Safe Limited Speed with Enabling Switch Monitoring (First or Single Unit)

+24V DC

SLS Request

800FM-KM23

800F-MX02V

Power to

Release

11 21 33

2 4

E-Stop

800FM-MT44

800F-MX02V

1

440J-N21TNPM

Enabling Switch

3

A1

A2

41 51

12 22 34

42 52

TLS3-GD2

440G-T27260


L1 L2 L3

A1 S11 S21

Pulse Test

Outputs

S12 S22

SS

Input

S52 S62 S72 S82

SLS

Input

ESM

Input

51 52

Door Lock

Control

X32 X42

Lock

Monitor

(3)

RJ45

Encoder

Input 1

(1)

A2

SLS Fault

Status Status

Y35 Y37

RJ45

Encoder

Input 2

SS

Output

34 44

DPI

MSR57P Relay


RL

Feed

Reset Feedback

SLS

Cmd

Stop

Cmd

GND

24V

DC

Y1 S34 Y2 Y33 Y32 Y30 Y31

S32

A1

S42

Door

Monitor

Motion

Power Out

14 24

13

SLS

Output

68 78

Reset

800FM-F6MX10

9 24V DC

8 DC Comm

7 Dig Comm

1 Stop

PowerFlex 70

AC Drive with

DriveGuard

1

3

2 Start

4 SLS Input

(2)

Gate Control

Power Supply

Safe Off Option

4

2

6 Enable

Gate

Control

Circuit

Remove jumpers


Motor

Aux. Signals to PLC


.


(3) Lock monitoring connections are not required for Safe Limited Speed with Enabling Switch Monitoring mode operation.


24V DC Com

(4)


Door Monitoring and

Enabling Switch

Monitoring Mode


Monitoring and Enabling Switch Monitoring, the relay performs Safe

Limited Speed (SLS) monitoring functions as described on page

105 , in

addition to the Safe Stop functions as described in Safe Stop Mode on page 89 .

The relay also monitors both the Enabling Switch Monitor input

(ESM_In) and the Door Monitor input (DM_In).


115


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 using this mode.

1. Set the SLS_In input to OFF.

The Safe Speed Limit must not be exceeded after the Safe

Limited Speed Monitoring Delay [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 relay 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 enabling switch until the door is closed and you have disabled the SLS_In input by setting it to the ON or closed position.

3. Release the enabling switch.

4. Press the reset button, if manual reset is configured.

The machine resumes normal run operation.

ATTENTION

Make sure that the SLS_In input cannot transition to ON while 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.

116




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, which initiates the configured 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 Safe Stop Type.

ATTENTION

While Safe Limited Speed Monitoring is active, the ESM_In input is not monitored until the DM_In input is detected as OFF.

Make sure that the ESM_In input is not relied upon for safety until the DM_In input has transitioned to OFF.

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.

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 relay initiates the configured 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 Safe Limited Speed Monitoring Delay [LimSpd Mon

Delay]. However, the DM_In input must be ON (door closed) during the delay or a Door Monitoring Fault occurs and the relay initiates the configured Safe Stop Type.

117


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 when the reset is requested by a transition of the SS_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 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 Safe Stop Type.

SLS with Door Monitoring and Enabling Switch


To configure the relay for Safe Limited Speed with Door Monitoring and Enabling Switch Monitoring, set the P58 [DM Input] and

P54 [ESM Input] parameters in addition to the Safe Stop parameters listed on page

99 and the Safe Limited Speed parameters listed on

page

108

.

Parameter

21

58

54

Safety Mode

DM Input

Enable SW Input

Description


Configuration for the Door Monitor input

(DM_In).

Setting

Setting: 6 = Master, Safe Limited Speed with Door

Monitor and Enabling Switch (LimSpd DM ES)


Configuration for the Enabling Switch input

(ESM_In).













4 = Dual-channel complementary 3 s (1NC + 1NO3s)




118



SLS with Door Monitoring and Enabling Switch


This example illustrates wiring for SLS with door monitoring and enabling switch monitoring.

Master, Safe Limited Speed with Door Monitoring and Enabling Switch Monitoring

(First or Single Unit)

+24V DC

SS

Request

SLS Request

800FM-KM23

800F-MX02V

Power to

Release

11 21 33

E-Stop

800FM-MT44

800F-MX02V

2

1

440J-N21TNPM

Enabling Switch

4

3

A1

A2

41 51

12 22 34

42 52

TLS3-GD2

440G-T27260


L1 L2 L3

A1 S11 S21

Pulse Test

Outputs

S12 S22

SS

Input

S52 S62

SLS

Input

S72

ESM

Input

S82 51 52

Door Lock

Control

X32 X42

Lock

Monitor

(3)

RJ45

Encoder

Input 1

(1)

A2 Y35 Y37

RJ45

Encoder

Input 2

SLS Fault

Status Status

SS

Output

34 44

DPI

MSR57P Relay


RL

Feed

Reset Feedback

SLS

Cmd

Stop

Cmd

GND

24V

DC

Y1 S34 Y2 Y33 Y32 Y30 Y31

S32

A1

S42

Door

Monitor

Motion

Power Out

14 24

13

SLS

Output

68 78

9 24V DC

8 DC Comm

7 Dig Comm

1 Stop

PowerFlex 70

AC Drive with

DriveGuard

1

3

2 Start

4 SLS Input

(2)

Gate Control

Power Supply

Safe Off Option

Reset

800FM-F6MX10

4

2

6 Enable

Gate

Control

Circuit

Remove jumpers


Motor

Aux. Signals to PLC

24V DC Com

(4)


.


(3) Lock monitoring connections are not required for Safe Limited Speed with Door Monitoring and Enabling Switch Monitoring mode operation.


Safe Limited Speed Status

Only Mode

When properly configured for Safe Limited Speed Status Only, the relay provides Safe Limited Speed status information in addition to the

Safe Stop functions as described in

Safe Stop Mode

on page

89

.

When the Safe Limited Speed input (SLS_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


119

Chapter 7 Safe Limited Speed (SLS) Modes 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 Safe Limited Speed Monitoring Delay [Lim

Spd Mon Delay] to delay the start of Safe Limited Speed monitoring. In this mode, Door Monitoring and Enabling Switch Monitoring are not available.

ATTENTION

When the relay is properly configured for Safe Limited Speed

Status Only mode, it will not automatically initiate a Safe Stop in the event of an overspeed condition.

Safe Speed

Limit

Safe Limited Speed monitoring is requested by a transition of the

SLS_In input from ON to OFF. If you configure a Safe Limited Speed

Monitoring Delay, the delay begins when Safe Limited Speed monitoring is requested by the SLS_In input transition from ON to

OFF. The relay begins monitoring for Safe Limited Speed when the delay times out. The SLS_Out output is ON if Safe Limited Speed monitoring is active and the speed is below the configured Safe Speed

Limit, considering hysteresis.

Timing Diagram for Safe Limited Speed Status Only

Safe Limited Speed

(SLS) Request

Safe Limited Speed

Active

SLS Monitoring

Delay

Low Threshold

(1)

Time

SLS_In

SLS_Out

(1) Low Threshold = (Speed Hysteresis/100) x Safe Speed Limit

120

Speed Hysteresis

The P56 [Speed Hysteresis] parameter provides hysteresis for the

SLS_Out output when the relay is configured for SLS Status Only and

Safe Limited Speed monitoring is active. The SLS_Out output is turned

ON if the speed is less than the Low Threshold, which equals {(Speed

Hysteresis/100) x Safe Speed Limit}. The SLS_Out output is turned OFF


Safe Limited Speed (SLS) Modes Chapter 7 when the speed is greater than or equal to the configured 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}.

SLS Status Only Parameter

List

To configure the relay for Safe Limited Speed Status Only monitoring, set these parameters in addition to the Safe Stop parameters listed on

page 99 .

Parameter

21

52

53

55

56

Safety Mode

Lim Speed Input

LimSpd Mon

Delay

Safe Speed

Limit

Speed

Hysteresis

Description


Configuration for the Safe Limited Speed input (SLS_In).

Defines the Safe Limited Speed Monitoring

Delay between the SLS_In ON to OFF transition and the initiation of the Safe

Limited Speed (SLS) monitoring.

Defines the speed limit that will be monitored during the Safe Limited Speed (SLS) mode.

Provides hysteresis for SLS_Out output when safe limited speed monitoring is active.

Setting

Setting: 7 = Master, Safe Limited Speed Status Only

(Lim Spd Stat)









Default: 0

Range: 0

…

6553.5 s

Default: 0

Range: 0

…



Default: 0 (2)

Range: 10

…

100%


(2) You must configure this parameter with a value in the range from 10…100% in this mode.


121


SLS Status Only Wiring

Examples

SS

Request

E-Stop

800FM-MT44

800F-MX02V

These examples illustrate wiring for SLS Status Only operation.

Master, Safe Limited Speed Status Only (Single Unit)

+24V DC

SLS Request

800FM-KM23

800F-MX02V Out 0

Out 1

Out 2

Out 3

Out 4

Out 5

Out 6

Out 7

A1 S11 S21

Pulse Test

Outputs

S12

SS

Input

S22 S52

SLS

Input

S62 S72 S82

ESM

Input

51 52

Door Lock

Control

X32 X42

Lock

Monitor

RJ45

Encoder

Input 1

(1)

A2

SLS Fault

Status Status

Y35 Y37

RJ45

Encoder

Input 2

SS

Output

34 44

MSR57P Relay

DPI

RL

Feed

Reset Feedback


SLS

Cmd

Stop

Cmd

GND

24V

DC

Y1 S34 Y2 Y33 Y32 Y30 Y31

S32 S42

Door

Monitor

Motion

Power Out

14 24

A1

13

SLS

Output

68 78

Reset

800FM-F6MX10

In7

In6

In5

In4

In3

In2

In1

In0

+24V DC

(2)

Aux. Signals to PLC

24V DC Com

(3)


Encoder Cable Specifications on page 42

.

(2) Power supply may or may not be isolated.


122



Master, Safe Limited Speed Status Only (First Unit)

SS

Request

E-Stop

800FM-MT44

800F-MX02V

SLS Request

800FM-KM23

800F-MX02V

Out 0

Out 1

Out 2

Out 3

Out 4

Out 5

Out 6

Out 7

A1 S11 S21

Pulse Test

Outputs

S12

SS

S22

Input

S52 S62 S72 S82

SLS

Input

ESM

Input

51 52 X32 X42

Door Lock

Lock

Control

Monitor

S32 S42

Door

Monitor

A 2

RJ45

Encoder

Input 1

(1)

RJ45

Encoder

Input 2

SLS Fault

Status Status

SS

Output

DPI

RL

Feed

MSR57P Relay

Reset Feedback


SLS

Cmd

Stop

Cmd

GND

24V

DC

Y35 Y37 34 44 Y1 S34 Y 2 Y33 Y32 Y 3 0 Y 3 1

Motion

Power Out

A1

13

SLS

Output

14 24 68 78

Reset

800FM-F6MX10

S52 S62

Next Downstream Axis

MSR57P Relay Terminals

In7

In6

In5

In4

In3

In2

In1

In0

Aux. Signals to PLC

24V DC Com

(3)


.



+24V DC

+24V DC

(2)


123


This example assumes that a programmable safety controller is monitoring all MSR57P relay functions and controlling the relay. 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 MSR57P in the this scenario.

•

Guardlocking switch inputs

•

Door locking

•

Door status (open or closed)

•

Enabling switch

Safe Limited Speed Status Only with Programmable Controller Monitoring

+24V DC

Out 0

Out 1

Out 2

Out 3

Out 4

Out 5

Out 6

Out 7

A1 S11 S21

Pulse Test

Outputs

S12 S22

SS

Input

S52

SLS

Input

S62 S72 S82

ESM

Input

51 52

Door Lock

Control

X32 X42

Lock

Monitor

RJ45

Encoder

Input 1

(1)

A2

SLS Fault

Status Status

Y35 Y37

RJ45

Encoder

Input 2

SS

Output

34 44

MSR57P Relay

DPI

RL

Feed

Reset Feedback


SLS

Cmd

Stop

Cmd

GND

24V

DC

Y1 S34 Y2 Y33 Y32 Y30 Y31

S32

A1

S42

Door

Monitor

Motion

Power Out

14 24

13

SLS

Output

68 78

+24V DC

(2)

Reset

800FM-F6MX10

In7

In6

In5

In4

In3

In2

In1

In0

Aux. Signals to PLC

24V DC Com

(3)

(1) For encoder wiring, see Encoder Cable Specifications on page 42 .



124


Slave Modes for Multi-axis Cascaded

Systems

Chapter

8

Introduction

Topic

Cascaded Configurations

Slave, Safe Stop Mode

Slave, Safe Stop Parameter List

Slave, Safe Stop Wiring Examples

Slave, Safe Limited Speed Mode

Slave, Safe Limited Speed Parameters

Slave, Safe Limited Speed Wiring Examples

Slave, Safe Limited Speed Status Only Mode

Slave, Safe Limited Speed Status Only Parameter List

Slave, Safe Limited Speed Status Only Wiring Examples

Multi-axis Connections

Cascaded System Examples

Page

125

127

127

129

132

132

133

135

135

135

137

139

Cascaded Configurations

Only the middle or last relays in a multi-axis system can be configured for slave modes. Use the P20 [Cascaded Config] parameter to define the relay’s position in the system as Single Unit (Single), Cascaded

First Unit (Multi First), Cascaded Middle Unit (Multi Mid), or Cascaded

Last Unit (Multi Last).

For cascaded speed monitoring safety relays, 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 and the Motion

Power output (MP_Out) for Safe Stop functions are connected to their respective axis. The inputs are cascaded from one relay to the next by connecting the outputs from the previous relay to the inputs of the next relay.


125

Chapter 8 Slave Modes for Multi-axis Cascaded Systems

33

21

11

34

22

12

51

41

A1

52

42

A2

Door Monitor Input

Lock Monitor Input

24V DC

TLS3-GD2

440G-T27260

Power to

Release

Safe Stop Input

Safe Limited Speed Input

Enabling Switch Monitor Input

Manual Reset

24V DC Com

First Axis

Feedback

Cascaded Connections

First Unit (Multi-First)

Master

Axis 1

S12 SS_In_0

S22 SS_In_1

SS_Out_0 34

SS_Out_1 44

S52 SLS_In_0

S62 SLS_In_1

S72 ESM_In_0

S82 ESM_In_1

S11 Pulse_Source_0


SLS_Out_0 68

SLS_Out_1 78

Middle Unit (Multi-Mid)

Slave

Axis 2

S12 SS_In_0

S22 SS_In_1

SS_Out_0 34

SS_Out_1 44

S52 SLS_In_0

S62 SLS_In_1

SLS_Out_0 68

SLS_Out_1 78

S32 DM_In_0

S42 DM_In_1

X32 LM_In_0

X42 LM_In_1

DC_Out_0 51

DC_Out_1 52

S32 DM_In_0

S42 DM_In_1

S34 Reset_In

Feedback A2

MP_Out_0 14

MP_Out_1 24

Auto

Reset

S34 Reset_In

Feedback

Second Axis

Feedback

DC_Out_0 51

DC_Out_1 52

Last Unit (Multi-Last)

Slave

Axis 3

S12 SS_In_0

S22 SS_In_1

SS_Out_0 34

SS_Out_1 44

S52 SLS_In_0

S62 SLS_In_1

SLS_Out_0 68

SLS_Out_1 78

S32 DM_In_0

S42 DM_In_1

A2

MP_Out_0 14

MP_Out_1 24

Auto

Reset

S34 Reset_In

Feedback

Third Axis

Feedback

DC_Out_0 51

DC_Out_1 52

To Door

Solenoid

MP_Out_0 14

MP_Out_1 24

A2

The inputs from the safety switches are monitored by the first relay, which is the master. A Safe Limited Speed Reset detected by the first relay is cascaded to the subsequent relays via the SLS_Out to SLS_In chain. Although all MSR57P 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 of the SS_In input to OFF is detected by the first relay and initiates the configured Safe Stop Type to all of the relays via the SS_Out to SS_In chain.

Any fault in a slave relay only initiates the configured Safe Stop Type to that relay and to slave relays further down the chain.

IMPORTANT

Safe Stop monitoring is not initiated for non-faulted relays earlier in the cascaded chain.

IMPORTANT

The safety reaction time for a cascaded system includes the sum of the reaction times of each relay in the chain.

126


Slave, Safe Stop Mode

Slave Modes for Multi-axis Cascaded Systems Chapter 8

When properly configured for Slave, Safe Stop mode, the speed monitoring safety relay performs the same functions as Safe Stop except that the relay 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 only commands the door to unlock if all units command the door to unlock.

Slave, Safe Stop Parameter

List

To configure the relay for a Slave, Safe Stop mode, set these parameters. See

Multi-axis Connections on page 137

for details on configuring slave relays.

Slave, Safe Stop Parameters

Parameter

20 Cascaded

21

Config

Safety Mode

Description



44 Safe Stop Input Configuration for Safe Stop input (SS_In).

45 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.

Setting

Options: 2 = Cascaded middle unit (Multi Mid)

3 = Cascaded last unit (Multi Last)

Option: 8 = Slave, Safe Stop (Slv Safe Stop)

Option: 5 = Dual-channel SS equivalent 3 s (2 OSSD 3s)

Default: 0 = Safe Torque Off with Standstill Checking

(Torque Off)

46 Stop Mon Delay Defines the monitoring delay between the request for a Safe Stop and the start of the Stop Delay

[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.

Options: 0 = Safe Torque Off with Standstill Checking

(Torque Off)

1 = Safe Stop 1

2 = Safe Stop 2

3 = Safe Torque Off without Standstill Checking

(Trq Off NoChk)

Default: 0

Range: 0

…

6553.5 s

If the Safe Stop Type is Safe Torque Off with or without Speed Checking, the Stop Monitoring

Delay must be 0 or an Invalid Configuration Fault occurs.

47 Max Stop Time Defines the maximum stop delay time that is used when the safe stop function is initiated by a stop type condition.

48 Standstill Speed Defines the speed limit that is used to declare motion as stopped.

Not valid for Safe Torque Off without Standstill

Speed Checking.

Default: 0

Range: 0

…

6553.5 s

Default: 0.001

Range: 0.001

…

65.535 rpm or mm/s based on rotary or linear configuration defined by encoder 1 feedback configuration



127


Slave, Safe Stop Parameters

Parameter

49 Standstill Pos

Description


Defines the position limit in encoder 1 degrees or mm that will be tolerated after a Safe Stop condition has been detected.

50 Decel Ref Speed Decel Reference Speed.

Setting

Default: 10

Range: 0

…

65,535 degrees (360° = 1 revolution) or mm based on rotary or linear configuration defined by


51 Stop Decel Tol

Determines deceleration rate to monitor for Safe

Stop 1 or Safe Stop 2.

Decel Tolerance.

Default: 0

Range: 0

…



Default: 0

Range: 0

…


This is the acceptable tolerance above the deceleration rate set by the P50 [Decel Ref Speed] parameter.

57 Door Out Type Door Control Output Type.

Defines the lock and unlock state for door control output (DC_Out).





The first and middle units of a multi-axis system must be configured as cascading (2).

58 DM Input Type Door Monitor Input Type.


Configuration for the door monitor input (DM_In).

128



Slave, Safe Stop Wiring

Examples

The examples on the following pages show two different Slave, Safe

Stop configurations.

The first example shows an MSR57P 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 MSR57P relay, as well as SS_Out and DC_Out output connections to the next downstream MSR57P relay. This unit is configured with automatic reset so it follows the function of the previous axis.

34 44

See Safe Stop with Door Monitoring Wiring Example

on page

104 for

an example of a first (master) unit.

Slave, Safe Stop, Middle Unit

+24V DC

Previous Upstream Axis MSR57P Relay Terminals

51 52



S32 S42

L1 L2 L3

A1 S11 S21

Pulse Test

Outputs

S12 S22

SS

Input

S52

SLS

Input

S62 S72 S82

ESM

Input

51 52

Door Lock

Control

X32 X42

Lock

Monitor

A2

RJ45

Encoder

Input 1

SLS Fault

Status Status

Y35 Y37

RJ45

Encoder

Input 2

SS

Output

34 44

MSR57P Relay

DPI

RL

Feed

Reset Feedback


SLS

Cmd

Stop

Cmd

GND

24V

DC

Y1 S34 Y2 Y33 Y32 Y30 Y31

S32

Motion

Power Out

14 24

S42

Door

Monitor

A1

13

SLS

Output

68 78

9 24V DC

8 DC Comm

7 Dig Comm

1 Stop

PowerFlex 70

AC Drive with

DriveGuard

1

3

2 Start

4 SLS Input

(1)

Gate Control

Power Supply

Safe Off Option

4

2

6 Enable

Gate

Control

Circuit

Remove jumpers

S12

Next Downstream

Axis MSR57P Relay

Terminals

S22

Motor

Aux. Signals to PLC

24V DC Com

(2)


(2) All cascaded MSR57P units must share a common ground. 24V DC Com must be at the same potential as the drive common because of the encoder

signal.


129


34 44

This example shows the last cascaded slave relay in the system. It has

SS_In and DM_In inputs from the previous upstream MSR57P relay, 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.

Slave, Safe Stop, Last Unit


51 52

TLS3-GD2

440G-T27260

Power to

Release

+24V DC

To First MSR57P Relay Terminals

S11 S21 X32 X42 S32 S42

11 21 33

A1

A2

41 51

12 22 34

42 52

A1 S11 S21

Pulse Test

Outputs

S12 S22

SS

Input

S52 S62 S72 S82

SLS

Input

ESM

Input

51 52

Door Lock

Control

X32 X42

Lock

Monitor

A2

RJ45

Encoder

Input 1

RJ45

Encoder

Input 2

SLS Fault

Status Status

Y35 Y37

SS

Output

34 44

DPI

MSR57P Relay

RL

Feed

Reset Feedback


SLS

Cmd

Stop

Cmd

GND

24V

DC

Y1 S34 Y2 Y33 Y32 Y30 Y31

S32

A1

S42

Door

Monitor

Motion

Power Out

14 24

13

SLS

Output

68 78

9 24V DC

8 DC Comm

7 Dig Comm

1 Stop

PowerFlex 70

AC Drive with

DriveGuard

1

3

2 Start

4 SLS Input

(1)

Gate Control

Power Supply

Safe Off Option

4

2

6 Enable

Gate

Control

Circuit

Remove jumpers

L1 L2 L3

Motor

Aux. Signals to PLC

24V DC Com

(2)



signal.

130



This example shows three relays connected together in a cascaded system. All relays must have a shared common ground.

First, Middle, and Last Relays in a Cascaded System with Door Control and Lock Monitoring

+24V dc

SS

Request

E-Stop

800FM-MT44

800F-MX02V

A1 S11 S21

Pulse Test

Outputs

S12

SS

S22

Input

S52

SLS

Input

S62 S72 S82

ESM

Input

51 52

Door Lock

Control

X32

Lock

X42

Monitor

RJ45

Encoder

Input 1 (1)

RJ45

Encoder

Input 2

A2

SLS

Status

Fault

Status

Y35 Y37

SS Output

34 44

Master MSR57P Relay

DPI

RL-

Feed

Y1

Reset Feedback

S34 Y2


SLS

Cmd

Stop

Cmd

Y33 Y32

Gnd

24V

DC

Y30 Y31

Motion

Power Out

14 24

S32 S42

Door

Monitor

A1

13

SLS

Output

68 78

Reset

800FM-F6MX10

Aux signals to PLC

9 24VDC

8 DC Comm

7 Dig Comm

1 Stop

PowerFlex 70

AC Drive with

DriveGuard

1

3

2 Start

4 SLS Input

Gate Control

Power Supply

Safe Off Option

4

2

6 Enable

Gate

Control

Circuit

Remove Jumper

L1 L2 L3

Motor

24V dc Com

+24V dc

TLS3 GD2 440G-T27260

Power to

Release

11 21 33

A1

A2

41 51

12 22 34

42 52

A1 S11 S21

Pulse Test

Outputs

S12

SS

S22

Input

S52

SLS

S62 S72 S82

ESM

Input Input

51 52

Door Lock

Control

X32

Lock

X42

Monitor

RJ45

Encoder

Input 1

A2

SLS Fault

Status Status

Y35 Y37

RJ45

Encoder

Input 2

SS Output

34 44

Slave (Middle) MSR57P Relay

DPI

RL-

Feed

Y1

Reset Feedback

S34 Y2


SLS

Cmd

Stop

Cmd

Y33 Y32

Gnd

Y30

24V

DC

Y31

Motion

Power Out

14 24

S32 S42

Door

Monitor

A1

13

SLS

Output

68 78

Aux signals to PLC

9 24VDC

8 DC Comm

7 Dig Comm

1 Stop

PowerFlex 70

AC Drive with

DriveGuard

1

3

2 Start

4 SLS Input

(1)

Gate Control

Power Supply

Safe Off Option

4

2

6 Enable

Gate

Control

Circuit

Remove Jumper

L1 L2 L3

Motor

24V dc Com

+24V dc

A1 S11 S21

Pulse Test

Outputs

S12

SS

S22

Input

S52

SLS

S62 S72 S82

ESM

Input Input

51 52

Door Lock

Control

X32

Lock

X42

Monitor

RJ45

Encoder

Input 1

A2

SLS Fault

Status Status

Y35 Y37

RJ45

Encoder

Input 2

SS Output

34 44

Slave (Last) MSR57P Relay

DPI

RL-

Feed

Y1

Reset Feedback

S34 Y2


SLS

Cmd

Stop

Cmd

Y33 Y32

Gnd

Y30

24V

DC

Y31

Motion

Power Out

14 24

S32 S42

Door

Monitor

A1

13

SLS

Output

68 78

Aux signals to PLC

9 24VDC

8 DC Comm

7 Dig Comm

1 Stop

PowerFlex 70

AC Drive with

DriveGuard

1

3

2 Start

4 SLS Input

(1)

Gate Control

Power Supply

Safe Off Option

L1 L2 L3

4

2

6 Enable

Gate

Control

Circuit

Remove Jumper

Motor

24V dc Com


131


Slave, Safe Limited Speed

Mode

When properly configured for Slave, Safe Limited Speed mode, the speed monitoring safety relay performs the same functions as Safe

Limited Speed mode as described on page

105 .

However, the relay 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.

TIP

Only the middle and last relays in a multi-axis system can be configured for slave modes.


Parameters

To configure the relay for Slave, Safe Limited Speed monitoring, set these parameters in addition to the Slave, Safe Stop parameters listed on page

127

. See Multi-axis Connections on page 137 for details on

configuring slave relays.

Parameter

20 Cascaded

Config

Description



52 Lim Speed Input Configuration for the Safe Limited Speed input

(SLS_In).

53 LimSpd Mon

Delay

Defines the Safe Limited Speed Monitoring Delay between the SLS_In ON to OFF transition and the initiation of the Safe Limited Speed (SLS) monitoring.

55 Safe Speed

Limit

Defines the speed limit that will be monitored during the Safe Limited Speed (SLS) mode.

Setting

Options: 2 = Cascaded middle unit (Multi Mid)

3 = Cascaded last unit (Multi Last)

Option: 9 = Slave, Safe Limited Speed (Slv Lim Spd)


Default: 0

Range: 0

Default: 0

…

(1)

6553.5 s

Range: 0

…



(1) You must configure a value greater than zero for this parameter in this mode.

132




Wiring Examples

These examples shows 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 MSR57P relay, as well as SS_Out, SLS_Out, and DC_Out output connections to the next downstream MSR57P relay.

See SLS with Door Monitoring Wiring Example

on page

112 for an

example of a first (master) unit.

Slave, Safe Limited Speed, Middle Unit

+24V DC


34 44 68 78



S32 S42

51 52

L1 L2 L3

A1 S11 S21

Pulse Test

Outputs

S12 S22

SS

Input

S52 S62 S72 S82

SLS

Input

ESM

Input

51 52

Door Lock

Control

X32 X42

Lock

Monitor

A2

RJ45

Encoder

Input 1

RJ45

Encoder

Input 2

SLS Fault

Status Status

Y35 Y37

SS

Output

34 44

MSR57P Relay

DPI

RL

Feed

Reset Feedback


SLS

Cmd

Stop

Cmd

GND

24V

DC

Y1 S34 Y2 Y33 Y32 Y30 Y31

S32

A1

S42

Door

Monitor

Motion

Power Out

14 24

13

SLS

Output

68 78

9 24V DC

8 DC Comm

7 Dig Comm

1 Stop

PowerFlex 70

AC Drive with

DriveGuard

1

3

2 Start

4 SLS Input

(1)

Gate Control

Power Supply

Safe Off Option

4

2

6 Enable

Gate

Control

Circuit

Remove jumpers

S12

S22

Next Downstream

Axis MSR57P Relay

Terminals

S52 S62



Motor

Aux. Signals to PLC

24V DC Com

(2)


(2) All cascaded MSR57P units must share a common ground.24V DC Com must be at the same potential as the drive common because of the encoder

signal.


133


This second example is configured as a cascaded last unit via the P20

[Cascaded Config] parameter (Multi Last). It has SS_In, SLS_In, and

DM_In input connections from the previous upstream MSR57P relay, but its DC_Out output is connected to a guardlocking interlock switch.

Slave, Safe Limited Speed, Last Unit


34 44 68 78 51 52

TLS3-GD2

440G-T27260

Power to

Release

+24V DC

To First MSR57P Relay Terminals

S11 S21

11 21 33

X32 X42

A1

41 51

12 22 34

A2

42 52

A1 S11 S21

Pulse Test

Outputs

S12 S22

SS

Input

S52 S62 S72 S82

SLS

Input

ESM

Input

51 52

Door Lock

Control

X32 X42

Lock

Monitor

RJ45

Encoder

Input 1

RJ45

Encoder

Input 2

A2

SLS Fault

Status Status

Y35 Y37

SS

Output

34 44

MSR57P Relay

DPI

RL

Feed

Reset Feedback


SLS

Cmd

Stop

Cmd

GND

24V

DC

Y1 S34 Y2 Y33 Y32 Y30 Y31

S32

A1

S42

Door

Monitor

Motion

Power Out

14 24

13

SLS

Output

68 78

9 24V DC

8 DC Comm

7 Dig Comm

1 Stop

PowerFlex 70

AC Drive with

DriveGuard

1

3

2 Start

4 SLS Input

(1)

Gate Control

Power Supply

Safe Off Option

L1 L2 L3

4

2

6 Enable

Gate

Control

Circuit

Remove jumpers

Motor

Aux. Signals to PLC

24V DC Com

(2)



signal.

134




Status Only Mode

When properly configured for Slave, Safe Limited Speed Status Only mode, the speed monitoring safety relay performs the same functions as Safe Limited Speed Status Only mode as described on page

119

.

However, the relay 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 MSR57P in a cascaded chain only goes high 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 relays in a multi-axis system can be configured for slave modes.


Status Only Parameter List

To configure the relay for Slave, Safe Limited Speed Status Only monitoring, set these parameters in addition to the Slave, Safe Stop parameters listed on page

127

and the Slave, Safe Limited Speed parameters listed on page

132

. See Multi-axis Connections on page

137

for details on configuring slave relays.

Parameter

20 Cascaded

Config

21 Safety Mode

56 Speed

Hysteresis

Description


Defines the primary operating mode of the speed monitoring safety relay.

Provides hysteresis for SLS_Out output when Safe

Limited Speed monitoring is active.

Setting

Options: 2 = Cascaded system middle unit (Multi Mid)

3 = Cascaded system last unit (Multi Last)

Option: 10 = Slave, Safe Limited Speed Status Only

(Slv Spd Stat)

Default: 0

Range: 10

…

100%


Status Only Wiring

Examples

These examples show two different Slave, Safe Limited Speed Status

Only 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 MSR57P relay, as well as SS_Out, SLS_Out, and DC_Out output connections to the


135

Chapter 8 Slave Modes for Multi-axis Cascaded Systems next downstream MSR57P relay. SLS Command and Stop Command outputs are connected to a 1791DS module.

IMPORTANT

The SLS_Out signals change state immediately based on the speed relative to the Safe Speed Limit if the Safe Limited

Speed Monitoring Delay [Lim Spd Mon Delay] is set to zero.

See

SLS Status Only Wiring Examples starting on page 122 for an

example of a first (master) unit.

Slave, Safe Limited Speed Status Only, Middle Relay

+24V DC


34 44 68 78

Out 0

Out 1

Out 2

Out 3

Out 4

Out 5

Out 6

Out 7

A1 S11 S21

Pulse Test

Outputs

S12

SS

Input

S22 S52

SLS

Input

S62 S72 S82

ESM

Input

51 52

Door Lock

Control

X32 X42

Lock

Monitor

A2

RJ45

Encoder

Input 1

SLS Fault

Status Status

Y35 Y37

RJ45

Encoder

Input 2

SS

Output

34 44

DPI

MSR57P Relay


RL

Feed

Reset Feedback

SLS

Cmd

Stop

Cmd

GND

24V

DC

Y1 S34 Y2 Y33 Y32 Y30 Y31

S32

Motion

Power Out

14 24

S42

Door

Monitor

A1

13

SLS

Output

68 78

S52 S62



In7

In6

In5

In4

In3

In2

In1

In0

S12

S22

Next Downstream

Axis MSR57P Relay

Terminals

Aux. Signals to PLC

These signals could be connected to the

I/O module or to a drive.

24V DC Com

(2)



+24V DC

(1)

136



This second example is configured as a cascaded last unit via the P20

[Cascaded Config] parameter (Multi Last). It has SS_In, SLS_In, and

DM_In input connections from the previous upstream MSR57P relay, but its SS_Out, SLS_Out, and Door Lock Control outputs are connected to a 1791DS module.

Slave, Safe Limited Speed Status Only, Last relay

+24V DC


34 44 68 78 51 52

Out 0

Out 1

Out 2

Out 3

Out 4

Out 5

Out 6

Out 7

A1 S11 S21

Pulse Test

Outputs

S12

SS

Input

S22 S52

SLS

Input

S62 S72 S82

ESM

Input

51 52

Door Lock

Control

X32

Lock

Monitor

RJ45

Encoder

Input 1

A2

SLS

Status

Fault

Status

Y35

RJ45

Encoder

Input 2

Y37

SS

Output

34 44

DPI

MSR57P Relay


RL

Feed

Reset Feedback

SLS

Cmd

Stop

Cmd

GND

24V

DC

Y1 S34 Y2 Y33 Y32 Y30 Y31

X42

S32 S42

Door

Monitor

Motion

Power Out

14 24

A1

13

SLS

Output

68 78

In7

In6

In5

In4

In3

In2

In1

In0

Aux. Signals to PLC

These signals could be connected to the

I/O module or to a drive.

24V DC Com

(2)



+24V DC

(1)

Multi-axis Connections

When configuring a multi-axis system, you need to consider each relay’s location in the system. The type of cascaded connections that can be made are dependent upon the Safety Mode configurations of the master and slave relays and their positions in the system.


137


Middle and last relays in the cascaded chain may be configured for

Automatic reset. A 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 SS_In input on the first axis.

For slave relays in a multi-axis system, the SS_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 MSR57P is also configured for OSSD.

For middle or last relays in multi-axis systems, the relay 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 relay, see

Door Control

on page

97 .

Safety Mode Combinations for Master and First Slave relays

Master Relay

Safe Limited Speed

Typical Safety Mode Combinations

First Slave Relay

(1)

(Second Relay in System)

Safe Stop

Safe Stop with Door Monitoring

Slave - Safe Stop

Slave - Safe Stop

Slave - Safe Stop

Slave - Safe Limited Speed

Slave - Safe Stop

Safe Limited Speed with Door Monitoring

Safe Limited Speed with Enabling Switch

Monitoring


Slave - Safe Stop


Safe Limited Speed with Door Monitoring and

Enabling Switch Monitoring

Slave - Safe Stop


Slave - Safe Stop

Safe Limited Speed Status Only

Slave - Safe Limited Speed Status Only

(1) P20 [Cascaded Config] parameter equals Cascaded Middle Unit (Multi Mid).

(2) DC_Out to DM_In connections are only required for systems implementing door control.

Cascaded Connections Allowed

SS_Out to

SS_In

SLS_Out to

SLS_In

DC_Out to

DM_In

(2)

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

—

—

—

Yes

—

Yes

—

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

—

Yes

Yes

Yes

Yes

Yes

Yes

Yes

138



The table shows the supported Safety Modes for slave relays (

n+1) cascaded from slaves (

n).

Safety Mode Combinations for Cascaded (Middle and Last) Slave Relays

Slave Relay (n)

Supported Safety Mode Combinations

Slave Relay (n+1)

Slave - Safe Stop



Slave - Safe Stop

Slave - Safe Stop


Slave - Safe Stop


(1) DC_Out to DM_In connections are only required for systems implementing door control.

Cascaded Connections Allowed

SS_Out to

SS_In

Yes

Yes

SLS_Out to

SLS_In

—

—

DC_Out to

DM_In

Yes

Yes

(1)

Yes

Yes

Yes

Yes

—

Yes

Yes

Yes

Yes

Cascaded System Examples

The following illustrations show a variety of possible cascaded configurations.

Safe Stop Input

Safe Stop Only (3-wire) Connections


Master

S12 SS_In_0

S22 SS_In_1

Axis 1

SS_Out_0 34

SS_Out_1 44


Slave

S12 SS_In_0

S22 SS_In_1

Axis 2

SS_Out_0 34

SS_Out_1 44


Slave

S12 SS_In_0

S22 SS_In_1

Axis 3

Reset

Input

24V dc Com

First Axis

Feedback

S34 Reset_In

Feedback A2

MP_Out_0 14

MP_Out_1 24

Auto

Reset

S34 Reset_In

Feedback

Second Axis

Feedback

A2

MP_Out_0 14

MP_Out_1 24

Auto

Reset

S34 Reset_In

Feedback

Third Axis

Feedback

MP_Out_0 14

MP_Out_1 24

A2


139


Safe Stop Input

Safe Stop and Safe Limited Speed (5-wire) Connections


Master

S12 SS_In_0

S22 SS_In_1

Axis 1

SS_Out_0 34

SS_Out_1 44


Slave

S12 SS_In_0

S22 SS_In_1

Axis 2

SS_Out_0 34

SS_Out_1 44


Slave

S12 SS_In_0

S22 SS_In_1

Axis 3


S52 SLS_In_0

S62 SLS_In_1

SLS_Out_0 68

SLS_Out_1 78

S52 SLS_In_0

S62 SLS_In_1

SLS_Out_0 68

SLS_Out_1 78

S52 SLS_In_0

S62 SLS_In_1

Reset

Input

24V dc Com

First Axis

Feedback

S34 Reset_In

Feedback A2

MP_Out_0 14

MP_Out_1 24

Auto

Reset

S34 Reset_In

Feedback

Second Axis

Feedback

A2

MP_Out_0 14

MP_Out_1 24

Auto

Reset

S34 Reset_In

Feedback

Third Axis

Feedback

MP_Out_0 14

MP_Out_1 24

A2

Safe Stop with Door Monitoring (3-wire) Connections

Safe Stop Input


Master

S12 SS_In_0

S22 SS_In_1

Axis 1

SS_Out_0 34

SS_Out_1 44


Slave

S12 SS_In_0

S22 SS_In_1

Axis 2

SS_Out_0 34

SS_Out_1 44


Slave

S12 SS_In_0

S22 SS_In_1

Axis 3

33

21

11

34

22

12

Door Monitor Input



S32 DM_In_0

S42 DM_In_1

MT-GD2, Trojan or Cadet Interlock

Reset

Input

24V dc Com

First Axis

Feedback

S34 Reset_In

Feedback A2

MP_Out_0 14

MP_Out_1 24

Auto

Reset

S34 Reset_In

Feedback

Second Axis

Feedback

A2

MP_Out_0 14

MP_Out_1 24

Auto

Reset

S34 Reset_In

Feedback

Third Axis

Feedback

MP_Out_0 14

MP_Out_1 24

A2

140



33

21

11

34

22

12

Safe Stop Input


Safe Stop and Safe Limited Speed with Door Monitoring (5-wire) Connections


Master

S12 SS_In_0

S22 SS_In_1

Axis 1

SS_Out_0 34

SS_Out_1 44

S52 SLS_In_0

S62 SLS_In_1

SLS_Out_0 68

SLS_Out_1 78


Slave

S12 SS_In_0

S22 SS_In_1

Axis 2

SS_Out_0 34

SS_Out_1 44

S52 SLS_In_0

S62 SLS_In_1

SLS_Out_0 68

SLS_Out_1 78


Slave

S12 SS_In_0

S22 SS_In_1

Axis 3

S52 SLS_In_0

S62 SLS_In_1

Door Monitor Input



S32 DM_In_0

S42 DM_In_1


Reset

Input

24V dc Com

First Axis

Feedback

S34 Reset_In

Feedback A2

MP_Out_0 14

MP_Out_1 24

Auto

Reset

S34 Reset_In

Feedback

Second Axis

Feedback

A2

MP_Out_0 14

MP_Out_1 24

Auto

Reset

S34 Reset_In

Feedback

Third Axis

Feedback

A2

MP_Out_0 14

MP_Out_1 24

33

21

11

34

22

12

Safe Stop Input


Safe Stop, Safe Limited Speed, and Enabling Switch with Door Monitoring (5-wire)

Connections


Master

Axis 1

S12 SS_In_0

S22 SS_In_1

SS_Out_0 34

SS_Out_1 44

S52 SLS_In_0

S62 SLS_In_1

SLS_Out_0 68

SLS_Out_1 78


Slave

Axis 2

S12 SS_In_0

S22 SS_In_1

SS_Out_0 34

SS_Out_1 44

S52 SLS_In_0

S62 SLS_In_1

SLS_Out_0 68

SLS_Out_1 78


Slave

Axis 3

S12 SS_In_0

S22 SS_In_1

S52 SLS_In_0

S62 SLS_In_1


S72 ESM_In_0

S82 ESM_In_1



Door Monitor Input

S32 DM_In_0

S42 DM_In_1


Reset

Input

24V dc Com

First Axis

Feedback

S34 Reset_In

Feedback A2

MP_Out_0 14

MP_Out_1 24

Auto

Reset

S34 Reset_In

Feedback

Second Axis

Feedback

A2

MP_Out_0 14

MP_Out_1 24

Auto

Reset

S34 Reset_In

Feedback

Third Axis

Feedback

MP_Out_0 14

MP_Out_1 24

A2


141


Safe Stop Input

Safe Stop with Door Monitoring and Door Control (5 + 2-wire) Connections


Master

Axis 1

S12 SS_In_0

S22 SS_In_1

SS_Out_0 34

SS_Out_1 44


Slave

Axis 2

S12 SS_In_0

S22 SS_In_1

SS_Out_0 34

SS_Out_1 44


Slave

Axis 3

S12 SS_In_0

S22 SS_In_1

33

21

11

34

22

12

51

41

A1

52

42

A2

TLS3-GD2

440G-T27260

Power to

Release

Door Monitor Input

Reset

Input

24V dc Com

First Axis

Feedback



S32 DM_In_0

S42 DM_In_1

X32 LM_In_0

X42 LM_In_1

DC_Out_0 51

DC_Out_1 52

S34 Reset_In

Feedback A2

MP_Out_0 14

MP_Out_1 24

Auto

Reset

Second Axis

Feedback

S32 DM_In_0

S42 DM_In_1

S34 Reset_In

Feedback

DC_Out_0 51

DC_Out_1 52

S32 DM_In_0

S42 DM_In_1

A2

MP_Out_0 14

MP_Out_1 24

Auto

Reset

S34 Reset_In

Feedback

Third Axis

Feedback

DC_Out_0 51

DC_Out_1 52

To Door

Solenoid

MP_Out_0 14

MP_Out_1 24

A2

Safe Stop Input

Safe Stop with Door Monitoring, Door Control, and Lock Monitoring (5+2-wire)

Connections


Master

Axis 1

S12 SS_In_0

S22 SS_In_1

SS_Out_0 34

SS_Out_1 44


Slave

Axis 2

S12 SS_In_0

S22 SS_In_1

SS_Out_0 34

SS_Out_1 44


Slave

Axis 3

S12 SS_In_0

S22 SS_In_1

33

21

11

34

22

12

51

41

A1

52

42

A2

Door Monitor Input

Lock Monitor Input

TLS3-GD2

440G-T27260

Power to

Release

Reset

Input

24V dc Com

First Axis

Feedback



S32 DM_In_0

S42 DM_In_1

X32 LM_In_0

X42 LM_In_1

DC_Out_0 51

DC_Out_1 52

S34 Reset_In

Feedback A2

MP_Out_0 14

MP_Out_1 24

Auto

Reset

Second Axis

Feedback

S32 DM_In_0

S42 DM_In_1

S34 Reset_In

Feedback

DC_Out_0 51

DC_Out_1 52

S32 DM_In_0

S42 DM_In_1

A2

MP_Out_0 14

MP_Out_1 24

Auto

Reset

S34 Reset_In

Feedback

Third Axis

Feedback

DC_Out_0 51

DC_Out_1 52

To Door

Solenoid

MP_Out_0 14

MP_Out_1 24

A2

142



Safe Stop Input


Safe Stop and Safe Limited Speed with Door Monitoring, Door Control, and Lock

Monitoring (7 + 2-wire) Connections


Master

Axis 1

S12 SS_In_0

S22 SS_In_1

SS_Out_0 34

SS_Out_1 44

S52 SLS_In_0

S62 SLS_In_1

SLS_Out_0 68

SLS_Out_1 78


Slave

Axis 2

S12 SS_In_0

S22 SS_In_1

SS_Out_0 34

SS_Out_1 44

S52 SLS_In_0

S62 SLS_In_1

SLS_Out_0 68

SLS_Out_1 78


Slave

Axis 3

S12 SS_In_0

S22 SS_In_1

SS_Out_0 34

SS_Out_1 44

S52 SLS_In_0

S62 SLS_In_1

SLS_Out_0 68

SLS_Out_1 78

33

21

11

34

22

12

51

41

A1

52

42

A2

TLS3-GD2

440G-T27260

Power to

Release

Door Monitor Input

Lock Monitor Input

Reset

Input

24V dc Com

First Axis

Feedback



S32 DM_In_0

S42 DM_In_1

X32 LM_In_0

X42 LM_In_1

DC_Out_0 51

DC_Out_1 52

S34 Reset_In

Feedback A2

MP_Out_0 14

MP_Out_1 24

Auto

Reset

Second Axis

Feedback

S32 DM_In_0

S42 DM_In_1

S34 Reset_In

Feedback

DC_Out_0 51

DC_Out_1 52

S32 DM_In_0

S42 DM_In_1

MP_Out_0 14

MP_Out_1 24

A2

Auto

Reset

S34 Reset_In

Feedback

Third Axis

Feedback

DC_Out_0 51

DC_Out_1 52

To Door

Solenoid

MP_Out_0 14

MP_Out_1 24

A2

Safe Stop, Safe Limited Speed, and Enabling Switch with Door Monitoring, Door

Control and Lock Monitoring (7 + 2-wire) Connections

33

21

11

34

22

12

Safe Stop Input



51

41

A1

52

42

A2

TLS3-GD2

440G-T27260

Power to

Release


Master

Axis 1

S12 SS_In_0

S22 SS_In_1

SS_Out_0 34

SS_Out_1 44

S52 SLS_In_0

S62 SLS_In_1

SLS_Out_0 68

SLS_Out_1 78

S72 ESM_In_0

S82 ESM_In_1




Slave

Axis 2

S12 SS_In_0

S22 SS_In_1

S52 SLS_In_0

S62 SLS_In_1

Door Monitor Input

Lock Monitor Input

Reset

Input

24V dc Com

First Axis

Feedback

S32 DM_In_0

S42 DM_In_1

X32 LM_In_0

X42 LM_In_1

DC_Out_0 51

DC_Out_1 52

S32 DM_In_0

S42 DM_In_1

S34 Reset_In

Feedback A2

MP_Out_0 14

MP_Out_1 24

Auto

Reset

S34 Reset_In

Feedback

Second Axis

Feedback

SS_Out_0 34

SS_Out_1 44

SLS_Out_0 68

SLS_Out_1 78

DC_Out_0 51

DC_Out_1 52


Slave

Axis 3

S12 SS_In_0

S22 SS_In_1

S52 SLS_In_0

S62 SLS_In_1

S32 DM_In_0

S42 DM_In_1

A2

MP_Out_0 14

MP_Out_1 24

Auto

Reset

S34 Reset_In

Feedback

Third Axis

Feedback

SS_Out_0 34

SS_Out_1 44

SLS_Out_0 68

SLS_Out_1 78

DC_Out_0 51

DC_Out_1 52

MP_Out_0 14

MP_Out_1 24

A2

To Door

Solenoid


143


Safe Stop with Door Monitoring, Safe Limited Speed, Lock Monitoring, and

Enabling Switch (7 + 2-wire) Connections

24V DC

Reset

Safe Stop Input




Master

S12 SS_In_0

S22 SS_In_1

Axis 1

SS_Out_0 34

SS_Out_1 44

S52 SLS_In_0

S62 SLS_In_1

SLS_Out_0 68

SLS_Out_1 78

S72 ESM_In_0

S82 ESM_In_1



33

21

11

51

41

A1

34

22

12

Door Monitor Input

52

42

A2

Lock Monitor Input

S32 DM_In_0

S42 DM_In_1

X32 LM_In_0

X42 LM_In_1

DC_Out_0 51

DC_Out_1 52

TLS3-GD2

440G-T27260

Power to

Release

Auto

Reset

First Axis

Feedback

24V dc Com

S34 Reset_In

Feedback


Slave

Axis 2

S12 SS_In_0

S22 SS_In_1

SS_Out_0 34

SS_Out_1 44

S52 SLS_In_0

S62 SLS_In_1

S32 DM_In_0

S42 DM_In_1

A2

MP_Out_0 14

MP_Out_1 24

Auto

Reset

S34 Reset_In

Feedback

Second Axis

Feedback

SLS_Out_0 68

SLS_Out_1 78

DC_Out_0 51

DC_Out_1 52


Slave

Axis 3

S12 SS_In_0

S22 SS_In_1

SS_Out_0 34

SS_Out_1 44

S52 SLS_In_0

S62 SLS_In_1

S32 DM_In_0

S42 DM_In_1

A2

MP_Out_0 14

MP_Out_1 24

Auto

Reset

S34 Reset_In

Feedback

Third Axis

Feedback

SLS_Out_0 68

SLS_Out_1 78

DC_Out_0 51

DC_Out_1 52

MP_Out_0 14

MP_Out_1 24

A2

To Door

Solenoid

2 OSSD

O0

O1

In0

In1

In2

SmartGuard 600

Controller

G0

This example shows reset control performed by the SmartGuard 600 controller. Any fault on any axis shuts down the entire system. The reset is controlled by the SmartGuard 600 controller.

144


Safe Maximum Speed and Direction

Monitoring

Chapter

9

Introduction

Topic

Safe Maximum Speed (SMS) Monitoring

Safe Maximum Acceleration (SMA) Monitoring

Safe Direction Monitoring (SDM)

Max Speed, Max Accel, and Direction Monitoring

Parameter List

Page

145

148

150

151

Safe Maximum Speed

(SMS) Monitoring

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 relay configuration is valid and Safety Mode is not Disabled.

When you configure the relay for Safe Maximum Speed, the feedback velocity is monitored and compared against a user-configurable limit.

You set the Safe Max Speed Limit, which is relative to encoder 1. If the monitored speed is greater than or equal to the configured Safe Max

Speed Limit, an SMS Speed Fault (Stop Category Fault) occurs.

Safe Max Speed Timing Diagram

Speed

Safe Max

Speed Limit

Time


145

Chapter 9 Safe Maximum Speed and Direction Monitoring

You define the Safe Stop Type initiated by the relay in the event of an

SMS Speed Fault by using the P63 [Max Spd Stop Typ] parameter.

Safe Maximum Speed Monitoring Stop Behavior

P63 [Max Spd Stop Typ]

Parameter

0 = Use Safe Torque Off with

Check for Standstill (Torque Off)

1 = Use Configured Stop Type

(Safe Stp Typ)

Description

The speed monitoring relay initiates Safe Torque Off with Check for Standstill any time an SMS Speed Fault is detected while the relay is monitoring motion.

The speed monitoring relay initiates the configured

Safe Stop Type (parameter 45) any time an SMS Speed

Fault is detected while the relay is monitoring motion.

If an SMS Speed Fault is detected during a Stop Monitoring Delay,

[Stop Mon Delay], the delay ends immediately and the configured Stop

Delay [Max Stop Time] begins.

SMS Speed Fault During Stop Monitoring Delay

SMS Speed Fault

Stop Delay Begins Immediately

Safe Max

Speed Limit

Standstill

Speed

Deceleration

Tolerance

Time

Configured Stop Monitoring Delay

If an 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 the maximum frequency

(1)

for your encoder type, the fault is reported, but no further action is taken. Deceleration monitoring performs the safety function during the Stop Delay [Max

Stop Time]. That is, if an SMS Speed Fault occurs during the Stop

Delay [Max Stop Time], the fault is ignored and the stopping action continues.

146

(1) 100 kHz for Sin/Cos or 200 kHz for Incremental



Safe Maximum Speed and Direction Monitoring Chapter 9

SMS Speed Fault When P63 [Max Spd Stop Typ] Set to ’Use Configured Stop Type

(Safe Stp Typ)’

Stop Request

SMS Speed Fault

Stop

Monitoring

Delay

Stop Delay

Safe Max

Speed Limit

Standstill Speed

Deceleration

Tolerance

Time

If an SMS Speed Fault is detected during the Stop Delay [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 the MP_Out output is set to OFF. The Stop Delay

[Max Stop Time] continues with standstill checking enabled.

SMS Speed Fault When P63 [Max Spd Stop Typ] Set to ’Use Safe Torque Off with

Check for Standstill (Torque OFF)’

SMS Speed

Stop

Request

Fault

Stop Delay

Safe Max

Speed Limit

Unlock Door

Standstill

Speed

Time

SS_In

SS_Out

MP_Out

DC_Out

For more information about faults, see

Fault Reactions on page 190

.

147


Safe Maximum

Acceleration (SMA)

Monitoring

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 relay configuration is valid and Safety Mode is not set to Disabled.

The resolution accuracy of the acceleration monitoring in revolutions/second

2

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

2

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].

When you configure the relay for Safe Maximum Acceleration, the relay 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 Safe Maximum

Acceleration Limit, an Acceleration Fault (Stop Category Fault) occurs.

Safe Max Acceleration Timing Diagram

Safe Max

Acceleration

Limit

Acceleration

Time

You define the Safe Stop Type initiated by the relay in the event of an

Acceleration Fault by using the P66 [Max Acc Stop Typ] parameter.

Safe Maximum Acceleration Monitoring Stop Behavior

P66 [Max Acc Stop Typ]

Parameter

0 = Use Safe Torque Off with

Check for Standstill (Torque Off)

1 = Use Configured Stop Type

(Safe Stp Typ)

Description

The speed monitoring relay initiates Safe Torque Off with Check for Standstill any time an Acceleration

Fault is detected while the relay is monitoring motion.

The speed monitoring relay initiates the configured

Safe Stop Type any time an Acceleration Fault is detected while the relay is monitoring motion.

148



If an Acceleration Fault is detected during a Stop Monitoring Delay

[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 [Stop Mon Delay] ends immediately and Stop Delay [Max Stop Time] begins.

If an Acceleration Fault is detected during the Stop Delay [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

(1)

for your encoder type, then the fault occurs with no further action. Deceleration Monitoring performs the safety function during the Stop Delay [Max Stop Time]. That is, if an Acceleration Fault occurs during the Stop Delay [Max Stop Time], the fault is ignored and the stopping action continues.

Acceleration Fault When P66 [Max Acc Stop Typ] Set to ’Use Configured Stop Type

(Safe Stp Typ)’

Stop

Request

Acceleration

Fault

Stop Delay

Standstill Speed

Deceleration

Tolerance

Time

If an Acceleration Fault is detected during the Stop Delay [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 the MP_Out output is set to OFF. The Stop Delay

[Max Stop Time] continues with standstill checking enabled.


(1) 100 kHz for Sin/Cos or 200 kHz for Incremental

149


Acceleration Fault When P66 [Max Acc Stop Typ] Set to ’Use Safe Torque Off with

Check for Standstill (Torque OFF)’.

Acceleration

Fault

Stop

Request

Stop Delay

Standstill Speed

SS_In

SS_Out

MP_Out

DC_Out

Time

For more information about faults, see Fault Reactions on page 190 .

Safe Direction Monitoring

(SDM)

When configured for Safe Direction Monitoring, the relay monitors the feedback direction and initiates the configured Safe Stop Type when motion in the illegal direction is detected. You configure Safe

Direction Monitoring using the P42 [Direction Mon] parameter. This parameter also determines the direction, positive or negative, in which motion is allowed.

Enable Safe Direction Monitoring

P42 [Direction Mon] Parameter

0 = Disabled

1 = Positive Always

2 = Negative Always

3 = Positive During SLS

4 = Negative During SLS

Description

Safe Direction Monitoring is disabled.

Safe Direction Monitoring is active any time the configuration is valid and not Disabled.

Safe Direction Monitoring is performed only when the relay is actively monitoring Safe

Limited Speed.

IMPORTANT

Be sure to set the P30 [Fbk 1 Polarity] and P35 [Fbk 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 Tolerance] parameter.

150



Positive Safe Direction Monitoring Diagram

Speed

300

0

Safe Direction

Time

Safe Direction Fault

Negative Safe Direction Monitoring Diagram

Safe Direction Fault

Speed

Time

0

-300

Safe Direction

If motion is detected in the incorrect direction while Safe Direction

Monitoring is active, a Direction Fault occurs. If a Direction Fault is detected while the relay is monitoring motion, the configured 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 190

.

Max Speed, Max Accel, and Direction Monitoring

Parameter List

Set these parameters to configure Safe Maximum Speed, Safe

Maximum Acceleration, and Safe Direction Monitoring.

Parameter

30 Fbk 1 Polarity

35 Fbk 2 Polarity

Description

Defines the direction polarity for encoder 1.


Setting



1 = Reversed



1 = Reversed


151


Parameter

43

61

62

63

Direction Tol

Max Speed

Enable

Max Spd Stop

Typ

Description

42 Direction Mon Defines the allowable direction if Safe

Direction Monitoring is enabled.

The position limit in encoder units tolerated in the wrong direction when Safe Direction

Monitoring is active.

Enable Safe Maximum Speed Monitoring.

Safe Max Speed Defines the maximum speed limit that will be tolerated if Safe Maximum Speed monitoring is enabled.

Safe Maximum Speed Monitoring Stop

Behavior.

Defines the stopping behavior that will be initiated in the event of an SMS Speed Fault.

Setting



1 = Positive always (Pos Always)

2 = Negative always (Neg Always)

3 = Positive during safe limited speed monitoring

(Pos in SLS)

4 = Negative during safe limited speed monitoring

(Neg in SLS)

Default: 10

Range: 0

…

65,535 deg or mm based on rotary or linear configuration defined by




1 = Enabled

Default: 0

Range: 0

…



Default: 0 = Use Safe Torque Off with Standstill Checking

(Torque Off)

Options: 0 = Use Safe Torque Off with Standstill Checking

(Torque Off)

1 = Use Configured Safe Stop Type (Safe Stp Typ)

64 Max Accel

Enable

See Safe Maximum Speed (SMS) Monitoring on page 145 .

Enable Safe Maximum Acceleration

Monitoring.

65

66

Safe Accel Limit Defines the Safe Maximum Acceleration Limit,

Max Acc Stop

Typ relative to encoder 1, for which the system is being monitored.

Safe Max Acceleration Monitoring Stop

Behavior.

Defines the stopping behavior that will be initiated in the event of an Acceleration Fault.



1 = Enabled

Default: 0

Range: 0

…

65,535 rev/s

2

or mm/s

2 based on rotary or linear configuration defined by


Default: 0 = Use Safe Torque Off with Check for Standstill

(Torque Off)

Range: 0 = Use Safe Torque Off with Check for Standstill

(Torque Off)


See Safe Maximum Acceleration (SMA)

Monitoring on page 148

.

152


Chapter

10

Safety Configuration and Verification

Introduction

Topic

Safety Configuration

Basics of Application Development and Testing

Commissioning the System

Editing the Configuration

Page

153

156

156

160

Safety Configuration

When you configure a speed monitoring safety system, you must record and verify the configuration signature, and set the safety-lock status of the system configuration. An optional password can be configured 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 device. 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

If you do not safety-lock the configuration, untested or unintentional changes can be made to the device configuration, which could result in unexpected system behavior.

You lock the configuration by using the P5 [Lock State] parameter.

153

Chapter 10 Safety Configuration and Verification

The Config Lock status indicator on the relay illuminates solid yellow when the configuration is locked. The Config Lock status indicator flashes yellow when the configuration is unlocked.

P

Config

Lock

PWR/Fault

Stop

Limited Speed

Standstill

Safe Speed


You can also 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.

Set 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 relay reset operations require the password to be entered. You can set a password when the relay is not safety-locked and the P6 [Operating Mode] parameter value equals 0 (Program).

Follow these steps to set a new password.

1. If you previously configured a password, enter the password by using the P1 [Password] parameter.

2. Enter the new password by using the P13 [New Password] parameter.

3. Set the P17 [Password Command] parameter to 1, which equals

Change Password.

154


Safety Configuration and Verification Chapter 10


1 Password Password for Lock and

Unlock function.

13 New Password 32-bit configuration password

17 Password

Command

Save new password command.

Setting

Range: 0

…

4,294,967,295

Range: 0…4,294,967,295

Default: 0 = No action

Options: 0 = No action

1 = Change Password

2 = Reset Password

Reset the Password

If you forget the password and need to reset it, follow these steps.

1. Read the contents of the P18 [Security Code] parameter.

2. Contact Rockwell Automation Technical Support (440-646-5800) and provide the Security Code value and the serial number of the relay.

A technical support representative will use the security code to calculate a Vendor Password value.

3. Enter the value provided by your Rockwell Automation

Technical Support representative into the P19 [Vendor Password] parameter.


Reset Password.

5. Enter the new password using the P13 [New Password] parameter.


Change Password.


Reset the Relay

When the relay is unlocked and the P6 [Operating Mode] parameter equals 0 (Program), you can reset the relay’s configuration parameters to their factory default settings, by setting the P7 [Reset Defaults] parameter to 1. The reset parameters are sent to the relay when the P6

[Operating Mode] parameter is changed to 1 (Run).

155


Basics of Application

Development and Testing

Configuration for the intended SIL CL3, PL(e), or Cat 4 system should be carried out by the system integrator or a user trained and experienced in safety applications. The developer must follow good design practices.

•

Use functional specifications, including flow charts, timing diagrams and sequence charts.

•

Perform a configuration review.

•

Perform configuration validation.

Commissioning the System

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

Configuration Signature ID

Generated

Make Required

Modifications

Tests

Passed?

Yes

Confirm the Project

Record the Configuration

Signature ID

Lock the Configuration

No

Verify Signature ID and Lock Status

156




Specify 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/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)

– Signal in 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.

157


Configure the Speed Monitoring Relay

You configure the relay using a HIM (catalog number 20-HIM-A3) to set the configuration parameters. You can also use DriveExplorer software, version 5.02 or later, or DriveExecutive software, version

4.01 or later.

The relay is configured in the Safe State. The relay must be unlocked to be configured. If a password exists, you must provide the password to unlock the relay.

Follow these steps to configure the relay.

1. Unlock the relay configuration, if it is locked, by setting the P5

[Lock State] parameter to 0 (Unlock).

2. If an error occurs, you need to enter the password, by using the

P1 [Password] parameter.

3. Place the relay in Program mode by setting the P6 [Operating

Mode] parameter to 0.

If you are using DriveExplorer or DriveExecutive software, you will see the P10 [Signature ID] parameter value change to 0.

IMPORTANT

When the relay is in Program mode, the P69 [IO Diag

Status] parameter is not updated or refreshed.

4. Edit parameters to meet your system configuration specification and risk assessment requirements.

5. When you are finished editing parameters, set the P6 [Operating

Mode] parameter to 1, which puts the relay into Run mode.

A configuration Signature ID is generated.

6. Record the configuration Signature ID from the contents of the

P10 [Signature ID] parameter.

7. Enter the password, if required.

8. Set the P5 [Lock State] parameter to 1 (Lock).

For a complete list of parameters and settings for the MSR57P relay, see

Appendix B .

158



Project Verification Test

To check that the speed monitoring relay’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.


Verify the Signature and Lock at the Speed Monitoring Relay

To meet SIL CL3, PL(e), Cat 4 requirements, you must verify that the correct configuration is locked in the speed monitoring relay.

To 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

158

.

To verify the lock status, you can view the Config Lock status indicator on the speed monitoring relay. The Config Lock indicator is solid yellow when the configuration is locked and flashing yellow when it is unlocked.

To verify the lock status, you can view the status of the P5 [Lock State] parameter as well as 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.

159


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:

• authorization.

• impact analysis.

• execution.

• test information.

• revision information.

The flowchart shows the steps necessary to edit the speed monitoring relay’s configuration.

Edit the Configuration

Unlock the Configuration

Make Desired Modifications to

Safety Parameters

Apply Changes

Configuration Signature ID Generated

Project Verification Test

Make Required

Modifications

Tests

Passed?

Yes

Confirm the Project

No

Record the Configuration Signature ID

Lock the Configuration

Verify the Lock Status and Signature ID

END

160


Chapter

11

Configuration Examples

Introduction

These examples guide you through the basic steps required to program an application that uses some of the safety functions of the

MSR57P Relay. The remaining chapters of this manual provide detailed information on the operation of each safety function.

Topic

Example Application 1

Example Application 2

Page

161

172

Example Application 1

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.

•

Door Monitoring (DM) of a guardlocking switch (TLS-3 GD2) configured as Power to Release.

•

A Reset button with 1 NO contact.

•

One encoder connected with Sin/Cos output signal and resolution of 1024.

•

A configured 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, or DriveExplorer or

DriveExecutive software to configure the relay.

For information on connecting and using a HIM, see

Appendix C

. For information on connecting to a personal computer and using software for configuration, see

Appendix D

.


161

Chapter 11 Configuration Examples

Example 1: Initial Security Group Settings

Security Group Parameters

HIM Screen Software Screen

F

Configuring

0.0

Auto

RPM

Password

Lock State

Operating Mode

162

Follow these steps to put the relay 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.

The locked or unlocked state is also indicated by the Config

Lock status indicator on the front of the relay. Flashing yellow is unlocked; solid yellow is locked.

2. If the relay 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 relay configuration.

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. If the relay is in Run mode (Operating Mode parameter equals

1), set the Operating Mode parameter to 0 to enable you to enter a new configuration.

7. 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.

8. Type the new password value.


Configuration Examples Chapter 11

9. Choose the P17 [Password Command] parameter.

10. Set the Password Command parameter value to 1, which equals

Change Password (Change PW).

11. Go to the next section to set the parameters found in the

General parameters group.

Example 1: General Group Settings

General Group Parameters


F

Configuring

0.0

Auto

RPM

Cascaded Config

Safety Mode

Reset Type


Follow these steps to configure the general operation of the relay.

1. From the General group, choose the P20 [Cascaded Config] parameter.

2. Set the Cascaded Config parameter to 0 (default) to configure the relay as a Single unit.

3. Choose the P21 [Safety Mode] parameter.

The default setting is 1, which equals Safe Stop.

4. Set the Safety Mode parameter value to 4 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.

5. Choose the P22 [Reset Type] parameter.

163


6. Set the 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.

7. Choose the P23 [Reset Loop] parameter.

8. Set the Reset Loop parameter value to 0 (default) to disable reset qualification monitoring.

This setting assumes that there are no external contactors or devices connected to the system which require monitoring.

9. Choose the P24 [OverSpd Response] parameter.

The default Overspeed Response time is 42 ms.

10. Set the OverSpd Response parameter value to 1, which equals

48 ms.

See Overspeed Response Time on page 75 for details.

11. Go to the next section to configure the type of feedback using the Feedback parameters group.

Example 1: Feedback Group Settings

Feedback Group Parameters


F

Configuring

0.0

Auto

RPM

Fbk Mode

Fbk 1 Type

Fbk 1 Units

164

Follow these steps to configure the type of feedback used by the relay.

1. From the Feedback group, choose the P27 [Fbk Mode] parameter.




2. Set the Fbk Mode parameter value to 0 (default) for redundant processing and cross-checking of the single encoder input in a

1oo2 architecture.

3. Choose the P28 [Fbk 1 Type] parameter.

The default value is 1 for incremental encoder input.

4. Set the 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 Fbk 1 Units parameter to 0 (default), which equals Rotary feedback.

7. Choose the P30 [Fbk 1 Polarity] parameter.

8. Set the 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’s specifications.

11. Choose the P32 [Fbk 1 Volt Mon] parameter.

12. Enter 5, 9, 12, or 14V 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 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.

165


15. Go to the next section to set the parameters found in the Stop parameters group.

Example 1: Stop Group Settings

Stop Group Parameters


F

Configuring

0.0

Auto

RPM

Safe Stop Input

Safe Stop Type

Stop Mon Delay

166

Follow these steps to configure the Stop operation of the relay.

1. From the Stop group, choose the P44 [Safe Stop Input] parameter.

2. Set the Safe Stop Input parameter value to 1 (default) for 2NC

(dual-channel equivalent) operation.

In this example application, the Safe Stop input (SS_In) monitors an E-Stop button with two normally-closed (2NC) contacts.

3. Choose the P45 [Safe Stop Type] parameter.

4. Set the 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 control to Unlock when the Standstill

Speed is detected.

5. Choose the P47 [Max Stop Time] parameter.

The default value is 10 s, but you can enter a value from

0…6553.5 s.




6. 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] you entered, a Stop Speed Fault occurs and door control remains set to Lock until the Standstill

Speed is reached.

7. 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.

8. Enter a value in the Standstill Speed parameter field to define the speed at which the relay determines standstill has been reached.

9. 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 Rotary feedback.

10. Enter the value to define the position limit in encoder units that is tolerated after standstill has been reached.

11. Go to the next section to set the parameters found in the Limited

Speed parameters group.

167


Example 1: Limited Speed Group Settings

Limited Speed Group Parameters


F

Configuring

0.0

Auto

RPM

Lim Speed Input

LimSpd Mon Delay

Enable SW Input

168

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.

2. Set the Lim Speed Input parameter value to 1 for 2NC


In this example application, the Safe Limited Speed input

(SLS_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 relay initiates the configured

Safe Stop Type.

When the relay 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.

3. Choose the P55 [Safe Speed Limit] parameter.

The default value is 0 rpm or mm/s. The valid range is from

0…6553.5.

4. 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.

5. Go to the next section to set the parameters that configure Door

Control operation.


Example 1: Door Control Group Settings

Door Control Group Parameters


F

Configuring

0.0

Auto

RPM

Door Out Type

DM Input

Lock Mon Enable



Follow these steps to configure Door Control operation for the relay.

1. From the Door Control group, choose the P57 [Door Out Type] parameter.

2. Set the 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. Set the DM Input parameter value to 1 for 2NC (dual-channel equivalent) operation.

In this example application, the DM Input (DM_In) monitors the

TLS-3 GD2 switch, which has two normally-closed (2NC) safety contacts.

5. Choose the P59 [Lock Mon Enable] parameter.

The default value is 0 (Disabled) for applications without an interlock switch.

6. Set the Lock Mon Enable parameter value to 1 (Enabled) because this application uses the TLS-3 GD2 interlock switch.

169


7. Choose the P60 [Lock Mon Input] parameter.

The default value is 0 (Not Used) for applications that do not use an interlock switch.

8. Set the Lock Mon Input parameter value to 1 for 2NC


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. Go to the next section to set the parameters that configure Safe

Maximum Speed monitoring.

Example 1: Max Speed Group

Max Speed Group Parameters

HIM Screen

Software Screen

F

Configuring

0.0

Auto

RPM

Max Speed Enable

Safe Max Speed

Max Spd Stop Typ

170

Follow these steps to configure Maximum Speed monitoring for the relay.

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 Max Speed Enable parameter value to 1 (Enabled), which monitors that the encoder feedback signal does not exceed the velocity configured using the Safe Max Speed parameter.




3. Choose the P62 [Safe Max Speed] parameter.

The default value is 0 rpm or mm/s. Enter a value from

0…6553.5.

4. Type the maximum allowable rpm value for velocity.


5. Choose the P63 [Max Spd Stop Typ] parameter.

6. Set the 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 relay initiates a Safe Torque Off with Standstill

Checking type of Safe Stop, regardless of the configured Safe

Stop Type.

7. Go on to the next section to put the relay into Run mode and lock the configuration.

Example 1: Final Security Group Settings

This example only includes the steps for entering a configuration using the HIM module or software program. You must also follow the requirements described in

Chapter 10

,

Safety Configuration and

Verification .

ATTENTION

You must verify the configuration and validate the entire system, including a complete functional test, before the operational startup of any 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 relay into Run mode, generate a configuration signature, and lock the configuration.

1. From the Security group, choose the P6 [Operating Mode] parameter.

171


Example Application 2

2. Set the Operating Mode parameter value to 1, which equals Run mode.

A configuration signature is generated.

3. Choose the P10 [Signature ID] parameter and record the configuration signature value stored in this parameter.

4. If you configured a password, choose the P1 [Password] parameter and type the password.

5. Choose the P5 [Lock State] parameter.

6. Set the Lock State parameter value to 1 (Lock) to lock the configuration.

The Config Lock status indicator is solid yellow when the relay configuration is locked.

This example application shows how to change the default configuration settings to set up the MSR57P relay 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.

•

A configured Safe Maximum Speed (SMS) limit.

•

Door Monitoring (DM)

•

Door Control (DC) to control a guardlocking switch (TLS-3 GD2,

Power to Release style).

•

A Reset button with 1NO 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.

•

One encoder 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, or DriveExplorer or

DriveExecutive software to configure the relay.

For information on connecting and using a HIM, see

Appendix C

. For information on connecting to a personal computer and using software for configuration, see

Appendix D .

172



Example 2: Initial Security Group Settings

Security Group Parameters


F

Configuring

0.0

Auto

RPM

Password

Lock State

Operating Mode


Follow these steps to put the relay 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.

The locked or unlocked state is also indicated by the Config

Lock status indicator on the front of the relay. Flashing yellow is unlocked; solid yellow is locked.

2. If the relay is locked (Lock State parameter value equals 1), set the Lock State parameter value to 0.

If an error occurs, a password has been configured to protect the relay configuration.

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. If the relay is in Run mode (Operating Mode parameter equals

1), set the Operating Mode parameter to 0 to enable you to enter a new configuration.

7. 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.

8. Type the new password value.

173


9. Choose the P17 [Password Command] parameter.

10. Set the Password Command parameter value to 1, which equals

Change Password (Change PW).

11. Go to the next section to set the parameters found in the

General parameters group.

Example 2: General Group Settings

General Group Parameters


F

Configuring

0.0

Auto

RPM

Cascaded Config

Safety Mode

Reset Type

174

Follow these steps to configure the general operation of the relay.

1. From the General group, choose the P20 [Cascaded Config] parameter.

2. Set the Cascaded Config parameter to 0 (default) to configure the relay as a Single unit.

3. Choose the P21 [Safety Mode] parameter.

The default setting is 1, which equals Safe Stop.

4. Set the Safety Mode parameter value to 6 for Master, Safe Limited

Speed with Door Monitoring and Enabling Switch Monitoring mode (Lim Speed DM ES).

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 Speed Limit. When the enabling switch is held in the middle position, the door can be opened while the machine is running below the Safe Speed Limit.



5. Choose the P22 [Reset Type] parameter.

6. Set the 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.

7. Choose the P23 [Reset Loop] parameter.

8. Set the Reset Loop parameter value to 0 (default) to disable reset qualification monitoring.

This setting assumes that there are no external contactors or devices connected to the system which require monitoring.

9. Choose the P24 [OverSpd Response] parameter.

The default Overspeed Response time is 42 ms.

10. Set the OverSpd Response parameter value to 0, which equals

42 ms.

See

Overspeed Response Time

on page

75

for details.

11. Go to the next section to configure the type of feedback by using the Feedback parameters group.

Example 2: Feedback Group Settings

Feedback Group Parameters


F

Configuring

0.0

Auto

RPM

Fbk Mode

Fbk 1 Type

Fbk 1 Units


175


176

Follow these steps to configure the type of feedback used by the relay.

1. From the Feedback group, choose the P27 [Fbk Mode] parameter.

2. Set the Fbk mode parameter value to 0 (default) for redundant processing and cross-checking of the single encoder input in a

1oo2 architecture.

3. Choose the P28 [Fbk 1 Type] parameter.

The default value is 1 for incremental encoder input.

4. Set the 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 Fbk 1 Units parameter to 0 (default), which equals Rotary feedback.

7. Choose the P30 [Fbk 1 Polarity] parameter.

8. Set the 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’s specifications.

11. Choose the P32 [Fbk 1 Volt Mon] parameter.

12. Enter 5, 9, 12, or 14V 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 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. Go to the next section to set the parameters found in the Stop parameters group.

Example 2: Stop Group Settings

Stop Group Parameters


F

Configuring

0.0

Auto

RPM

Safe Stop Input

Safe Stop Type

Stop Mon Delay

Follow these steps to configure the Stop operation of the relay.

1. From the Stop group, choose the P44 [Safe Stop Input] parameter.

2. Set the Safe Stop Input parameter value to 1 (default) for 2NC


In this example application, the Safe Stop input (SS_In) monitors an E-Stop button with two normally-closed (2NC) contacts.

3. Choose the P45 [Safe Stop Type] parameter.


177


178

4. Set the 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 relay switches off Motion Power and sets door control logic to

Unlock.

5. Choose the P47 [Max Stop Time] parameter.

The default value is 0 s, but you can enter a value from

0…6553.5 s.

6. Type the value of the expected ramp 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] you entered, a Stop Speed Fault occurs and door control logic remains set to Lock until Standstill

Speed is reached.

7. 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.

8. Enter a value in the Standstill Speed parameter field to define the period of time that must pass with no relative position change before the relay determines standstill has been reached.

9. 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 Rotary feedback.

10. Enter the value to define the position limit in encoder units that is tolerated after standstill has been reached.

11. 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.

12. Enter a number greater than the Max Speed (2000 in this example).



13. 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.

14. Enter 100% for this example.

15. Go to the next section to set the parameters found in the Limited

Speed parameters group.

Example 2: Limited Speed Group Settings

Limited Speed Group Parameters


F

Configuring

0.0

Auto

RPM

Lim Speed Input

LimSpd Mon Delay

Enable SW Input


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.

2. Set the Lim Speed Input parameter value to 1 for 2NC


In this example application, the Safe Limited Speed input

(SLS_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 relay initiates the configured

Safe Stop Type.

When the relay 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.

179


3. Choose the P53 [LimSpd Mon Delay] parameter.

The default value is 0 s. The valid range is from 0…6553.5 s.

Type a value to define the desired delay between the SLS_In input ON to OFF transition and the start of Safe Limited Speed monitoring.

4. Choose the P54 [Enable SW Input] parameter.

The default value is 0 (Not Used) for applications without an enabling switch.

5. Set the Enable SW Input parameter value to 1 for 2NC


In this example application, the ESM_In input monitors an enabling switch with two normally-closed (2NC) contacts. As long as the enabling 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.


0…6553.5.

7. Type the maximum allowable rpm value for safe (reduced) velocity.


8. Go to the next section to set the parameters that configure Door

Control operation.

180


Example 2: Door Control Group Settings

Door Control Group Parameters


F

Configuring

0.0

Auto

RPM

Door Out Type

DM Input

Lock Mon Enable



Follow these steps to configure Door Control operation for the relay.

1. From the Door Control group, choose the P57 [Door Out Type] parameter.

2. Set the 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. Set the DM Input parameter value to 1 for 2NC (dual-channel equivalent) operation.

In this example application, the DM Input (DM_In) monitors the

TLS-3 GD2 switch, which has two normally-closed (2NC) safety contacts.

5. Choose the P59 [Lock Mon Enable] parameter.

The default value is 0 (Disabled) for applications without an interlock switch.

6. Set the Lock Mon Enable parameter value to 1 (Enabled) because this application uses the TLS-3 GD2 interlock switch.

181


7. Choose the P60 [Lock Mon Input] parameter.

The default value is 0 (Not Used) for applications that do not use an interlock switch.

8. Set the Lock Mon Input parameter value to 1 for 2NC


In this example application, the Lock Monitor Input (LM_In) monitors the TLS-3 GD2 switch, which has two normally-closed

(2 N.C.) interlock monitoring contacts.

9. Go to the next section to set the parameters that configure Safe

Maximum Speed monitoring.

Example 2: Max Speed Group

Max Speed Group Parameters

HIM Screen

Software Screen

F

Configuring

0.0

Auto

RPM

Max Speed Enable

Safe Max Speed

Max Spd Stop Typ

182

Follow these steps to configure Maximum Speed monitoring for the relay.

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 Max Speed Enable parameter value to 1 (Enabled), which monitors that the encoder feedback signal does not exceed the velocity configured using the Safe Max Speed parameter.



3. Choose the P62 [Safe Max Speed] parameter.


0…6553.5.

4. Type the maximum allowable rpm value for velocity.


5. Choose the P63 [Max Spd Stop Typ] parameter.

6. Set the 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 relay initiates the configured Safe Stop Type.

7. Go on to the next section to put the relay into Run mode and lock the configuration.


Example 2: Final Security Group Settings

This example only includes the steps for entering a configuration using the HIM module or software program. You must also follow the requirements described in

Chapter 10

,

Safety Configuration and

Verification .

ATTENTION

You must verify the configuration and validate the entire system, including a complete functional test, before the operational startup of any 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 relay into Run mode, generate a configuration signature, and lock the configuration.

1. From the Security group, choose the P6 [Operating Mode] parameter.

2. Set the Operating Mode parameter value to 1, which equals Run mode.

A configuration signature is generated.

183


3. Choose the P10 [Signature ID] parameter and record the configuration signature value stored in this parameter.

4. If you configured a password, choose the P1 [Password] parameter and type the password.

5. Choose the P5 [Lock State] parameter.

6. Set the Lock State parameter value to 1 (Lock) to lock the configuration.

The Config Lock status indicator is solid yellow when the relay configuration is locked.

184


Chapter

12

Troubleshoot the MSR57P Relay

Introduction

Topic

Status Indicators

Nonrecoverable Faults

Fault Recovery

Input and Output Faults

Fault Codes and Descriptions

Fault Reactions

Status Attributes

Page

185

186

187

187

187

190

192

Status Indicators

P

PWR/Fault

Stop

Config

Lock

Limited Speed

Standstill

Safe Speed


The MSR57P relay features eight indicators to provide status information.

Indicator Status

PWR/Fault

(1)

Green/On

Red/Flashing

Red/On

Red/Green Flashing

Config Lock

(1) Yellow/On

Yellow/Flashing

Stop Green/On

Red/On

Limited

Speed

Red/Flashing

Green/On

Green/Flashing

Off

Red/Flashing

Description

The relay is operating normally and is in Run mode.

A recoverable fault has occurred.

A nonrecoverable fault has occurred.

(All other indicators are OFF.)

The configuration is being downloaded or a firmware upgrade is in progress.

The relay’s configuration is locked.

The relay’s configuration is unlocked.

The Safe Stop (SS) input is closed.

The SS input is open or pressed.

The SS input has a fault.

The Safe Limited Speed (SLS) input is closed for normal Run operation.

The SLS input is open for a safe speed request to allow access to the machine (Maintenance operation).

The SLS function is not configured.

The SLS input has a fault.


185

Chapter 12 Troubleshoot the MSR57P Relay

Indicator

Motion

Power

Door

(2)

Safe Speed

(3)

Standstill

Status

Green/On

Off

Red/Flashing

Green/On

Red/On

Red/Flashing

Off

Green/On

Off

Red/Flashing

Green/On

Off

Red/Flashing

Description

The Motion Power (MP) output is ON.

The MP output is OFF.

The MP output has a fault.

The door is closed.

The door is open.

Door Monitor or Lock Monitor input switch has a fault.

Door monitoring is not configured.

Safe Limited Speed is being actively monitored and is below the configured Safe

Limited Speed value after an SLS request has been made.

Safe Limited Speed is not being monitored.

An SLS Speed Fault has occurred.

Standstill Speed has been detected.

Speed is greater than the configured Standstill

Speed.

Motion has been detected after stopped condition or a Stop Speed Fault has occurred.

(1) PWR/Fault green indicator and Config Lock indicator flash in synch when the relay is in Program mode.

(2) In cascading applications, the status of the door is only indicated by the Door indicator on the master unit. The

Door status indicators on middle and last units remain OFF.

(3) When the relay is configured for Slave, SLS Status Only mode, the Safe Speed indicator is solid green when the monitored speed of an individual MSR57P unit is below the Safe Speed Limit, following hysteresis. The

Safe Speed indicator is OFF when the monitored speed is above the configured safe speed limit. In this mode, the SLS_In value does not affect the state of the Safe Speed indicator.

When you apply power to the relay, the red/green indicators flash alternate colors and the Config Lock indicator flashes on and off twice before all indicators except for the PWR/Fault indicator turn off. The

PWR/Fault indicator remains flashing until the relay enters Run or

Program mode.

Nonrecoverable Faults

In addition to the reportable faults described in this chapter, the relay also generates nonrecoverable faults when a problem with the relay 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 relay may need to be replaced.

186


Fault Recovery

Troubleshoot the MSR57P Relay Chapter 12

If the fault is no longer present, the fault condition may be cleared by a successful SS Reset, except in the case of an Invalid Configuration

Fault, MP Out Fault, or Reset On At PwrUp Fault. An Invalid

Configuration Fault is cleared by a successful reconfiguration. An MP

Out Fault or Reset On At PwrUp Fault is cleared at power down or by a successful reconfiguration.

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.

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, if the inputs are configured with one of the following settings.

•


•


•


Fault Codes and

Descriptions


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 relay.

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 relay is powered up or reset when the queue is not empty. Code 0 equals No Entry.

The following tables list the faults, fault codes, and display text for the faults. These faults can be viewed by accessing the P67 [Fault Status] parameter.

See Appendix C

for information on using a HIM to access the fault history queue. See

Appendix D for information on using

DriveExplorer software to access the fault history queue.

187


Safe State Faults

3

4

Code Display Text Description

0

1

2

Combined Flt

Core Error

Invalid Cfg

A combined fault is indicated if any error has occurred.

A nonrecoverable microprocessor error has occurred.

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

196 .

5

MP Out Flt

Reset PwrUp

Fbk 1 Flt

An MP Output Fault indicates an error in the MP_Out output.

A Reset Power Up 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.

A Feedback 1 Fault occurs if any of the following conditions are detected at encoder 1:

6

7

8

13

27

28

Fbk 2 Flt

Dual Fbk Spd

Dual Fbk Pos

Mov in Stop

Fbk 1 V Fault

Fbk 2 V Fault

•

An open wire is detected.

•

A short-circuit is detected.

•

A sine/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 signal transitions are detected.

A Feedback 2 Fault occurs if any of the following 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.

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.

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.

If the relay is configured for a stop type that includes stopped speed checking, a Move 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

An Encoder 1 Voltage Fault occurs if the encoder voltage at encoder 1 is detected as out of range.

An Encoder 2 Voltage Fault occurs if the encoder voltage at encoder 2 is detected as out of range.

188



Fault While Stopping Faults


11 Decel Flt A Deceleration Fault occurs 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 relay 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].

Stop Category Fault Descriptions

22

23

25

16

14

15

20


9 SS In Flt An SS_In Fault occurs if an error is detected in the SS_In dual-channel input.

10 SS Out Flt An SS_Out Fault occurs if an error is detected in the SS_Out dual-channel output.

SLS In Flt

SLS Out Flt

DM In Flt

I/O

Faults

(1)

An SLS_In Fault occurs if an error is detected in the SLS_In dual-channel input.

An SLS_Out Fault occurs if an error is detected in the SLS_Out dual-channel output.

A DM_In Fault occurs if an error is detected in the DM_In dual-channel input.

17

18

19

DC Out Flt

LM In Flt

ESM In Flt

SLS Speed Flt

SMS Spd Flt

Accel Flt

Dir Flt

Motion

Faults

A DC_Out Fault occurs if an error is detected in the DC_Out dual-channel output.

An LM_In Fault occurs if an error is detected in the LM_In dual-channel input.

An ESM_In Fault occurs if an error is detected in the ESM_In dual-channel input.

The monitored speed was detected at greater than or equal to the Safe Speed Limit during Safe

Limited Speed monitoring.

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.

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.

A Direction Fault indicates that motion was detected in the restricted direction during safe direction monitoring (SDM).


189


Stop Category Fault Descriptions


21 Door Mon Flt If the relay is configured for Safe Limited Speed (SLS), but SLS monitoring is not active, the DM_In input must be ON (door closed) or a Door Monitoring Fault occurs.

26 ESM Mon Flt

A Door Monitoring Fault occurs if the door is open (DM_In input is OFF) when an SS Reset or SLS

Reset is requested (SLS_In transitions to ON).

If a configured SLS Monitoring Delay [Lim Spd 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 relay is configured for door monitoring and enabling switch monitoring and is actively monitoring safe limited speed, a Door Monitoring Fault occurs if the DM_In input transitions from

ON to OFF (door is opened), while the ESM_In input is OFF.

If the relay 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.

Monitor

Fault

If the relay is configured for enabling switch monitoring only and a configured SLS monitoring delay

[Lim Spd 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 relay 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.

24 Lock Mon Flt

If you attempt an SS Reset while the SLS_In input is OFF and the ESM_In input is OFF, an ESM

Monitoring Fault occurs.

If the relay is configured for lock monitoring, a Lock Monitoring Fault occurs when:

29 RL Flt

• 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.

• the LM_In input is detected as ON when the DM_In signal transitioned from ON to OFF.

An RLM Reset Fault occurs if the MSR57P relay is configured to qualify an SS Reset with the RL_In input and an SS Reset is attempted when the MP_Out output is OFF and the RL_In input is OFF.

(1) For more information on these faults see Input and Output Faults on page 187 .

Fault Reactions

When a fault occurs, the type of fault and the status of the system determine the resulting state of the system.


If a Safe State Fault occurs in any operational state including the

Disabled state, the relay goes to the Safe State. In the Safe State, all safety outputs are in their safe states.

190



Stop Category Faults and Fault While Stopping Faults

If a Stop Category Fault or Fault While Stopping Fault occurs while the relay is monitoring motion, the relay initiates the configured Safe Stop

Type.

The type of fault detected determines the relay’s response when the fault occurs while the relay is executing the configured Safe Stop

Type.

Faults Detected While Executing a Safe Stop

Type of Fault

Fault While Stopping Faults:

Response

•

Deceleration Fault (Decel Flt)

•

Stop Speed Fault (Stop Spd Flt)

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)

•

Direction Fault (Dir Flt), if the fault occurred while a safe stop was in progress.

These Stop Category Faults:

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 reached. The relay continues to monitor for faults.

•

SLS Speed Fault (SLS Spd Flt)

•

Direction Fault (Dir Flt), if the fault was detected before the safe stop was initiated. In this case, the relay does not perform

Direction Monitoring while executing the configured Safe Stop

Type.

•

Door Monitoring Fault (Door Mon Flt)

•

ESM Monitoring Fault (ESM Mon Flt)

•

Lock Monitoring Fault (Lock Mon Flt)

•

RLM Reset Fault (RL Flt)

•

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)

The relay continues to execute the configured Safe Stop Type and monitor for faults.

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 relay continues to monitor for faults.


191


If a Stop Category Fault or Fault While Stopping Fault occurs after

Standstill Speed has been reached and the relay has set door control logic to Unlock, the relay goes to the Safe State.

ATTENTION

If a fault occurs after Standstill Speed has been reached, door control logic may remain unlocked.

A Safe State Fault may set the Door Control output (DC_Out) to

OFF.

Status Attributes

For diagnostic purposes only, you can view status attributes by accessing the P68 [Guard Status] parameter and the P69 [IO Diag

Status] parameter from a HIM or via DriveExplorer or DriveExecutive software.

The status attributes are only valid when the MSR57P relay is in Run mode. If the MSR57P relay 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.

Guard Status

3

4

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

2 MP_Out

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.

This bit is set to 0, if the MP_Out dual-channel output is being commanded to the OFF state. This bit is set to 1 if the MP_Out dual-channel output is being commanded to the ON state.This bit is the commanded value, not the readback value.

SS In

SS Req

This bit displays the logical value, 1 or 0, evaluated for the dual-channel SS_In input.

This bit is set to 1 when a safe stop is initiated by either a transition of the SS_In input from ON to OFF or by a

Stop Category Fault.

5 SS In Prog

This bit is reset to 0 when a successful SS Reset occurs and when the Safety Mode is set to Disabled (0).

This bit is set to 1 when a safe stop is initiated by the transition of the SS_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.

192



Guard Status


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 relay is executing the Safe Stop.

7 SS Stopped

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.

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.

8

9

10

11

12

13

14

15

16

17

18

SS Out

SLS In

SLS Req

SLS In Prog

SLS Out

SMS In Prog

SMA In Prog

SDM In Prog

DC Lock

DC Out

DM In

This bit is set to 0 by an SS Reset or the occurrence of a Stop Category Fault.

It is always 0 when the relay is configured for a Safe Torque Off without Standstill Speed Checking.

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 a readback value.

This bit is set to 0 if the SS_Out output is being commanded to the OFF state.

This bit reflects the logical value evaluated for the dual-channel SLS_In input.

This bit is set to 1 if the Safe Limited Speed operation has been requested while the relay is actively monitoring motion or a SLS Monitoring Delay [LimSpd Mon Delay] is in progress.

This bit is set to 1 when Safe Limited Speed monitoring is active.

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.

This bit is set to a 1 if Safe Maximum Speed monitoring is enabled and Safe Maximum Speed is being monitored.

This bit is set to 1 if Safe Maximum Acceleration monitoring is enabled and safe maximum acceleration is actively being monitored.

If Safe Direction monitoring is enabled and configured for Positive Always or Negative Always, the

SDM_In_Progress bit is set to 1 any time the relay is configured for any Safety Mode other than Disabled.

If Safe Direction monitoring is enabled and configured for Positive During SLS or Negative During SLS, then this bit is set to 1 if the relay is actively monitoring for Safe Limited Speed. It is set to 0 in any other operating mode.

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.

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 DC_Out output is being commanded to the OFF state.

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.


193


Guard Status


19 DM In Prog The status of this bit is dependent on the relay’s speed monitoring configuration. The bit is 1 when:

20 LM In

• the relay is configured for Safe Stop with Door Monitoring and is monitoring motion, or is executing a Safe

Stop.

• the relay is configured for Safe Limited Speed with Door Monitoring and the relay is not actively monitoring for Safe Limited Speed, is in a SLS Monitoring Delay [LimSpd Mon Delay], or is executing a Safe Stop.

• the relay is configured for Safe Limited Speed with Door Monitoring and Enabling Switch Monitoring, and

– the relay is not actively monitoring for Safe Limited Speed, is in a SLS Monitoring Delay [LimSpd Mon

Delay], or is executing a Safe Stop.

– the relay is actively monitoring for Safe Limited Speed when the ESM_In input is OFF and the DM_In input is ON.

This bit is always set to 0 when the relay is not configured for Door Monitoring.

This bit is set to 1 if the logical value of the dual-channel LM_In input is evaluated as 1.

21 ESM In

This bit is set to 0 if the logical value of the dual-channel LM_In input is evaluated as 0.

This bit is set to 1 if the logical value of the dual-channel ESM_In input is evaluated as 1.

22 ESM In Prog

This bit is set to 0 if the logical value of the dual-channel ESM_In input is evaluated as 0.

This bit is set to 1 if the Safety Mode is configured for Enabling Switch Monitoring, Safe Limited Speed monitoring is active, and the SLS_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.

23 Reset In

24

25

Wait Reset

Wait SS Cyc

This bit indicates when an SS Reset is required. The bit is set to 1 whenever the relay is successfully configured and is in the Safe State or when Standstill Speed has been reached.

This bit indicates when the SS_In input must be cycled prior to a SS Reset being performed. The bit is set to 1 if the SS_In input is ON and a fault is detected or the Wait Stop Request attribute equals 1. It is set to 0 if the

SS_In input is detected as OFF.

26 Wait No Stop This bit is set (1) when a stop request is made using the HIM stop button. It is set to 0 when the HIM start button is pushed, following a reset, or at power-up.

27 SLS Cmd This bit reflects the status of the SLS_Command output. A 1 indicates that the output is ON; a 0 indicates that the

output is OFF. See SLS_Command Output on page 71 .

28 Stop Cmd This bit reflects the status of the Stop_Command output. A 1 indicates that the output is ON; a 0 indicates that

the output is OFF. See Stop_Command Output on page 70 .

29

Reserved

This bit is set to 0 when the Safety Mode is not configured for Enabling Switch Monitoring.

This status bit reflects the state of the Reset_In input. A 1 indicates the Reset_In input is ON; a 0 indicates the

Reset_In input is OFF.

31

194




I/O Diagnostic Status Attributes

These attributes are stored in the P69 [I/O Diagnostic Status] parameter. Each bit reflects the present state of I/O signal and is used for diagnostics: 0 = open; 1 = closed.

I/O Diag Status

8

9

10

11

12

13

2

3

4

Bit

0

1

5

6

7

Display Text

SS In Ch 0

SS In Ch 1

SS Out Ch 0

SS_Out Ch 1

SLS In Ch 0

SLS In Ch 1

SLS Out Ch 0

SLS Out Ch 1

ESM In Ch 0

ESM In Ch 1

DM In Ch 0

DM In Ch 1

DC Out Ch 0

DC Out Ch 1

14

15

16

17

18

19

LM In Ch 0

LM In Ch 1

Reset In

RL In

SLS Cmd

Stop Cmd

20 MP Out Ch 0

21 MP Out Ch 1

Bits 22…31 are Reserved (0).

IMPORTANT

When the MSR57P relay is not in Run mode, the P69 [I/O

Diagnostic Status] parameter is not updated.

195


Configuration Fault Codes

Use these fault codes, stored in P70 [Config Flt Code], to identify the reason for an Invalid Configuration Fault.

30

31

32

33

34

35

26

27

28

29

23

24

25

18

19

20

21

22

14

15

16

17

10

11

12

13

8

9

6

7

4

5

2

3

Value Description

0

1

No Fault.

Password Required.

Safety Mode (21) value not legal based on Cascaded Config (20) value.

Door Out Type (57) value not legal based on Cascaded Config (20) value.

Stop Mon Delay (46) value not legal based on Safe Stop Type (45) value.

Decel Ref Spd (50) value not legal based on Fbk 1 Resolution (31) value.

Standstill Speed (48) value not legal based on Cascaded Config (20) value.

LimSpd Mon Delay (53) value not legal based on Safety Mode (21) value.

Safe Speed Limit (55) value not legal based on Safety Mode (21) and Fbk 1 Resolution (31) value.

Speed Hysteresis (56) value not legal based on Safety Mode (21) value.

Safe Max Speed (62) value not legal based on Fbk 1 Resolution (31) value.

Direction Mon (42) value not legal based on Safety Mode (21) value.

Lock Mon Enable (59) value not legal based on Safety Mode (21) value.

Fbk 2 Resolution (36) value not legal based on Fbk Mode (27) value.

Display

No Fault

Password Req

P21 (P20)

P57 (P20)

P46 (P45)

P50 (P31)

P48 (P20)

P53 (P21)

P55 (P21 P31)

P56 (P21)

P62 (P31)

P42 (21)

P59 (P21)

P36 (P27)

Fbk 2 Polarity (35) value not legal based on Fbk Mode (27) value.

Fbk Speed Ratio (39) value not legal based on Fbk Mode (27) value.

Fbk Pos Tol (41) value not legal based on Fbk Mode (27) value.

Fbk Speed Tol (40) value not legal based on Fbk Mode (27) value.

Safe Stop In Typ (44) value not legal based on Safety Mode (21) value.

Lim Speed Input (52) value not legal based on Safety Mode (21) value.

DM Input Type (58) value not legal based on Cascaded Config (20) and Safety Mode (21) value.

Enable SW In Typ (54) value not legal based on Safety Mode (21) value.

Lock Mon In Type (60) value not legal based on Safety Mode (21) value and Lock Mon Enable (59) value.

Illegal Cascaded Config (20) value.

Illegal Reset Type (22) value.

Illegal Reset Loop (23) value.

Illegal Safe Stop Type (45) value.

Illegal Stop Decel Tol (51) value.

Illegal Fbk Mode (27) value.

Illegal Fbk 1 Type (28) value.

Illegal Fbk 1 Resolution (31) value.

Illegal Fbk1 Volt Mon (32) value.

Illegal Fbk 2 Volt Mon (37) value.

Illegal OverSpd Response (24) value.

Illegal MP_Out Mode (71) value.

Unknown error.

P35 (P27)

P39 (P27)

P41 (P27)

P40 (P27)

P44 (P21)

P52 (P21)

P58 (P 20 P21)

P54 (P21)

P60 (P21, P59)

P20

P22

P23

P45

P51

P27

P28

P31

P32

P37

P24

P71

Unknown Err

196


Appendix

A

Specifications

Introduction

Topic

General Specifications

Environmental Specifications

Certifications

Encoder Specifications

Page

197

198

199

199

General Specifications


Attribute

Standards

Safety category

Power supply

Value

IEC/EN60204-1, ISO12100,

IEC 61508, IEC 61800-5-2

Cat. 4 and PL(e) per EN ISO 13849-1;

SIL CL3 per IEC 61508 and EN 62061

24V DC, 0.8…1.1 x rated voltage

(2)

PELV or SELV

10.4 A max @ terminal A1 + 13 Aggregate current of

MSR57P

Power consumption

MP outputs 14, 24,

SLS outputs 68, 78

SS outputs 34, 44

SLS_Status output Y35,

Fault_Status output Y37

Door control outputs

51, 52

5 W

24V DC, 2 A, short-circuit protected

24V DC, 100 mA, short-circuit protected


24V DC, short-circuit protected

•

1.5 A, bipolar (Power to Release/Power to Lock) configuration

•

20 mA per output, cascading (2Ch Source) configuration

24V DC, 100 mA, short-circuit protected Stop_Command output

Y32,

SLS_Command output

Y33


Output Y1 24V DC, 20 mA, short-circuit protected

Pulse outputs S11, S21 24V DC, 100 mA, short-circuit protected

Pulse inputs S12, S22,

S32, S42, S52, S62, S72,

S82, X32, X42

11 mA per input, max

Inputs S34, Y2 11 mA per input, max

Input ON Voltage, min 11V

Input OFF Voltage, max 5V

Input OFF Current, max 2 mA

197

Appendix A Specifications

Environmental

Specifications

Attribute

Input-to-output response time (SS_In, SLS_In,

DM_In, ESM_In, LM_In)

Overspeed Response

Time

Value

20 ms

User-configurable

Power-on delay, max

Pollution degree

Enclosure protection

Terminal protection

Wire Type

3 s

2

IP40

IP20

Use copper that will withstand 60/75 °C (140/167 °F)

Conductor size

(1)

0.2…2.5 mm

2

(12…24 AWG)

Terminal screw torque 0.6…0.8 Nm (5…7 lb-in)

Case material

Mounting

Weight, approx.

Polyamide PA 6.6

35 mm DIN rail

350 g (0.77 lb)

(1) Refer to 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 a 6 A slow-blow or 10 A fast-acting fuse.

Attribute Value

Temperature, operating -5…55 °C (23…131 °F)

Relative humidity

Vibration

90% RH noncondensing

10…55 Hz, 0.35 mm displacement

Shock, operating

ESD immunity

10 g, 16 ms, 100 shocks

4 kV contact discharges; 8 kV air discharges

Radiated RF immunity 10 V/m from 80…1000 MHz; 3 V/m from 1.4…2.0 GHz;

1V/m from 2.0…2.7GHz

EFT/B immunity Power, dc: ±2 kV

I/O signal lines: ±1 kV

Surge transient immunity Power, dc: ±0.5 kV line-line and ±0.5 kV line-earth

I/O signal lines: ±1 kV line-earth

Conducted RF immunity 10V rms from 150 kHz…80 MHz

Radiated Emissions Group 1, Class A

198


Specifications Appendix A

Certifications

Certification

c-UL-us

CE

C-Tick

TÜV

(1)

(1) When product is marked.

Value

UL Listed, certified for US and Canada.

European Union 2004/108/EC EMC Directive, compliant with:

•

EN 61000-6-4; Industrial Emissions.

•

EN 61131-2 Programmable Controllers (Clause 8, Zone A & B).

•

EN 61326-3-1; Meas./Control/Lab., Industrial Requirements.

•

EN 61000-6-2; Industrial Immunity.

Australian Radiocommunications Act, compliant with:

AS/NZS CISPR 11; Industrial Emissions.

TÜV Certified for Functional Safety: up to SIL CL3, according to IEC

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

Guardmaster MSR57P Speed Monitoring Safety Relay User Manual, publication 440R-UM004.

See the Product Certification link at http://ab.com

for Declarations of

Conformity, Certificates, and other certifications details.

Encoder Specifications

Type

Generic

Incremental

Generic

Sin/Cos

Stegmann

Sin/Cos

Parameter

TTL incremental encoder support

Differential input voltage (AM and BM)

Input signal frequency (AM and BM)

AM/BM differential input voltage (p-p)

AM/BM input frequency

AM/BM differential input voltage (p-p)

AM/BM input frequency

Description

5V, differential A quad B

1.0…7.0V

200 kHz, max

0.6…1.2V

100 kHz, max

1V ±10%

100 kHz, max


199

Appendix A Specifications

200


Parameter Groups

Appendix

B

Parameter Data

Parameters are organized into both a linear list by parameter number, and into device-specific files and groups.

Parameters for the speed monitoring safety relay appear in the groups

Security, General, Feedback, Stop, Limited Speed, Door Control, Max

Speed, and Faults.

MSR57P Parameter Groups

Parameters

Security General

1 Password

5 Lock State

6 Operating Mode

7 Reset Defaults

10 Signature ID

13 New Password

17 Password

Command

18 Security Code

19 Vendor Password

70 Config Flt Code

20 Cascaded Config

21 Safety Mode

22 Reset Type

23 Reset Loop

24 OverSpd Response

25 Language Code

26 Max Display Spd

71 MP Out Mode

72 SS Out Mode

73 SLS Out Mode

Feedback

27 Fbk Mode

28 Fbk 1 Type

29 Fbk 1 Units

30 Fbk 1 Polarity

31 Fbk 1 Resolution

32 Fbk 1 Volt Mon

33 Fbk 1 Speed

34 Fbk 2 Units

35 Fbk 2 Polarity

36 Fbk 2 Resolution

37 Fbk 2 Volt Mon

38 Fbk 2 Speed

39 Fbk Speed Ratio

40 Fbk Speed Tol

41 Fbk Pos Tol

42 Direction Mon

43 Direction Tol

Stop

44 Safe Stop Input

45 Safe Stop Type

46 Stop Mon Delay

47 Max Stop Time

48 Standstill Speed

49 Standstill Pos

50 Decel Ref Speed

51 Stop Decel Tol

Door Control

57 Door Out Type

58 DM Input

59 Lock Mon Enable

60 Lock Mon Input

74 Door Out Mode

Faults

67 Fault Status

68 Guard Status

69 IO Diag Status

70 Config Flt Code

Limited Speed

52 Lim Speed Input

53 LimSpd Mon Delay

54 Enable SW Input

55 Safe Speed Limit

56 Speed Hysteresis

Max Speed

61 Max Speed Enable

62 Safe Max Speed

63 Max Spd Stop Typ

64 Max Accel Enable

65 Safe Accel Limit

66 Max Acc Stop Typ


201

Appendix B Parameter Data

Parameters and Settings in a Linear List

The table lists the configurable parameters and their valid settings in numerical order. If any values other than those listed in the table are configured for any of the parameters, an Invalid Configuration Fault occurs.

List of Parameters

No.

Name Description Values

R

3

4

1

2

5

6

Password

Reserved

Lock State

Operating

Mode

Password for Lock and Unlock function.

Command to lock or unlock the relay configuration.

Command to place the system in Program or Run mode.

Reset

Defaults

Reserved

Resets relay to factory defaults.

Signature

ID

Reserved

Safety configuration identifier.

New

Password

Reserved

32-bit configuration password.

Range: 0

…

4,294,967,295

Default: 0 = Unlock

Options: 0 = Unlock

1 = Lock

Default: 0 = Program

Options: 0 = Program

1 = Run

2 = Config flt


1 = Reset to factory defaults (Reset Fac)

14

15

16

17

11

12

13

7

8

9

10 Range:

Range:

0

0

…

…

4,294,967,295

4,294,967,295

18

19

20

Password

Command

Save new password command.

Default: 0 = No action


1 = Change Password (Change PW)

2 = Reset Password (Reset PW)

Range: 0

…

65,535 Security

Code

Vendor

Password

Cascaded

Config

Used for Reset Password command.

Vendor password for Reset Password command.


Range: 0

…

65,535

Default: 0 = Single Unit System (Single)

Options: 0 = Single Unit System (Single)

1 = Cascaded System First Unit (Multi First)

2 = Cascaded System Middle Unit (Multi Mid)

3 = Cascaded System Last Unit (Multi Last)

R/W

R/W

R/W

R

W

R/W

R

R/W

R/W

202


Parameter Data Appendix B


No.


21

22

23

24

25

26

27

28

29

30

Safety

Mode

Reset Type

Reset Loop

OverSpd

Response

Language

Code

Fbk 1 Type

Fbk 1 Units

Fbk 1

Polarity


Defines the type of reset used by the safety relay.

Defines whether the Reset Loop input (RL_In) is used to qualify a Safe Stop Reset.

Configuration for the feedback interface sampling rate.

Determines the language of the parameter display.

Max

Display

Spd

Determines scaling for Fbk 1 speed process display value.

Fbk Mode Selects the number of encoders and the type of discrepancy checking.

Selects the type of feedback for encoder 1.

Selects rotary or linear feedback for encoder 1.


Default: 1 = Master, Safe Stop (Safe Stop)


1 = Master, Safe Stop (Safe Stop)

2 = Master, Safe Stop with Door Monitoring (Safe Stop DM)

3 = Master, Safe Limited Speed (Lim Speed)

4 = Master, Safe Limited Speed with Door Monitoring

(Lim Speed DM)

5 = Master, Safe Limited Speed with Enabling Switch Control

(Lim Speed ES)

6 = Master, Safe Limited Speed with Door Monitor and

Enabling Switch (LimSpd DM ES)

7 = Master, Safe Limited Speed Status Only (Lim Spd Stat)

8 = Slave, Safe Stop (Slv Safe Stp)

9 = Slave, Safe Limited Speed (Slv Lim Spd)

10 = Slave, Safe Limited Speed Status Only (Slv Spd Stat)

Default: 2 = Manual Monitored (Monitored)

Options: 0 = Automatic

1 = Manual

2 = Manual Monitored (Monitored)

Default: 0 = Always Qualified (Disable)

Options: 0 = Always Qualified (Disable)

1 = Qualified by RL_In (Enable)

Default: 0 = 42 ms

Options: 0 = 42 ms

1 = 48 ms

2 = 60 ms

3 = 84 ms

4 = 132 ms

5 = 228 ms

6 = 420 ms

Default: 0 = English

Options: 0 = English

1 = French

2 = Spanish

3 = Italian

4 = German

5 = Reserved

6 = Portuguese

7 = Reserved

8 = Reserved

9 = Dutch

Default: 1800

Range: 1

…

65,535 rpm or mm/s

Default: 0 = 1 Encoder (Single Fbk)

Options: 0 = 1 Encoder (Single Fbk)

1 = 2 Encoders with Speed and Position Discrepancy Checking

(Dual S/P Chk)

2 = 2 Encoders Speed Discrepancy Checking (Dual Spd Chk)

3 = 2 Encoders Position Discrepancy Checking (Dual Pos Chk)

Default: 1 = TTL (Incremental)

Options: 0 = Sine/Cosine

1 = TTL (Incremental)



1 = Linear (mm)



1 = Reversed

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W


203



No.


38

39

31

32

33

34

35

36

37

40

41

42

43

Fbk 1

Resolution

Fbk 1 Volt

Mon

Fbk 1

Speed

Fbk 2 Units

Fbk 2

Polarity

Counts/Revolution.


Displays the output speed of encoder 1

Selects rotary or linear feedback system for encoder 2.


Default: 1024

Range: 1

…

65,535 pulses/revolution or pulses/mm based on rotary or linear configuration defined by P29 [Fbk 1 Units] parameter



5 = 5V ±10%

9 = 7…12V

12 = 11…14V

14 = 11.5…15.5V

Range: -214,748,364.8

…

214,748,364.7 rpm or mm/s based on rotary or linear configuration defined by P29 [Fbk 1 Units] parameter



1 = Linear (mm)



1 = Reversed

R

R/W

R

R/W

R/W

Fbk 2

Resolution

Counts/Revolution.

Default: 0

Range: 0

…

65,535 pulses/revolution or pulses/mm based on rotary or linear configuration defined by P34 [Fbk 2 Units] parameter

R

R/W Fbk 2 Volt

Mon



(1 encoder).



5 = 5V ±10%

9 = 7…12V

12 = 11…14V

14 = 11.5…15.5V

Range: -214,748,364.8

…

214,748,364.7 rpm or mm/s Fbk 2

Speed

Fbk Speed

Ratio


Fbk Speed

Tol

Fbk Pos Tol

Direction

Mon

Dual Feedback Speed Discrepancy Tolerance.

Acceptable difference in speed between Fbk 1 Speed and

Fbk 2 Speed.

Acceptable difference in position between encoder 1 and encoder 2.

Defines the allowable direction if Safe Direction Monitoring is enabled.

Range: 0

…

6553.5 rpm or mm/s units are based on rotary or linear configuration defined by the P29

[Fbk 1 Units] parameter

Default: 0

Range: 0

…

65,535 deg or mm units are based on rotary or linear configuration defined by the P29



Direction

Tol

Dual Feedback Speed Ratio.

Defines the ratio of the expected speed of encoder 2 divided by the expected speed of encoder 1

Not valid when Fbk Mode = 0 (1 encoder).

The position limit in encoder units tolerated in the wrong direction when Safe Direction Monitoring is active.

Default: 0.0000

Range: 0.0001

…

10,000.0

ratio based on rotary or linear configuration defined by the P29


Default: 0


1 = Positive always (Pos Always)

2 = Negative always (Neg Always)

3 = Positive during safe limited speed monitoring (Pos in SLS)

4 = Negative during safe limited speed monitoring (Neg in SLS)

Default: 10

Range: 0

…

65,535 deg or mm based on rotary or linear configuration defined by the


R

R/W

R/W

R/W

R/W

R/W

204




No.


44

45

46

47

48

49

50

51

52

53

54

Safe Stop

Input

Safe Stop

Type

Stop Mon

Delay

Max Stop

Time

Standstill

Speed

Standstill

Pos

Decel Ref

Speed

Stop Decel

Tol

Lim Speed

Input

Configuration for Safe Stop input (SS_In).

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.

Defines the monitoring delay between the request and the

Stop Delay [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.

If the Safe Stop Type is Safe Torque Off with or without

Standstill Speed Checking, the Stop Monitor Delay must be

0 or an Invalid Configuration Fault occurs.

Stop Delay

Defines the maximum stop delay time that is used when the

Safe Stop function is initiated by a stop type condition.

Defines the speed limit that is used to declare motion as stopped.

Not valid for Safe Torque Off without Standstill Checking.


Defines the position limit window in encoder 1 degrees or mm that will be tolerated after a safe stop condition has been detected.

Not valid for Safe Torque Off without Standstill Checking.

Deceleration Reference Speed.

Determines deceleration rate to monitor for Safe Stop 1 or

Safe Stop 2.

Decel Tolerance.

This is the acceptable tolerance above the deceleration rate set by the P50 [Decel Ref Speed] parameter.

Configuration for the Safe Limited Speed input (SLS_In).

Default: 1 = Dual-channel equivalent (2NC)








Default: 0 = Safe Torque Off with Standstill Checking (Torque Off)

Options: 0 = Safe Torque Off with Standstill Checking (Torque Off)

1 = Safe Stop 1

2 = Safe Stop 2

3 = Safe Torque Off without Standstill Checking (Trq Off NoCk)

Default: 0

Range: 0

…

6553.5 s

Default:

Range:

Default:

Range: 0.001

…

65.535 rpm or mm/s based on rotary or linear configuration defined by the


Range: 0

…

65,535 degrees (360° = 1 revolution) or mm based on rotary or linear configuration defined by the P29 [Fbk 1 Units] parameter

Default:

0

0

0

…

6553.5 s

0.001

Default: 10

Range: 0

…

65,535 rpm or mm/s based on rotary or linear configuration defined by the


Default: 0

Range: 0

…


R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

LimSpd

Mon Delay

Defines the Safe Limited Speed Monitoring Delay between the SLS_In ON to OFF transition and the initiation of the

Safe Limited Speed (SLS) monitoring.

Enable SW

Input

Configuration for the Enabling Switch input (ESM_In).









Default: 0

Range: 0

…

6553.5 s









R/W

R/W


205



No.


55

56

57

58

59

60

61

62

63

64

65

Safe Speed

Limit

Speed

Hysteresis

Door Out

Type

DM Input

Defines the speed limit that will be monitored in Safe

Limited Speed (SLS) mode.

Provides hysteresis for SLS_Out output when Safe Limited

Speed monitoring is active.

Door Control 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 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).

Configuration for the Door Monitor input (DM_In).

Default: 0

Range: 0

…

6553.5 rpm or mm/s based on rotary or linear configuration defined by P29 [Fbk 1 Units] parameter

Default: 0

R/W

R/W

Range: 0% when P21 [Safety Mode] = 1, 2, 3, 4, 5, 6, 8, or 9

10…100% when P21 [Safety Mode] = 7 or 10





R/W

R/W

Lock Mon

Enable

Lock Mon

Input

Max Speed

Enable

Safe Max

Speed

Max Spd

Stop Typ

Max Accel

Enable

Safe Accel

Limit

Lock Monitoring can only be enabled when the speed monitoring safety relay is a single unit or as the first unit in a multi-axis system (P20 [Cascaded Config] equals 0 or 1).

Configuration for the Lock Monitor input (LM_In).

Enable Safe Maximum Speed Monitoring.

Defines the maximum speed limit that will be tolerated if

Safe Maximum Speed monitoring is enabled.

Safe Maximum Speed Monitoring Stop Behavior.

Defines the safe stop type that will be initiated in the event of a SMS Speed Fault.

Enable Safe Maximum Acceleration Monitoring.

Defines the Safe Maximum Acceleration Limit, relative to encoder 1, for which the system is being monitored.









Default: 0 = Disable

Options: 0 = Disable

1 = Enable











1 = Enable

Default: 0

Range: 0

…

65,535 rpm or mm/s based on rotary or linear configuration defined by the P29 [Fbk 1

Units] parameter

Default: 0 = Use Safe Torque Off with Check for Standstill (Torque Off)

Options: 0 = Use Safe Torque Off with Check for Standstill (Torque Off)




1 = Enable

Default: 0

Range:

0

…

65,535 rev/s

2

or mm/s

2 based on rotary or linear configuration defined by the


R/W

R/W

R/W

R/W

R/W

R/W

R/W

206




No.


66

67

Max Acc

Stop Typ

Fault

Status

Safe Maximum Acceleration Monitoring Stop Behavior.

Defines the safe stop type that will be initiated in the event of an Acceleration Fault.

Bit-encoded faults.

Default: 0 = Use Safe Torque Off with Check for Standstill (Torque Off)

Range: 0 = Use Safe Torque Off with Check for Standstill (Torque Off)


Bit 24:

Bit 25:

Bit 26:

Bit 27:

Bit 28:

Bit 29:

Bit 30:

Bit 31:

Bit 16:

Bit 17:

Bit 18:

Bit 19:

Bit 20:

Bit 21:

Bit 22:

Bit 23:

Bit 8:

Bit 9:

Bit 10:

Bit 11:

Bit 12:

Bit 13:

Bit 14:

Bit 15:

Bit 0:

Bit 1:

Bit 2:

Bit 3:

Bit 4:

Bit 5:

Bit 6:

Bit 7:

Combined Fault Status (Combined Flt)

Reserved for Core Error (Core Error)

Invalid Configuration Fault (Invalid Cfg)

MP Out Fault (MP Out Flt)

Reset On at PwrUp Fault (Reset PwrUp)

Feedback 1 Fault (Fbk 1 Flt)

Feedback 2 Fault (Fbk 2 Flt)

Dual FB Speed Fault (Dual Fbk Spd)

Dual FB Position Fault (Dual Fbk Pos)

SS_In Fault (SS In Flt)

SS_Out Fault (SS Out Flt)

Deceleration Fault (Decel Flt)

Stop Speed Fault (Stop Spd Flt)

Motion After Stopped Fault (Mov in Stop)

SLS_In Fault (SLS In Flt)

SLS_Out Fault (SLS Out Flt)

SLS_Speed Fault (SLS Spd Flt)

SMS_Speed Fault (SMS Spd Flt)

Acceleration Fault (Accel Flt)

Direction Fault (Dir Flt)

DM_In Fault (DM In Flt)

Door Monitoring Fault (Door Mon Flt)

DC_Out Fault (DC Out Flt)

LM_In Fault (LM In Flt)

Lock Monitoring Fault (Lock Mon Flt)

ESM_In Fault (ESM In Flt)

ESM Monitoring Fault (ESM Mon Flt)

Encoder 1 Voltage Fault (Fbk 1 V Flt)

Encoder 2 Voltage Fault (Fbk 2 V Flt)

RLM Reset Fault (RL Flt)

Reserved

Reserved

R/W

R


207



No.

Name Description

68 Guard

Status

Values

Bit 0: StatusOK

Bit 1: Configuration_Lock (Config Lock)

Bit 2: MP_Out_Value (MP Out)

Bit 3: SS_In_Value (SS In)

Bit 4: SS_Request_Status (SS Req)

Bit 5: SS_In_Progress (SS In Prog)

Bit 6: SS_Decelerating_Status (SS Decel)

Bit 7: SS_Axis_Stopped_Status (SS Stopped)

Bit 8: SS_Output_Value (SS Out)

Bit 9: SLS_In_Value (SLS In)

Bit 10: SLS_Request_Status (SLS Req)

Bit 11: SLS_In_Progress (SLS In Prog)

Bit 12: SLS_Output_Value (SLS Out)

Bit 13: SMS_In_Progress (SMS In Prog

Bit 14: SMA_In_Progress (SMA In Prog)

Bit 15: SDM_In_Progress (SDM In Prog)

Bit 16: DC_Lock_Status (DC Lock)

Bit 17: DC_Out_Value (DC Out)

Bit 18: DM_In_Value (DM In)

Bit 19: DM_In_Progress (DM In Prog)

Bit 20: LM_In_Value (LM In)

Bit 21: ESM_In_Value (ESM In)

Bit 22: ESM_In_Progress (ESM In Prog)

Bit 23: Reset_In_Value (Reset In)

Bit 24: Waiting_for_SS_Reset (Wait Reset)

Bit 25: Waiting_for_Cycle_SS_In (Wait SS Cyc)

Bit 26: Waiting_for_Stop_Request_Removal (Wait No Stop)

Bit 27: SLS_Comand_Value (SLS Cmd)

Bit 28: Stop_Command_Value (Stop Cmd)

Bit 29…Bit 31: Reserved

0 = Fault; 1 = OK

0 = Unlock; 1 = Lock

0 = Off; 1 = On

0 = Off; 1 = On

0 = Inactive; 1 = Active




0 = Off; 1 = On

0 = Off; 1 = On



0 = Off; 1 = On




1 = Lock; 0 = Unlock

0 = Off; 1 = On

0 = Off; 1 = On


0 = Off; 1 = On

0 = Off; 1 = On


0 = Off; 1 = On




0 = Off; 1 = On

0 = Off; 1 = On

R

208




No.


69 IO Diag

Status

Indicates present state of I/O used for diagnostics.

Bit 0: SS_in_ch_0 status (SS In Ch 0)

Bit 1: SS_in_ch_1 status (SS In Ch 1)

Bit 2: SS_out_ch_0 status (SS Out Ch 0)

Bit 3: SS_out_ch_1 status (SS Out Ch 1)

Bit 4: SLS_in_ch_0 status (SLS In Ch 0)

Bit 5: SLS_in_ch_1 status (SLS In Ch 1)

Bit 6: SLS_out_ch_0 status (SLS Out Ch 0)

Bit 7: SLS_out_ch_1 status (SLS Out Ch 1)

Bit 8: ESM_in_ch_0 status (ESM In Ch 0)

Bit 9: ESM_in_ch_1 status (ESM In Ch 1)

Bit 10: DM_in_ch_0 status (DM In Ch 0)

Bit 11: DM_in_ch_1 status (DM In Ch 1)

Bit 12: DC_out_ch_0 status (DC Out Ch 0)

Bit 13: DC_out_ch_1 status (DC Out Ch 1)

Bit 14: LM_in_ch_0 status (LM In Ch 0)

Bit 15: LM_in_ch_1 status (LM In Ch 1)

Bit 16: Reset_In status (Reset In)

Bit 17: RL_In status (RL In)

Bit 18: SLS_command status (SLS Cmd)

Bit 19: Stop_command status (Stop Cmd)

Bit 20: MP_Out_Ch_0 status (MP Out Ch 0)

Bit 21: MP_Out_Ch_1 status (MP Out Ch 1)

Bit 22: Reserved (0)










Values

0 = Open; 1 = Closed

IMPORTANT: When the MSR57P relay is not in the Run mode, the P69 [IO

Diag Status] parameter is not updated.

R


209



No.


70 Config Flt

Code

Configuration Fault Code.

210

Values

Options: 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 Speed 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 Speed Input] 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 onP21 [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 = Illegal P23 [Reset Loop] value.

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 = Illegal P71 [MP Out Mode] value.

35 = Unknown error (Unknown Err).

R



No.


71

72

73

74

MP Out

Mode

SS Out

Mode

SLS Out

Mode

Door Out

Mode

Defines whether the MP_Out output is pulse-tested.

Defines whether the SS_Out output is pulse-tested.

Defines whether the SLS_Out output is pulse-tested.

Defines whether the DC_Out output is pulse-tested.

(1)

(1)

(1)

(1)



1 = No pulse test



1 = No pulse test



1 = No pulse test



1 = No pulse test



R/W

R/W

R/W

R/W


211


212


Appendix

C

Using a HIM

Introduction

Topic

Connect a HIM Module

Setting Parameters with a HIM Module

Accessing the Fault History Queue

Page

213

214

215

Connect a HIM Module

You can set the MSR57P parameters by using a HIM module or a personal computer running DriveExplorer or DriveExecutive software.

Connect the 20-HIM-A3 module to the relay by using a 20-HIM-H10 cable.

20-HIM-A3 Module

20-HIM-10 Cable


213

Appendix C Using a HIM

Setting Parameters with a

HIM Module

A HIM module displays only one parameter at a time. The keypad lets you scroll through the HIM menu structure to find the parameters you need to set.

Once the HIM module is connected to the safety relay, follow these steps to set parameters.

1. If necessary, configure the HIM module to display parameters by logical groups.

b. Press or to select File - Group - Par from the

Param Dspy Item menu and press .

F

Configuring

0.0

Auto

RPM

Main Menu:

Diagnostics

Parameter

Device Select

2. In the Main Menu, press and press .

or

F

Configuring

0.0

Auto

RPM

F

GP:File

Parameter Groups

to scroll to Parameter

3. Press in that file.

to choose the Parameter file and display the groups

F

Configuring

0.0

Auto

RPM

F

GP:Group

Security

General

Feedback

to display the 4. Scroll to the desired group and press parameters in that group.

F

Configuring

0.0

Auto

RPM

Cascaded Config

Safety Mode

Reset Type

214


Using a HIM Appendix C

5. Scroll to the desired parameter and press parameter value screen.

F

Configuring

0.0

Auto

RPM

FGP:

Safety Mode

Par 21

Safe Stop

to display the

6. Press

7. Press

to edit the parameter.

or to change the value.

8. If desired, press

Sel

to move from digit to digit, letter to letter, or bit to bit.

Digits or bits that you can change are highlighted.

9. Press to save the value or

Esc

to cancel the change.

10. Press

Esc

to return to the group list.

TIP

Numeric Keypad Shortcut

You can also press

ALT typing its number.

+

+/–

to access a parameter by

ATTENTION

The red stop button on the HIM keypad does not have safety integrity. Do not use the stop button to execute a safe stop.

TIP

If the red stop button on the HIM keypad is pressed, you must press the green button on the HIM keypad to reset the MSR57P.

Accessing the Fault History

Queue

To view the contents of the fault history queue, choose

Diagnostics>Faults>View Fault Queue from the top-level menu.


215

Appendix C Using a HIM

216


Appendix

D

Use DriveExplorer or DriveExecutive

Software

Introduction

Connect a Personal

Computer

Topic

Connect a Personal Computer

Using DriveExplorer Software

Using DriveExecutive Software

Page

217

218

221

You must have either DriveExplorer or DriveExecutive software installed on your personal computer and an serial or USB converter.

Description

DriveExplorer software

DriveExecutive software

RSLinx

(1)

software

Serial Converter

(2)

Universal Serial Bus Converter

(3)

Catalog Number Version

9306-4EXP02ENE 5.02 or later

9303-4DTE01ENE

9355 series

1203-SSS (series B)

1203-USB

4.01 or later

2.50.00 or later

3.004 or later

1.001 or later

(1) RSLinx software is required by DriveExecutive software, but it is not required by DriveExplorer software.

(2) The serial converter, catalog number 1203-SSS (series B), contains: 1203-SFC cable from personal computer serial to the converter, 1202-C10 cable from the converter to DPI port, and a serial converter body.

(3) Catalog number 1203-USB contains the converter body, a 20-HIM-H10 cable to connect to the DPI port, and a type A to type B USB cable to connect the 1203-USB converter to a personal computer.

A free version of DriveExplorer Lite software is available for download at http://www.ab.com/drives/driveexplorer/free_download.html

.

Follow these steps to connect the personal computer to the DPI port on the front of the relay.

1. Connect the appropriate cable between the COM port on your personal computer and the communication port on the serial or

USB converter.


217

Appendix D Use DriveExplorer or DriveExecutive Software

2. Connect the appropriate cable between the serial or USB converter and the DPI connector on the relay.

Using USB Converter

20-HIM-H10 Cable

Using Serial Converter

1202-C10 Cable

Power Status

Indicator

Power Status

Indicator

Using DriveExplorer

Software

218

1203-SFC Cable

Type A to Type B USB

Cable

DriveExplorer or DriveExecutive Software

DriveExplorer or DriveExecutive Software

3. Observe the status indicator to verify that the serial or USB converter has power.

4. Configure communication following the steps in

Using

DriveExplorer Software

on page

218 or

Using DriveExecutive

Software

on page

221

.

You need to configure communication between DriveExplorer software and the DPI port on the relay before you can use the software to edit the relay’s parameters.

Configure Serial Communication

Follow these steps to configure communication between

DriveExplorer software on your personal computer, the serial or USB communication converter, and the DPI port on the relay.

If you are using the 1203-USB converter, you must install the USB drivers on your personal computer. The drivers are provided on the

DriveExplorer Lite CD supplied with the converter.

For information on installing drivers, refer to the USB Converter User

Manual, publication DRIVES-UM001 .

1. Launch DriveExplorer software.


Use DriveExplorer or DriveExecutive Software Appendix D

2. From the Explore menu, choose Connect and Configure

Communication.

3. On the Configure Communication dialog, choose the serial port to which you are connected and type the baud rate.

If you are using the USB converter, the communication port must match the port that was mapped when you installed the

USB drivers and the communication rate must be set to

115,200 bps.

When communication is established, DriveExplorer software maps your relay.

Successful uploading of your relay parameters results in an MSR57P relay parameter display.

Edit Parameters in DriveExplorer Software

In DriveExplorer software, you can choose parameters from the linear list or by using the file and group.

The left pane of the DriveExplorer software interface shows the connected devices and the right pane lists the parameters available.

DriveExplorer MSR57P Parameter Display


DriveExplorer Software Parameter Information

Column Description of Contents

S Status

N:P,P#

R =

* =

N =

P =

P# =

Read only

Editable

The node number of the device on the network

The port number (0 if a device)

The parameter number associated with a specific programming parameter

Name

Value

Units

The item name

The present value of the item

The unit of measurement for the item

219


Follow these steps to edit a parameter.

1. Expand the MSR57P relay.

2. Choose either Parameter List or expand the Parameter file to display the parameter groups.

TIP

The configuration can only be edited when the MSR57P relay is unlocked and in Program mode.

3. You can edit a parameter by double-clicking it and entering the new value.

4. Follow the procedure in

Configure the Speed Monitoring Relay

on page

158 to configure the MSR57P relay.

After you edit parameters, you can upload them and save them to a file on you personal computer. The file can be used as a backup, printed, or downloaded to another MSR57P relay.

For detailed information on using DriveExplorer software, consult online help.

Access the Fault History Queue

Follow these steps to view the contents of the fault history queue.

1. From the DriveExplorer menu, choose Explore>Device

Properties.

2. Click the Faults tab on the device dialog.

220


Using DriveExecutive

Software


You need to configure communication between DriveExecutive software and the DPI port on the relay before you can use the software to edit the relay’s parameters.

Configure Serial Communication

Follow these steps to configure communication between

DriveExecutive software on your personal computer, the AnaCANda or USB communication converter, and the DPI port on the relay.

1. Open RSLinx software.

IMPORTANT

DriveExecutive software must exchange information via RSLinx software. This requires serial communication between the DPI port on the relay and your personal computer. The Ethernet network, or other communication standards are not compatible.

2. In RSLinx software, configure a communication driver to interface between your personal computer and the DPI port on the relay. a. Click Add New. b. From the Available Driver Types pull-down menu, choose

RS-232 DF1.

c. Click OK.


221


3. Configure the RS232 DF1 device as shown.

222

a. Choose the Comm Port to which you are connected.

If you are using the USB converter, the comm port must be the port that was mapped when you installed the USB drivers.

b. Choose the correct baud rate for the relay.

If you are using the USB converter the correct communication rate is 115,200 bps.

c. Close any conflicting programs that might be using this port at this time.

d. From the Device pull-down menu, choose the SCANport device.

e. In the Station Number box, type 01.

5. Click OK.



6. Open RSWho in RSLinx software to verify that the new driver is recognized.


7. Close RSLinx software.

8. Open DriveExecutive software.

9. Advance to Drive Selection and choose Connect to Drive.

10. Choose your workstation (01 in the preceding diagram) and click OK.

DriveExecutive software connects with the relay and begins to upload its parameters. A parameter upload initially occurs, followed by a file group upload. Each upload displays in a separate dialog.

223


Edit Parameters

In DriveExecutive software, you can choose parameters from the linear list or by using the file and group.

The left pane of the DriveExecutive software dialog shows the connected devices and the right pane lists the parameters available.

DriveExecutive Parameter Information

Column Description of Contents

Parameter Name

Value

Units

Internal Value

Comment

Default

Min

Max

Alias

Short name of the parameter.

Current value of the parameter.

Units of measurement for this parameter.

Internal values are unscaled values used by the device and by controllers that communicate with the device. The information in this field provides the scaling information to calculate the internal value from a scaled value.

Displays comments previously entered.

Displays the default setting.

The minimum value is the lowest possible value for this parameter.

The maximum value is the highest possible value for this parameter.

Displays an alias, or alternative name, previously entered.

224



Follow these steps to edit a parameter.

1. Expand the MSR57P relay.

2. Choose either Parameter List or expand the Parameter file under the MSR57P relay to display the parameter groups.

3. Edit a parameter by double-clicking it and typing the new value.

4. Follow the procedure in

Configure the Speed Monitoring Relay on page 158

to configure the MSR57P relay.

After you edit parameters, you can upload them and save them to a file on you personal computer. You can then use this file as a backup, print it, or download it to another MSR57P relay.

For detailed information on using DriveExecutive software, consult online help.


225


226


Introduction

Appendix

E

Application Examples

Topic

PowerFlex 70 Drive with Safe-Off Application Example

PowerFlex 700 Drive without Safe-Off

Kinetix 6000 or Kinetix 7000 Drives with Safe-off Example

Kinetix 2000 Drive without Safe-off Example

Page

228

231

233

235

This application appendix provides examples of relay and drive combinations. Refer to the manuals listed in the

Additional Resources

on page

11

for important information on installing, grounding, wiring, and operating the devices shown in the appendix.

ATTENTION

Implementation of safety circuits and risk assessment is the responsibility of the machine builder.


227

Appendix E Application Examples

PowerFlex 70 Drive with

Safe-Off Application

Example

Stopped

Safe Speed

Running

E-Stop

Reset

Run Maintenance

Mode

228

This example is configured for Safe Stop 1. The control cabinet contains an MSR57P relay, a PowerFlex 70 AC Drive with Safe-Off function, as well as a PanelView terminal. The MSR57P relay monitors speed via an incremental encoder connected to the PowerFlex 70 drive.

The control panel lets the operator select Run or Maintenance speeds.

The door has an interlock switch with guardlocking to limit access to the machine when the machine is operating at normal Run speed.

A towerlight indicates machine status.


Application Examples Appendix E

PowerFlex 70

Drive with

Safe-Off

Motor

Power

Cable

PowerFlex 70 Drive System Layout

Safe

Stop

SLS Request

Encoder Cable

1585J-M8RB-2M5

Configuration Tools

20-HIM-A3

20-HIM-H10

-OR-

1203-USB or

1203-SSS(B)

PC

Encoder 1

Input

Start/Stop Command and Motion Power

Outputs

Encoder

Feedback

Cable

MSR57P Relay

Primary Encoder:

845T-DZ42PEN-1

Configuration Tools

Guardlocking

Switch

TLS3-GD2


229


PowerFlex 70 Drive Example Wiring Diagram

+24V DC

A1 S11 S21

Pulse Test

Outputs

S12

SS

Request

E-Stop

800FM-MT44

800F-MX02V

SLS Request

800FM-KM23

800F-MX02V

S22

SS

Input

S52

SLS

Input

S62 S72 S82

ESM

Input

51

Reset

800FM-F6MX10

52

Door Lock

Control

X32 X42

Lock

Monitor

A2

RJ45

Encoder

Input 1

SLS

Status

Fault

Status

Y35

RJ45

Encoder

Input 2

Y37

SS

Output

34 44

MSR57P Relay

DPI

RL

Feed

Reset Feedback


SLS

Cmd

Stop

Cmd

GND

24V dc

Y1 S34 Y2 Y33 Y32 Y30 Y31

Power to

Release

11 21 33

A1

A2

41 51

12 22 34

42 52

TLS3-GD2

440G-T27260

S32

Door

Monitor

Motion

Power Out

14 24

A1

S42 13

SLS

Output

68 78


1

3

9 24V dc

8 DC Comm

7 Dig Comm

1 Stop

PowerFlex 70

AC Drive with

DriveGuard

Gate Control

Power

2 Start

4 SLS Input

(1)

Safe Off Option

Supply

4

2

6 Enable

Gate

Control

Circuit

Remove jumpers

L1 L2 L3

Aux. Signals to PLC

(1) Digital input 4.

Proper configuration is required for inputs 1, 2, 4, and 6 on the PowerFlex 70 Drive.

Motor

24V dc Com

230



PowerFlex 700 Drive without Safe-Off

PowerFlex 700 Drive

PowerFlex 700 Drive System Layout

Enabling Switch

Safe Stop

SLS Request

Cable

1585J-M8RB-2M5

Motor Power

Cable

Encoder 1

Input

-OR-

20-HIM-H10

Configuration Tools

1203-USB

AnaCANda

20-HIM-A3

PC

Two

Contactors in

Series

Encoder

Feedback

Cable

Encoder 2

Input

MSR57P Relay

MP Outputs

Secondary

(Load Side)

Encoder

Guardlocking

Switch

TLS3-GD2

Optional

Primary Encoder:

HPK-Series Servo Motors


231


PowerFlex 700 Drive Wiring Diagram

SS

Request

SLS Request

800FM-KM23

800F-MX02V

E-Stop

800FM-MT44

800F-MX02V

2

1

440J-N21TNPM

Enabling Switch

4

3

Power to

Release

11 21 33

A1

A2

41 51

12 22 34

42 52

TLS3-GD2

440G-T27260

+24V DC


L1 L2 L3

PowerFlex 700 Drive

R S T

A1 S11 S21

Pulse Test

Outputs

S12 S22

SS

Input

S52 S62 S72 S82

SLS

Input

ESM

Input

51 52

Door Lock

Control

X32 X42

Lock

Monitor

A2

RJ45

Encoder

Input 1

SLS

Status

Fault

Status

Y35 Y37

RJ45

Encoder

Input 2

SS

Output

34 44

MSR57P Relay

DPI

RL

Feed

Rese t

Feedback


SLS

Cmd

Stop

Cmd

GND

24V dc

Y1 S34 Y2 Y33 Y32 Y30 Y31

S32 S42

Door

Monitor

Motion

Power Out

14 24

A1

13

SLS

Output

68 78

Reset

800FM-F6MX10

K1

K2

K1

K2

24 24V DC

25 Dig. Comm

26 DC Comm

27 Stop

28 Start

30 SLS Input

(1)

Stop

Start

Aux. Signals to PLC

(1) Proper configuration is required for Stop, Start, and SLS inputs (digital input 4) on the PowerFlex 700 Drive.

24V DC Com

K1

U V

L1 L2 L3

W

K2

M

232


Kinetix 6000 or Kinetix 7000

Drives with Safe-off

Example

Stopped

Safe Speed

Running

E-Stop

Reset

Run Maintenance

Mode



TIP

Kinetix drives define the positive direction for encoders as B leading A. Therefore if drive polarity for the Kinetix drive is configured as positive, then the P30 [Fbk 1

Polarity] for the MSR57P should be configured as negative.

This example is configured for Safe Stop 1. The control cabinet contains an MSR57P relay, a Kinetix 6000 drive with Safe-off function, as well as a PanelView terminal. The MSR57P relay monitors speed via a Sin/Cos encoder connected to the Kinetix 6000 drive.

The control panel lets the operator select Run or Maintenance speeds.

The door has an interlock switch with guardlocking to limit access to the machine when the machine is operating at normal Run speed. In addition, an enabling switch is required to be held in the middle position while operators are within the machine environment to keep the machine running at safe speed.

A towerlight indicates machine status.

233


Kinetix 6000 or

Kinetix 7000 Drive with Safe-off

Low Profile

Connector

2090-K6CK-D15M

Kinetix 6000 or Kinetix 7000 Drive System Layout

Safe

Stop

Enabling Switch

SLS Request

Motion Power Outputs and

Feedback Monitoring From the

MSR57P Relay to Kinetix Safe-off

Interface

Encoder Cable

1585J-M8RB-2M5

20-HIM-A3

-OR-

20-HIM-H10

1203-USB or

1203-SSS(B)

PC

Encoder

Feedback

Cable

MP-Series Bulletin MPL

Servo Motors

Encoder 1

Input

Motor

Power

Cable

MSR57P

Relay

Aux. Signals to Logix Controller

Configuration Tools

Guardlocking Switch

TLS3-GD2

Kinetix 6000 or Kinetix 7000 Drive Wiring Example

+24V dc

A1 S11 S21

Pulse Test

Outputs

S12 S22

SS

Input

SS

Request

SLS Request

800FM-KM23

800F-MX02V

E-Stop

800FM-MT44

800F-MX02V

2

1

440J-N21TNPM

Enabling Switch

S52 S62 S72 S82

SLS

Input

ESM

Input

51 52

4

3

Door Lock

Control

X32 X42

Lock

Monitor

A2

RJ45

Encoder

Input 1

SLS Fault

Status Status

Y35 Y37

RJ45

Encoder

Input 2

SS

Output

34 44

DPI

MSR57P Relay

RL

Feed

Rese t

Feedback

Y1 S34 Y2


SLS

Cmd

Stop

Cmd

GND

24V dc

Y33 Y32 Y30 Y31

Power to

Release

11 21 33

A1

A2

41 51

12 22 34

42 52

TLS3-GD2

440G-T27260

S32

14 24

Door

Monitor

Motion

Power Out

A1

S42 13

SLS

Output

68 78


Kinetix 6000 and

7000 AC Drive with

GuardMotion

EN1+

R1

SAFETY EN-

R2

Safety

Monitor

EN2+

Gate Control

Power Supply

R2

Gate

Control

Circuit

FDBK1

R1

R1

FDBK1

FDBK2

FDBK2

R2

Gate

Control

Enable

L1 L2 L3

Motor

Reset

800FM-F6MX10



24V dc Com

234



Kinetix 2000 Drive without

Safe-off Example

Kinetix 2000 Drive System Layout

Kinetix 2000 Drive without

Safe-off (No Safety Header)

Safe

Stop

Enabling Switch

SLS Request

Low Profile

Connector

2090-K2CK-D15M

Encoder Cable

1585J-M8RB-2M5

Motor

Power

Cable

MP-Series Bulletin MPL

Servo Motors

20-HIM-A3

Encoder 1

Input

Encoder

Feedback

Cable

MSR57P

Relay

Start/Stop Command to Logix Controller

20-HIM-H10

-OR-

1203-USB or

1203-SSS(B)

Configuration Tools

Guardlocking Switch

TLS3-GD2

PC

Kinetix 2000 Drive Wiring Diagram

SS

Request

SLS Request

800FM-KM23

800F-MX02V

2

E-Stop

800FM-MT44

800F-MX02V

1

440J-N21TNPM

Enabling Switch

4

3

Power to

Release

11 21 33

TLS3 GD2

440G-T27260

A1

A2

41 51

12 22 34

42 52

Remove 2 internal jumpers

A1 S11 S21

Pulse Test

Outputs

S12 S22

SS

Input

S52

SLS

S62 S72 S82

ESM

Input Input

51 52

Door Lock

Control

X32 X42

Lock

Monitor

RJ45

Encoder

Input 1

RJ45

Encoder

Input 2

A2

SLS Fault

Status Status

Y35 Y37

SS Output

34 44

MSR57P Relay

DPI

RL-

Feed

Y1

Reset Feedback

S34 Y2


SLS

Cmd

Stop

Cmd

Y33 Y32

Gnd

24V

DC

Y30 Y31

Motion

Power Out

14 24

S32 S42

Door

Monitor

A1

13

SLS

Output

68 78

Aux signals to PLC

Reset

800FM-F6MX10

To Controller

SLS Request

+24V DC

100S-C Contactor

Resistive Brake Module

COIL A1

CONSTAT 41

K1

CONSTAT 42

COIL A2

T1

Kinetix 2000

AC Drive

Common

L1 L2 L3

Enable

K2

U V W

U V W

Motor

24V DC Com

Proper configuration in RSLogix 5000 software is required. To enable safety functions, choose Drive Enable Input Checking on the

Drive/Motor tab in the Axis Properties dialog of the drive.

For more information, refer to the Kinetix 2000 Multi-axis Servo Drive

User Manual, publication 2093-UM001.


235


236


(PL)e

16

Symbols

Numerics

1203-SSS

217

1203-USB

217

1203-USB converter

configure communication

218

1585J-M8RB-2M5 cable

42

2 Channel Sourcing

97

20-HIM-A3 module

27

,

213

20-HIM-H10 cable

213

A

access

hazardous area

116

automatic reset

74

SLS Reset

107

SS reset

96

C

cable

pinout

42

cascaded config

73

,

125

,

138

cascaded connections

64

,

65

,

68

CAT 4

13

Cat 4

9

performance definition

15

certifications

199

clearance

32

commission the system

156

-

159

commutation

21

Config Lock indicator

154

,

159

configuration

lock

153 signature. See Signature ID.

specification

157

Configuration Lock bit

154

,

159

configure

parameters

158

confirm the configuration

159

connect

feedback cable

42

HIM module

213

personal computer

217


Index

D

DC_Out output

66

wiring

67

,

68

deceleration monitoring

91

,

94

,

95

dimensions

31

DIN rail

32

Disabled mode

24

discrepancy checking

encoders

82

DM_In input

60

Door Control

97

-

98

multi-axis systems

138

-

139

wiring

67

Door Control output

fault conditions

98

See also DC_Out output

Door Monitoring Fault

118

DPI port

213

,

217

,

218

,

221

DriveExecutive software

catalog number

217


221

connect to

217

interface

224

set parameters

224

version

27

,

217

DriveExplorer software

catalog number

217


219

connect to

217

interface

219

set parameters

219

version

27

,

217

dual channel operation

57

dual encoder

configurations

82

resolution

82

dual feedback position discrepancy tolerance

definition

83

dual feedback speed discrepancy tolerance

definition

84

dual feedback speed ratio

definition

83

E

edit the configuration

158

,

160

emergency shutdown systems

13

EN 60204-1

15

EN 62061

13

,

16

,

197

,

199

enclosure

31

237

Index

238 encoder

connecting

36

-

40

resolution

75

specifications

199

ESM_In input

61

,

113

European norm.

definition

9

F

failure fault

contact information

22

Door Monitoring

118

fault codes

configuration faults

196

Fault While Stopping Faults

189

Safe State Faults

188

Stop Category Faults

189

fault history queue

187


220

HIM

215

fault recovery

187

Fault While Stopping Faults

189

,

191

Fault_Status output

70

features

26

feedback

device types

81

fault

86

parameters

86

polarity

82

resolution

81

type

81

feedback monitoring

81

-

87

G

Guard Status attributes

192

H

HIM module

catalog number

27

set parameters

214

hold last state

SLS_Out output

121

I

I/O Diagnostic Status attributes

195

IEC 61508

13

,

16

,

197

,

199

inputs

57

ISO 13849-1

13

,

15

,

16

,

197

,

199

K

keypad

215

L

language

display options

79

LED Indicators

185

LM_In input

61

Lock Monitoring

25

,

99

wiring

67

lock status

153

low profile connector kits

wiring

51

low threshold

120

,

121

See also Speed Hysteresis.

M

manual monitored reset

74

SLS Reset

107

SS Reset

96

manual reset

74

SLS Reset

107

SS Reset

96

Max Display Speed

80

Max Stop Time

definition

89

motors

feedback pin-outs

44

mounting

32

MP_Out output

69

wiring

69

,

70

multi-axis

configuration

137

-

139

connections

??-

126

,

138

,

139

Door Control

138

-

139

wiring

64

,

65

O

outputs

63

OverSpd Response

75

P

parameter list

all parameters

202

-

210

feedback

86

general

80

Max Speed and Direction Monitoring

151

Safe Limited Speed

108


Index


121

Safe Stop

99

Safe Stop with Door Monitoring

103

Slave, Safe Limited Speed

132

Slave, Safe Limited Speed Status Only

135

Slave, Safe Stop

127

SLS with Door Monitoring

111

SLS with Door Monitoring and Enabling

Switch Monitoring

118

SLS with Enabling Switch Monitoring

114

parameters

complete list

202

configure

158

edit

158

,

160

groups

201

password

PFD

change

154

new

154

reset

155

PFH

definition

10

,

16

definition

10

,

16

pin-outs

motor feedback connector

44

PL

definition

10

PL(e)

9

,

13

,

199

polarity

82

power supply

32

Power to Lock

97

Power to Release

97

probability of failure on demand

See PFD.

probability of failure per hour

See PFH.

proof tests

16

pulse test outputs

57

Reset Loop input

wiring

63

reset qualification

75

reset type

74

Reset_In input

107

risk assessment

29

,

157

RSLinx software

217

,

221

version

27

R

recover from fault

187

remove terminal blocks

32

reset

device configuration

155

password

155

qualification

75

See also SS Reset, SLS Reset, or Reset

Type.

reset input

62

wiring

62

S

Safe Accel Limit

See Safe Maximum Acceleration Limit.

Safe Direction Monitoring

150

negative

151

overview

25

positive

151

Safe Limited Speed mode

105

Safe Limited Speed Monitoring Delay

106

,

117

,

120


See SLS Reset.

Safe Limited Speed Status Only mode

119

Safe Limited Speed with Door

Monitoring and Enabling Switch

Monitoring mode

115

Safe Limited Speed with Door

Monitoring mode

110

Safe Limited Speed with Enabling

Switch Monitoring mode

112

Safe Max Acceleration Monitoring

overview

25

Safe Max Speed

145

Safe Maximum Acceleration Limit

148

Safe Maximum Acceleration Monitoring

overview

25

Safe Maximum Acceleration monitoring

148

-

150

Safe Maximum Speed Monitoring

overview

25

Safe Maximum Speed monitoring

145

-

147

Safe Speed Limit

105

,

117

,

121


186

,

188

,

190

Safe Stop 1

91

Safe Stop 2

91

Safe Stop mode

89

Safe Stop Reset

See SS Reset.

Safe Stop Types

90

-

92


239

Index

240

Safe Stop with Door Monitoring mode

102

Safe Torque Off with Standstill Checking

90

Safe Torque Off without Standstill

Checking

92

safety certification

TÜV Rheinland

13

,

199

safety functions overview

23

safety information

30

Safety mode

24

,

74

slave combinations

139

safety reaction time

18

overspeed response

75

safety-lock

153

serial communication

DriveExecutive software

221


218

Serial converter

catalog number

217

serial converter

218

set parameters

using a HIM

214

using software

217

Signature ID

153

,

158

,

159

SIL 3

9

,

13

,

199

SIL 3 certification

user responsibilities

14

single encoder configurations

82

single-channel operation

57

Slave, Safe Limited Speed mode

132

Slave, Safe Limited Speed Status Only mode

135

Slave, Safe Stop mode

127

SLS Reset

74

,

107

,

113

automatic

106

,

107

manual

107

manual monitored

107


Switch Monitoring mode

118

SLS with Door Monitoring mode

111

SLS_Command output

71

SLS_In input

60

,

107

SLS Reset

107

,

113

SLS_Out output

65

hold last state

121

SLS_Status output

71

spacing

32

specifications

encoder

199

environmental

198

general

197

Speed Hysteresis

120

speed resolution

75

speed value display

80

SS Reset

74

,

95

-

96



118

SS_In input

60

SS_Out output

63

Standstill Position Tolerance

definition

94

Standstill Speed

definition

93

status attributes

192

status indicators

185

stop category

definitions

15

Stop Category Faults

189

,

191

Stop Delay

See Max Stop Time.

Stop Monitoring Delay

definition

89

Stop_Command output

71

T

terminal block

remove

33

terminal screws

connections

34

torque

34

timing diagram

Safe Limited Speed

106


120

Safe Stop 1

92

Safe Stop 2

92

Safe Torque Off with Standstill Checking

90

Safe Torque Off Without Standstill

Checking

93

U

USB converter

218


V

validation

third-party

159

verify

configuration

159

lock status

159

Signature ID

159

W

wiring

DC_Out output

67

,

68

DM_In input

67

input examples

59

LM_In input

67

low profile connectors

51

MP_Out output

69

,

70

multi-axis connections

64

,

65

Index reset_In input

62

RL_In input

63

wiring example

Safe Limited Speed mode

109

Safe Limited Speed Status Only mode

122

,

124

Safe Stop mode

102

Safe Stop with Door Monitoring mode

104

Slave, Safe Limited Speed

133

-

134

Slave, Safe Limited Speed Status Only mode

135

-

137

Slave, Safe Stop mode

129

-

130



119

SLS with Door Monitoring mode

112

SLS with Enabling Switch Monitoring mode

115


241

Index

242


Rockwell Automation

Support

Rockwell Automation provides technical information on the Web to assist you in using its products. At http://support.rockwellautomation.com

, 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://support.rockwellautomation.com

.

Installation Assistance

If you experience a problem within the first 24 hours of installation, please review the information that's contained in this manual. You can also contact a special Customer Support number for initial help in getting your product up and running.

United States

Outside United

States

1.440.646.3434

Monday – Friday, 8 a.m. – 5 p.m. EST

Please contact your local Rockwell Automation representative for any technical support issues.

New Product Satisfaction Return

Rockwell 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

Outside United

States

Contact your distributor. You must provide a Customer Support case number (see phone number above to obtain one) to your distributor in order to complete the return process.

Please contact your local Rockwell Automation representative for the return procedure.


244

Copyright © 2008 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.