GuardLogix Controller to Kinetix 6000 Drive with Safe-Off using EtherNet/IP CompactBlock Guard I/O Module

Safety Application Example GuardLogix Controller to Kinetix 6000 Drive with Safe-Off using EtherNet/IP CompactBlock Guard I/O Module Safety Rating: SIL3/Category 3 (also see SIL3/CAT4 section), according to IEC 61508 & EN954-1. Introduction...2 Important User Information...2 General Safety Information...3 Description...4 Setup and Wiring...5 Configure...6 Programming...26 Performance Data...27 Achieving SIL3/CAT4...28 Additional Resources...30

2 Introduction In September 2006, NFPA 79 added an exception to the requirement for electromechanical disconnection of an actuator any time an E-stop is invoked. Safety PLCs and other programmable devices such as drives are allowed to be the final switching element, provided they are designed to relevant safety standards. This change is already in effect in IEC 60204-1. With this modification, manufacturers can realize a major cost savings in terms of equipment, wiring, and cabinet space. This application example shows how to control a Kinetix 6000 with Safe-Off, via a GuardLogix integrated safety controller, with a gate switch (SensaGuard) using an EtherNet/IP CompactBlock Guard I/O module. Features and Benefits This configuration provides the flexibility of expansion and integration to other EtherNet/IP safety and standard systems. Adding a drive with Safe-Off capabilities can offer increased productivity through reduced downtime. This application shows how a fully integrated safety solution can be performed using RSLogix 5000 software. 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.

3 Throughout this manual, when necessary, we use notes to make you aware of safety considerations. 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. 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. Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present. Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures. General Safety Information This application example is for advanced users and assumes that you are trained and experienced in safety system requirements. A risk assessment should be performed to make sure all task and hazard combinations have been identified and addressed. The risk assessment may require additional circuitry to reduce the risk to a tolerable level. Safety circuits must take into consideration safety distance calculations which are not part of the scope of this document. Contact Rockwell Automation to find out more about our safety risk assessment services.

4 Description This application example shows how to wire and program a SIL3/CAT3-rated safety circuit with a Kinetix 6000 drive, an EtherNet/IP CompactBlock Guard I/O module, a GuardLogix controller, and a SensaGuard non-contact switch. Safety Function A SIL3/CAT3 safety function should perform the following: Check the status of the inputs and wiring and shut down the system in case of any fault. Monitor the output devices before start-up and prevent the system from starting if there is an existing fault on the output device. Be capable of identifying faults and shutting down the system immediately or performing the safety function when demanded if there are multiple faults on the system. The RSLogix 5000 software has safety application instructions which monitor various safety inputs and safety outputs. These instructions have all the required logic built into them and are certified by TÜV. Example Bill of Material This application example uses these components. Catalog Number Description Quantity 1791ES-IB8XOBV4 Safety I/O module with solid state outputs 1 1756-L61S GuardLogix primary controller 1 1756-LSP GuardLogix safety partner 1 1756-A7 7 slot chassis 1 1756-ENBT/A ENBT Ethernet communication module 1 1756-M08SE 8 axis Sercos card 1 440NZ21SS2AN9 SensaGuard gate sensor 1 2094-AC09-M02 Kinetix 6000 IAM 1 2094-AM01-S Kinetix 6000 AM with Safe-Off 1 TLA110PHJ32AA Servo motor 1

5 Setup and Wiring For detailed information on installing and wiring, refer to the product manuals listed in the Additional Resources. System Overview Wiring

6 Configure the System Configure the IP Address of the EtherNet/IP CompactBlock Guard I/O Module using BOOTP/DHCP Server Software When configuring the I/O module for the first time, use BOOTP/DHCP server software. 1. Connect your equipment. 2. Open BOOTP/DHCP server software and wait for the MAC address to appear. The MAC address of the CompactBlock Guard I/O module is located on a label on the top of the module. It is printed under a bar code on the left side of the label. 3. Double-click the MAC address. 4. Enter your IP address. 5. Click OK.

7 6. Wait for the unit to respond with the MAC and IP address. 7. Click Disable BOOTP/DHCP. This allows the unit to keep the fixed IP address. 8. Close the application. The IP address has been configured.

8 Create a New Project File in RSLogix 5000 Software To create a new project file, follow these steps: 1. Run RSLogix 5000 software. 2. From the Quick Start page, choose New Project. The new controller dialog box appears. 3. From the Type pull-down menu, choose 1756-L61S ControlLogix5561S Safety Controller. 4. From the Revision pull-down menu, choose 16.

9 5. In the Name field, type GuardLogix_with_K6000_using_Safe_Off for the controller name. 6. Choose a 1756-A7, 7-slot chassis. 7. Choose the slot location of your primary controller. 8. In the Create In field, type C:\RSLogix5000\Projects\Labs. 9. Verify that your entries match those in the steps above and then click OK. 10. Accept any warnings. 11. From the Controller Organizer, right-click ControllerGuardLogix_with_K6000_using_Safe_Off. 12. Choose Properties. 13. From the Controller Properties dialog box, choose the Date/Time tab. 14. From the Date/Time tab view, check Make this controller the Coordinated System Time master. 15. Click OK. 16. Save your project file.

10 Configuring EtherNet/IP CompactBlock Guard I/O Module using RSLogix 5000 Software To configure the EtherNet/IP CompactBlock Guard I/O module using RSLogix 5000, follow these steps: 1. Right-click 1756 Backplane. 2. Choose New Module. 3. Choose your 1756-ENBT module. 4. Click OK.

11 5. Set up the 1756-ENBT module with a Name, Slot Number, Firmware Revision and unique IP address. 6. Click OK. 7. Choose EtherNet/IP network. 8. Choose New Module. 9. Open the safety tree. 10. Select 1791ES-IB8XOBV4. 11. Click OK.

12 12. Complete the entries for the dialog box: Type a unique name. Type the IP address of the Guard I/O module. Type a description. 13. Click Change. 14. Set up the Input Status as shown. 15. Click OK. 16. Click the Input Configuration tab.

13 17. Set the first two inputs to Safety. 18. Set the third input to Safety with Pulse Test. 19. Make the following settings: Not Used: safety input channel is disabled. Safety Pulse Test: safety input is configured for pulse test operation. Safety: the safety input is used with a safety field device. Standard: safety input has a standard field device wired to it. 20. Click the Test Output tab. 21. Use this configuration. 22. Click the Output Configuration tab. 23. Use the configuration shown here.

14 24. Click OK 25. Save your project file. Configuring the Sercos Module and Kinetix 6000 using RSLogix 5000 Software To configure the Sercos module and Kinetix 6000 follow these steps: 1. Right-click 1756 Backplane. 2. Choose New Module. 3. Select Motion control card 1756-M08SE.

15 4. Set up the Module Properties as shown. 5. Name the module S06_SERCOS. 6. Choose Slot 6. 7. Set Electronic Keying to Compatible Keying. 8. Click OK. 9. Right-click the newly created module in Slot 3. 10. Choose properties. The Module Properties dialog box appears. 11. Leave all values at default. 12. Click OK. 13. From the I/O Configuration tree, right-click 1756-M08SE S06_Sercos module. 14. Choose New Module. 15. From the Select Module window dialog box, expand the +Drives item. 16. Select the drive description listed on the drive nameplate for the IAM module.

16 17. Select 2094-AC09-M02. 18. Click OK. 19. Name the IAM module S06_N01_Drive1. 20. Set the Electronic Keying to Compatible Keying. 21. In the Module Properties dialog box, choose the Associated Axes tab. 22. Click New Axis.

17 23. In the Name field of the New Tag dialog box, type AXIS_01. 24. Click OK. 25. From the Node 1: pull-down menu, choose AXIS_01. 26. Click OK.

18 Set Up the Motion Group Follow these steps to set up the motion group. 1. In the Controller Organizer, right-click Motion Groups. 2. Choose New Motion Group. 3. Type Motion_Group1 in the Name field. 4. Check Open MOTION_GROUP Configuration. 5. Click OK.

19 6. When the Motion Group wizard appears, select Axis_01. 7. Click Add. 8. Click Next. 9. Click Next again. 10. Click Finish. Configure Axis Properties Follow these steps to configure the axis properties. 1. Double-click the Axis_01 axis you created. The Kinetix 6000 IAM drive module you added in the I/O Configuration is assigned to the AXIS_01 axis. The Module Type field is automatically populated for you because you chose the catalog number for the Kinetix 2000 or Kinetix 6000 drive when you added it to the I/O Configuration.

20 2. Click the Motion Planner tab and review the parameters. Keep the default settings. 3. Click the Units tab. Use revolutions for the unit of measure. 4. Enter revs in the Position Units box. The Average Velocity Timebase is the timeslice used to calculate the average velocity. 5. Click Apply to accept your changes. 6. Click the Drive/Motor tab. 7. Choose the appropriate Motor Catalog Number. 8. Use this Axis Information as shown above: Attribute 1: Position Feedback Attribute 2: Velocity Command The attributes chosen here are automatically returned to the axis tag as feedback data to the processor. 9. Click Apply to accept your changes. In the Motor Feedback tab, the parameters are defined for you because you defined the motor catalog number on the Drive/Motor tab. 10. Click OK. 11. Save your project. Selecting the motor hardware in this way is an extremely powerful feature. Programs relating to hardware are only in the I/O tree. No further programmatic modifications are required. This allows you to use an existing program on different hardware with minor effort thus decreasing your time to market. 12. Download your project to the controller.

Perform a Hookup Test You must perform a hookup test to check connectivity and wiring to the drive and motor. Before running any of the tests on the Hookup tab, check the Kinetix 6000 status: Drive LED displays must be showing 4. The Bus LED on the drive must be flashing green. The Comm LED on the drive must be solid green. The drive enable switches must be in the full clockwise position. 1. From the Motion Groups folder in the Controller Organizer, right-click AXIS_01 and choose Properties. 2. Click the Hookup tab. 3. Enter a Test Increment of 1.0 revs. This will provide enough axis travel to detect a marker. 4. Click Apply. 21 5. Click Test Marker. 6. When the following dialog box appears, follow the instructions in the Information box (that is, rotate motor one full revolution in either the clockwise or counter-clockwise direction). When you have completed the rotation, the Command Status will change from Executing to Command Complete.

22 7. Click OK. 8. Click Test Feedback. You should now see the following dialog box. 9. Follow the instructions in the Information Box to complete the manual rotation of AXIX_01 in the clockwise direction to set the polarity for the drive feedback. When you have completed the rotation, the Command Status changes from Executing to Command Complete. 10. Click OK to acknowledge completion of the test. 11. Click OK again to apply changes. 12. When the information box shown below appears, click OK one more time to exit the Encoder Test. 13. Click the Test Command & Feedback button.

14. When the dialog below appears, click Yes. This test does not require manual intervention. You will hear the servo enable and you should observe AXIS_01 jog one clockwise revolution. 23 15. When the Command Status indicates Command Complete, click OK. 16. When you see the following prompt, answer the question according to the observed axis movement. 17. Answer OK to any prompts that appear. Follow these steps to Auto the Axis. Before running the autotune process, check the following Kinetix drive setup status: Make sure numeric displays on drives are showing 4. Check to see if the Bus LED on the drive is flashing green. Check to see if the Comm on the drive is solid green. Check that the drive enable switches are in the full clockwise position. 18. From the Controller Organizer, open the Axis Properties dialog box for AXIS_01.

24 19. From the Axis Properties dialog box, select the Tune tab. 20. Set the Travel Limit to 500 revs. 21. Set the Speed in the range of 40 80% of the Dynamics tab Maximum Speed setting. For example, if the Maximum Speed is 70.83 revs/s, the range is 28.33 (40%) 56.67 (80%). The Dynamics tab is located next to the Tune tab. The dynamics information is set based on the motor selected in the Drive/Motor setup tab. 22. Click Apply to acknowledge the new tuning parameters. 23. Click Start Tuning. 24. Click Yes on the dialog box to acknowledge that motion is going to occur. You should hear the servo enable for as long as it takes it to get to the revs/sec speed you configured for the process. This process should take less than one second. 25. When the command is complete, click OK. The Tune Results dialog box appears.

25 26. Once you have reviewed the values, click OK to close the dialog box. 27. Click OK to Apply the Tuning values to any prompts that appear. You should now be back to the Axis Properties dialog box. 28. Take a few moments to review the Gains and Dynamics tabs. The Gains and Dynamics fields have been populated as a result of the Autotuning process you just completed. 29. After reviewing these tabs, click OK to close the Axis Properties dialog box. 30. Save your project.

26 Programming In this section, you will program the software for this safety circuit in the main routine of the Safety Task. 1. In the Main Routine Safety Task, write the following code: 2. Save your project. 3. Download to the controller. 4. Test your safety program.

27 Performance Data The timing diagram for this circuit shows that there is a small delay before the feedback switches over. This is represented by (R). This reaction is due to the time it takes the output to turn on, turn on the contactor, and receive the feedback. The ROUT instruction monitors the time period of R. If this time becomes greater than 250 ms then the ROUT instruction goes into a fault condition.

28 Achieving SIL3/CAT4 To achieve SIL3/CAT4, you need to make a few modifications to the software configuration, ladder logic, and wiring circuit. The wiring diagram below has a contactor K1 which turns off power to the motor under a hazardous condition. K1 is turned on via the outputs from the EtherNet/IP CompactBlock Guard I/O module and feedback from this contactor is feedback into Input 3. When fitting the K1 contactor in this manner, you may need an external breaking resistor. Output test pulses must be configured on the O2 and O3 outputs.

29 Input 3 is configured, as shown. Additional code is also required, as shown.

30 Additional Resources For more information about the products used in this example refer to these resources. Resource CompactBlock Guard I/O EtherNet/I/P Safety Modules publication 1791ES-IN001 Guard I/O EtherNet/P Safety Modules publication 1791ES-UM001 GuardLogix Safety Application Instruction Set publication 1756-RM095 GuardLogix Controller Systems publication 1756-RM093 Kinetix Safe-off Feature Safety Reference Manual publication GMC-RM002D Kinetix 6000 Multi-axis Servo Drives User Manual 2094-UM001 Description Installation Instructions for the 1791ES-IB8XOBV4 module User manual for the 1791ES-IB8XOBV4 module Instruction Set for the GuardLogix controller Explains how the GuardLogix controller can be used in safety applications Wiring and troubleshooting information for Kinetix 6000 and Kinetix 7000 drives with Safe-Off Installation instructions for mounting, wiring and troubleshooting your Kinetix 6000 drive and system integration for your drive/motor combination with a Logix controller. 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. Allen-Bradley, Rockwell Automation, CompactBlock Guard I/O, GuardLogix, Kinetix, RSLogix, and SensaGuard are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies. Copyright 2008 Rockwell Automation, Inc. All rights reserved. Printed in U.SA