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PowerFlex 750-Series Safe Speed Monitor Option Module Safety Reference Manual

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PowerFlex 750-Series Safe Speed Monitor Option ModuleCatalog Number 20-750-S1Safety Reference ManualOriginal InstructionsImportant User InformationRead this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice.If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.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.Labels may also be on or inside the equipment to provide specific precautions. WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.IMPORTANTIdentifies information that is critical for successful application and understanding of the product.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.ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).Rockwell Automation Publication 750-RM001H-EN-P - February 20173Table of ContentsPrefaceSummary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Additional Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Chapter 1Safety ConceptSafety Certification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Important Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Safety Category 4 Performance Definition. . . . . . . . . . . . . . . . . . . 14Stop Category Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Performance Level and Safety Integrity Level (SIL) CL3 . . . . . . 15Functional Proof Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15PFD and PFH Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16PFD and PFH Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Safe State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Safety Reaction Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Considerations for Safety Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Output Pulse Test Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . 19Encoder Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Considerations for Single-encoder Applications. . . . . . . . . . . . . . 19Understanding Commutation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Contact Information if Safety Option Failure Occurs . . . . . . . . . . . . 20Chapter 2About the PowerFlex Safe Speed Monitor Option ModuleSafety Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Safety Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Disabled Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Lock Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Safe Maximum Speed, Safe Maximum Acceleration, and Safe Direction Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Hardware Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Chapter 3Installation and WiringGeneral Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Power Supply Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Set the Safety Enable Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Install the Safe Speed Monitor Option Module . . . . . . . . . . . . . . . . . . 30Installation in Frame 8 and Larger Drives. . . . . . . . . . . . . . . . . . . . 31Terminal Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Compatible Encoders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Connect an Encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334Rockwell Automation Publication 750-RM001H-EN-P - February 2017Table of ContentsChapter 4Speed Monitoring I/O SignalsInputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Safe Stop Input (SS_In). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Safe Limited Speed Input (SLS_In) . . . . . . . . . . . . . . . . . . . . . . . . . 38Door Monitor Input (DM_In) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Enabling Switch Monitor Input (ESM_In) . . . . . . . . . . . . . . . . . . 39Lock Monitor Input (LM_In). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Reset Input (Reset_In). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Safe Stop Output (SS_Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Safe Limited Speed Output (SLS_Out). . . . . . . . . . . . . . . . . . . . . . 42Door Control Output (DC_Out) . . . . . . . . . . . . . . . . . . . . . . . . . . 44Chapter 5General Device and Feedback Monitoring ConfigurationCascaded Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Safety Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Reset Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Overspeed Response Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Speed Resolution Accuracy for Rotary Systems. . . . . . . . . . . . . . . 50Speed Resolution Accuracy for Linear Systems . . . . . . . . . . . . . . . 52General Parameter List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Feedback Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Feedback Polarity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Single Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Dual Encoders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Feedback Voltage Monitor Range. . . . . . . . . . . . . . . . . . . . . . . . . . . 57Feedback Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Feedback Parameter List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Chapter 6Safe Stop and Safe Stop with Door Monitoring ModesSafe Stop Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Safe Stop Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Standstill Speed and Position Tolerance . . . . . . . . . . . . . . . . . . . . . 65Deceleration Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Safe Stop Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Door Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Lock Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Safe Stop Parameter List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Safe Stop Wiring Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Safe Stop with Door Monitoring Mode . . . . . . . . . . . . . . . . . . . . . . . . . 71Lock Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72SS Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72Safe Stop with Door Monitoring Parameter List . . . . . . . . . . . . . . . . . 72Safe Stop with Door Monitoring Wiring Example . . . . . . . . . . . . . . . 73Rockwell Automation Publication 750-RM001H-EN-P - February 20175Table of ContentsChapter 7Safe Limited Speed (SLS) ModesSafe Limited Speed (SLS) Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75Safe Limited Speed Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Safe Limited Speed Parameter List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Configuring the PowerFlex 750-Series Drive for SLS Operation. . . 79Safe Limited Speed Wiring Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Safe Limited Speed with Door Monitoring Mode . . . . . . . . . . . . . . . . 81Safe Limited Speed Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82SLS with Door Monitoring Parameter List . . . . . . . . . . . . . . . . . . . . . . 82SLS with Door Monitoring Wiring Example . . . . . . . . . . . . . . . . . . . . 83Safe Limited Speed with Enabling Switch Monitoring Mode. . . . . . 83Safe Stop Reset (SS Reset) and Safe Limited Speed Reset (SLSReset) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84SLS with Enabling Switch Monitoring Parameter List. . . . . . . . . . . . 84SLS with Enabling Switch Monitoring Wiring Example . . . . . . . . . . 85Safe Limited Speed with Door Monitoring and Enabling Switch Monitoring Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86Behavior During SLS Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . 87Behavior While SLS Monitoring is Inactive. . . . . . . . . . . . . . . . . . 88Behavior During SLS Monitoring Delay. . . . . . . . . . . . . . . . . . . . . 88Safe Stop Reset (SS Reset) and Safe Limited Speed Reset (SLSReset) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88SLS with Door Monitoring and Enabling Switch Monitoring Parameter List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89SLS with Door Monitoring and Enabling Switch Monitoring Wiring Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90Safe Limited Speed Status Only Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 91Speed Hysteresis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92SLS Status Only Parameter List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92SLS Status Only Wiring Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93Chapter 8Slave Modes for Multi-axis Cascaded SystemsCascaded Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97Slave, Safe Stop Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99Slave, Safe Stop Parameter List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99Slave, Safe Stop Wiring Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101Slave, Safe Limited Speed Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104Slave, Safe Limited Speed Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . 104Slave, Safe Limited Speed Wiring Examples. . . . . . . . . . . . . . . . . . . . . 105Slave, Safe Limited Speed Status Only Mode. . . . . . . . . . . . . . . . . . . . 108Slave, Safe Limited Speed Status Only Parameter List. . . . . . . . . . . . 108Slave, Safe Limited Speed Status Only Wiring Examples. . . . . . . . . 109Multi-axis Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

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