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Hydraulics
Electric Drives
and Controls
Pneumatics
Service
Automation
Rexroth IndraDrive
Integrated Safety Technology
Mobile
Hydraulics
R911297838
Edition 01
Title
Rexroth IndraDrive
Integrated Safety Technology
Type of Documentation
Document Typecode
Internal File Reference
Purpose of Documentation
Record of Revisions
Copyright
Description
Release
Date
Notes
DOK-INDRV*-SI*-VRS**-FK01-EN-P
03.2004
First edition
Validity
Published by
The specified data is for product description purposes only and may not
be deemed to be guaranteed unless expressly confirmed in the contract.
All rights are reserved with respect to the content of this documentation
and the availability of the product.
Bosch Rexroth AG
Bgm.-Dr.-Nebel-Str. 2 D-97816 Lohr a. Main
Telephone +49 (0)93 52/40-0 Tx 68 94 21 Fax +49 (0)93 52/40-48 85
http://www.boschrexroth.com/
Dept. ED
Note
DOK-INDRV*-SI*-VRS**-FK01-EN-P
Title
Type of documentation
Document typecode
Part number
Rexroth IndraDrive M
Drive Controllers
Power Section
DOK-INDRV*-HMS+HMD****-PR01-EN-P
R911295014
Rexroth IndraDrive
Drive Controllers
Control Section
DOK-INDRV*-CSH********-PR01-EN-P
R911295012
Electromagnetic
Compatibility (EMC) in
Drive and Systems
DOK-GENERL-EMV********-PR02-EN-P
R911259814
Rexroth IndraDrive
Drive Controllers
Parameter Description
DOK-INDRV*-GEN-**VRS**-PA01-EN-P
R911297317
Rexroth IndraDrive
Drive Controllers
Troubleshooting Guide
DOK-INDRV*-GEN-**VRS**-WA01-EN-P
R911297319
Fig.:
DOK-INDRV*-SI*-VRS**-FK01-EN-P
Further documentations
Notes
DOK-INDRV*-SI*-VRS**-FK01-EN-P
Contents I
Contents
1
1-1
2-1
2.1
2.2
Explanations.................................................................................................................................. 2-2
2.3
2.4
2.5
3-1
3.2
4-1
4.1
4.2
4.3
4.4
5-1
5.1
5.2
5.3
5.4
5.5
5.6
6-1
6.2
DOK-INDRV*-SI*-VRS**-FK01-EN-P
II Contents
6.4
6.5
6.6
6.7
6.8
7-1
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
Acceptance Test
8.1
8-1
DOK-INDRV*-SI*-VRS**-FK01-EN-P
Contents III
9-1
9.1
9.2
9.3
9.4
9.5
9.6
10-1
11-1
12 Index
DOK-INDRV*-SI*-VRS**-FK01-EN-P
12-1
IV Contents
DOK-INDRV*-SI*-VRS**-FK01-EN-P
1.1
Product Presentation
The control sections of the IndraDrive drive range can be equipped with a
"Starting lockout" optional module or a "Safety technology I/O" optional
module. In this way, IndraDrive is equipped with integrated safety
technology, which provides the user with an electronic starting lockout as
well as a universally programmable monitor for safety related
motion/stopping process.
"Integrated safety technology" refers to application-related safety
functions that are applicable for personal protection on machines in
accordance with EN 954 category 3.
The "Starting lockout" optional module provides the following applicationrelated safety function:
Safety related starting lockout (stop category 0 according to
EN 60204-1).
The "Safety technology I/O" optional module provides the following
application-related safety functions:
Safety related standstill (stop category 1 according to EN 60204-1).
Safety related operational stop (stop category 2 according to
EN 60204-1).
Safety related drive interlock (stop category 1 according to EN 602041).
Safely monitored stopping (for functions "Safety related standstill",
"Safety related operational stop", "Safety related drive interlock")
Safety related reduced speed
Safety related limited maximum velocity
Safely monitored acceleration/deceleration ramp (in preparation)
Safety related limited increment
Safety related direction of motion
Safety related limited absolute end position (in preparation)
Safety related homing (required for "Safety related limited absolute
position"
Safety related limited absolute position (in preparation)
Safety related diagnostic outputs
Safety related control of a door locking device
Safety related brake management (in preparation)
The safety functions can be selected via 24 V inputs on the drive
controller.
The safety technology has been tested and certified by an EU prototype
test of the SIBE Switzerland certification authority (http://www.sibe.ch)
(see "Declaration of Conformity and Mark Certificate").
DOK-INDRV*-SI*-VRS**-FK01-EN-P
DOK-INDRV*-SI*-VRS**-FK01-EN-P
2.1
Introduction
Dangerous movements! Danger to life, danger
of injury, severe bodily injury or property
damage!
WARNING
Read these instructions before the initial startup of the equipment in order
to eliminate the risk of bodily harm or material damage. Follow these
safety instructions at all times.
Do not attempt to install or start up this equipment without first reading all
documentation provided with the product. Read and understand these
safety instructions and all user documentation of the equipment prior to
working with the equipment at any time. If you do not have the user
documentation for your equipment, contact your local Bosch Rexroth
representative to send this documentation immediately to the person or
persons responsible for the safe operation of this equipment.
If the equipment is resold, rented or transferred or passed on to others,
then these safety instructions must be delivered with the equipment.
WARNING
DOK-INDRV*-SI*-VRS**-FK01-EN-P
2.2
Explanations
The safety instructions describe the following degrees of hazard
seriousness. The degree of hazard seriousness informs about the
consequences resulting from non-compliance with the safety instructions.
Warning symbol with signal
word
DANGER
WARNING
CAUTION
Fig. 2-1:
DOK-INDRV*-SI*-VRS**-FK01-EN-P
2.3
2.4
General Information
Bosch Rexroth AG is not liable for damages resulting from failure to
observe the warnings provided in this documentation.
Read the operating, maintenance and safety instructions in your
language before starting up the machine. If you find that you cannot
completely understand the documentation for your product, please ask
your supplier to clarify.
Proper and correct transport, storage, assembly and installation as
well as care in operation and maintenance are prerequisites for
optimal and safe operation of this equipment.
Only persons who are trained and qualified for the use and operation
of the equipment may work on this equipment or within its proximity.
The persons are qualified if they have sufficient knowledge of the
assembly, installation and operation of the equipment as well as an
understanding of all warnings and precautionary measures noted in
these instructions.
Furthermore, they must be trained, instructed and qualified to
switch electrical circuits and equipment on and off in accordance
with technical safety regulations, to ground them and to mark them
according to the requirements of safe work practices. They must
have adequate safety equipment and be trained in first aid.
Only use spare parts and accessories approved by the manufacturer.
Follow all safety regulations and requirements for the specific
application as practiced in the country of use.
The equipment is designed for installation in industrial machinery.
The ambient conditions given in the product documentation must be
observed.
Use only safety features and applications that are clearly and explicitly
approved in the Project Planning Manual.
For example, the following areas of use are not permitted: construction
cranes, elevators used for people or freight, devices and vehicles to
transport people, medical applications, refinery plants, transport of
hazardous goods, nuclear applications, applications sensitive to high
frequency, mining, food processing, control of protection equipment
(also in a machine).
DOK-INDRV*-SI*-VRS**-FK01-EN-P
DOK-INDRV*-SI*-VRS**-FK01-EN-P
2.5
DOK-INDRV*-SI*-VRS**-FK01-EN-P
DOK-INDRV*-SI*-VRS**-FK01-EN-P
DOK-INDRV*-SI*-VRS**-FK01-EN-P
DOK-INDRV*-SI*-VRS**-FK01-EN-P
3.1
Appropriate use
Introduction
Rexroth products represent state-of-the-art developments and
manufacturing. They are tested prior to delivery to ensure operating safety
and reliability.
The products may only be used in the manner that is defined as
appropriate. If they are used in an inappropriate manner, then situations
can develop that may lead to property damage or injury to personnel.
Note:
Before using Rexroth products, make sure that all the pre-requisites for
an appropriate use of the products are satisfied:
DOK-INDRV*-SI*-VRS**-FK01-EN-P
Personnel that in any way, shape or form uses our products must first
read and understand the relevant safety instructions and be familiar
with appropriate use.
If the product takes the form of hardware, then they must remain in
their original state, in other words, no structural changes are
permitted. It is not permitted to decompile software products or alter
source codes.
Make sure that the products have been installed in the manner
described in the relevant documentation.
3.2
Inappropriate use
Using the drive controllers outside of the above-referenced areas of
application or under operating conditions other than described in the
document and the technical data specified is defined as inappropriate
use".
Drive controllers may not be used if
they are subject to operating conditions that do not meet the above
specified ambient conditions. This includes, for example, operation
under water, in the case of extreme temperature fluctuations or
extremely high maximum temperatures or if
DOK-INDRV*-SI*-VRS**-FK01-EN-P
4.1
General Information
The operational safety of a machine depends largely upon the extent of
hazardous motions generated by this machine. In Normal mode (also
called Production mode or Automatic mode) of a machine, protective
devices prevent personnel from accessing danger zones. Protective
devices also prevent parts from being ejected outwards.
In the Special mode of machines and installations (also called Manual
mode or Setup mode), it is often necessary for operators to access
danger zones when it is impossible to de-energize the entire installation.
In such situations, machine operators must be protected by mechanisms
internal to the drive and the control unit.
The integrated Rexroth safety technology offers the user the
requirements, on the control unit and drive side, for implementing
functions of personal and machine protection with a minimum of planning
and installation work required. Compared to conventional safety
technology, integrated safety technology considerably increases the
functionality and uptime of the machine.
4.2
DOK-INDRV*-SI*-VRS**-FK01-EN-P
Category 1)
System behavior 2)
Predominantly
characterized by selection
of components.
Predominantly
characterized by selection
of tested components.
Predominantly
characterized by selection
of tested components and
by testing the safety
functions using the control.
Predominantly
characterized by the
structure.
Predominantly
characterized by the
structure.
An accumulation of
unrecognized errors can
cause the safety function to
be lost.
DOK-INDRV*-SI*-VRS**-FK01-EN-P
4.3
Standard
Title
Date of issue
Electric drives
pr EN 61800-5-2)
200x
Simple controls
EN 954-1
1996
Complex controls
IEC 61508-1 to
IEC 61508-7
Functional Safety
Safety Systems
1998 to
2000
Fig. 4-2:
Title
Date of issue
EN 60204-1
Safety of Machinery,
Electric Equipment of Machines
1998
EN 292-1 and -2
Safety of Machinery,
Basic Concepts, General Principles for Design
2000
EN 1050
1996
EN 954-1
Safety of Machinery,
Safety-Related Parts of Control Systems
1996
EN 1921
1996
EN 775
1993
EN 1037
Safety of Machinery,
Prevention of Unexpected Start-Up
1995
1990
EN 12415
2000
EN 12417
2001
EN 1010-1
Safety of Machinery,
Safety Requirements for Construction of Printing and Paper Processing
Machines
1993
Draft
IEC 62061
Safety of Machinery,
Electrical, Electronic and Programmable Electronic Control Systems
200x
prEN 848-3
200x
EN 999
Safety of Machinery,
The positioning of protective equipment in respect of approach speed of
parts of the human body
Safety of Machinery,
Interlocking devices associated with guards - Principles for design and
selection
Fig. 4-3:
Standards relevant to machines
1998
EN 1088
DOK-INDRV*-SI*-VRS**-FK01-EN-P
1995
EN 12415
EN 1010
EN 775
Processing
centers
Automatic
lathes
Printing
Industrial
and paper
robots
processing
machines
Automated
Wood
manufacturing processing
systems
machines
Enabling control
Category 3
Category 3
Category 3
Category 3
Category 3
Speed reduction,
incl. protection
against unexpected
start-up (n=0)
Category 3
Category 3
Category 3
Category 3
Category 3
Category 3
Category 3
Category 3
Category 3
Category 3
Category 3
Category 3
(electronic)
Category 1 for
maintenance
doors
Category 1
(with contacts)
Category 3
Limitation of end
positions
Category 3
Emergency stop
Category 1
(with contacts)
Category 1
(with
contacts)
acc. to
acc. to
EN 60204-1 EN 60204-1
Category 3
(electronic)
Category 3
(electronic)
4.4
prEN 848-3
Category B and
enabling
control device
Locking of protective
equipment
EN 1921
Category 3
Category 1
(with contacts)
Category 3
(electronic)
Fig. 4-4:
Note:
Definition of Terms
Electric drive system
Safety related
Stopping process
DOK-INDRV*-SI*-VRS**-FK01-EN-P
Standstill
Operational stop
Reduced speed
The use of the "Safety related reduced speed" measure implies that a
person can escape the danger caused by hazardous motions in time. In
general, this can be supposed if the resulting speed does not exceed
15 m/min in the case of hazardous motions without the danger of bruising
and cutting, and 2 m/min in the case of hazardous motions with the
danger of bruising and cutting.
In accordance with the Machinery Directive (98/37/EG), the machine
manufacturer has to carry out hazard analysis and then risk management.
With these data, the values for reduced velocities have to be determined.
The following list contains guide values for different types of machines
(excerpt from standards and working papers on safety measures for
Special mode). The abbreviation "SS" stands for "Safety related reduced
speed" and abbreviation "SI" stands for "Safety related reduced
increment".
Machining centers
Axes:
or
"In particular":
SI=75 mm+ jog switch
SS=5 m/min (max. 10 m/min) + jog switch
or
Jog switch
Enabling control
DOK-INDRV*-SI*-VRS**-FK01-EN-P
The operating mode switch determines the operating mode relevant for
safe operation, such as:
Normal mode (Production mode, Automatic mode, etc.) and
Special mode (Manual mode, tool or workpiece changing and cleaning
procedure, as long as movement is required)
The selected kind of control has to be on a higher level than all other
control functions except for the one for the emergency command device.
The operating mode switch can be replaced by other means of selection
which allow only certain groups of operators to carry out certain machine
functions (e.g. access code for certain numerical control functions etc.).
Each position of the operating mode switch may correspond to only one
control or operating mode. (For details, see Machinery Directive
98/37/EG, Appendix I, Section 1.2.5.)
DOK-INDRV*-SI*-VRS**-FK01-EN-P
5.1
General Information
Optional module "Starting lockout" has 24 V inputs for selection using two
channels and a potential-free changeover contact (all 3 connections
accessible) for dual-channel feedback.
Note:
5.2
Safety Function
The safety function is implemented for personal protection in accordance
with EN 954 category 3.
DANGER
DOK-INDRV*-SI*-VRS**-FK01-EN-P
5.3
Forced Dynamization
The goal of forced dynamization is to detect static error conditions, socalled "sleeping errors" during selection and in the interrupting circuits.
Both the control section in standard design and the option "starting
lockout" have their own interrupting circuits.
Note:
After the drive control is started, a life counter starts. The life counter is
reset each time that the starting lockout is selected. When the life counter
expires, a warning requesting that forced dynamization be carried out
(activate the starting lockout) is sent to the higher-level control.
P-0-0103, Time interval of forced dynamization can be used to set the
time interval for the life counter. When the time interval is exceeded, the
drive generates warning E3110 Time interval for forced dynamization
exceeded.
The operating hours of the power section for which the "starting lockout"
function was selected the last time are saved in parameter P-0-0102,
Oper. hours power section at last activat. of start. lockout.
A history of the time intervals set by the user in P-0-0103, Time interval
for forced dynamization is stored in parameter P-0-0104, Change
history time interval of forced dynamization.
5.4
5.5
DOK-INDRV*-SI*-VRS**-FK01-EN-P
Note:
5.6
Examples of Application
24 V
F1*
24 VE
S2
ASn
ASQ
Control
section
Power
section
Channel 2
ASQ1
ASQ2
AS-A
S1
AS-B
Channel 1
0 VE
0V
DF0048v3.EPS
+24 V
F1*
24 VE
S2
ASn
ASQ
Control
section
Power
section
Channel 2
ASQ1
ASQ2
AS-A
S1
0V
AS-B
Channel 1
0 VE
DF0049v3.EPS
DOK-INDRV*-SI*-VRS**-FK01-EN-P
open
0 V +24 V +24 V
F1*
closed
Ch2
Ch1
24 VE
ASn
ASQ
Control
section
Power
section
Channel 2
ASQ1
ASQ2
AS-A
AS-B
0V
Channel 1
0 VE
DF0050v2.EPS
DOK-INDRV*-SI*-VRS**-FK01-EN-P
Note:
+24 V
24 VE
AS
ASn
ASQ
Control
section
Power
section
Channel 2
Inputs
Outputs
PLC
ASQ1
ASQ2
AS-A
AS-B
Channel 1
0 VE
0V
DF0051v2.EPS
Fig. 5-4:
+24 V
F1*
AS
24 VE
ASn
ASQ
Control
section
Channel 2
Outputs
PLC
Inputs
Power
section
ASQ1
ASQ2
AS-A
AS-B
0V
Channel 1
0 VE
DF0052v2.EPS
DOK-INDRV*-SI*-VRS**-FK01-EN-P
DOK-INDRV*-SI*-VRS**-FK01-EN-P
6.1
Basic Structure
The IndraDrive drive system (axis / spindle / roller) is made up of the
components control section, power section and motor.
IndraDrive provides "integrated safety technology" using the interaction of
hardware and software components.
Processing and
error reaction
Selection and
feedback of
safety related
functions
Control
section
Safety
related
action
Power
section
I/O
Channel 1
Processor A
I/O
Channel 2
Processor B
Channel 1
Channel 2
Fig. 6-1:
Note:
DOK-INDRV*-SI*-VRS**-FK01-EN-P
machine tools
DOK-INDRV*-SI*-VRS**-FK01-EN-P
6.2
DOK-INDRV*-SI*-VRS**-FK01-EN-P
DANGER
function
is
DOK-INDRV*-SI*-VRS**-FK01-EN-P
DANGER
DOK-INDRV*-SI*-VRS**-FK01-EN-P
DOK-INDRV*-SI*-VRS**-FK01-EN-P
Pertinent Parameters
The following parameters are used in conjunction with the function "safety
related homing procedure":
P-0-3228, C4000 Homing procedure command channel 2
S-0-0148, C0600 Drive-controlled homing procedure command
P-0-3210, Safety technology control word
P-0-3213, Safety technology status
P-0-3231, Safety related reference position channel 2
P-0-3229, Tolerance window for safety related homing procedure
S-0-0147, Homing parameter
S-0-0052, Reference distance 1
S-0-0051, Position feedback 1 value
S-0-0053, Position feedback 2 value
P-0-3280, Actual position value, channel 2
P-0-3240, Control word for safety related motion 1
P-0-3250, Control word for safety related motion 2
P-0-3260, Control word for safety related motion 3
P-0-3270, Control word for safety related motion 4
Operating Principle
There are two options of starting the safety related homing procedure via
two channels:
By directly writing "11" to parameter P-0-3228, C4000 Homing
procedure command channel 2.
Note:
Automatically at the start of command S-0-0148, C0600 Drivecontrolled homing procedure command in conjunction with the
parameterized function "safety related limited absolute position". (The
command S-0-0148, C0600 Drive-controlled homing procedure
command at the beginning also starts the command P-0-3228, C4000
Homing procedure command channel 2 which then runs in parallel.)
Note:
DOK-INDRV*-SI*-VRS**-FK01-EN-P
DOK-INDRV*-SI*-VRS**-FK01-EN-P
DOK-INDRV*-SI*-VRS**-FK01-EN-P
Note:
DOK-INDRV*-SI*-VRS**-FK01-EN-P
DOK-INDRV*-SI*-VRS**-FK01-EN-P
6.3
Transfer
Selection Inputfilter
10 ms
System
control
Default
error
reaction
Inspection of
channel
states
P-0-3221
2 ms
Safety related
technology function
Monitoring active
P-0-32xx
2 ms
1 ms
1 ms
1 ms
F3xxx
F7xxx
F7xxx
best possible
deceleration
fastest possible
deceleration
fastest possible
deceleration
DF000093v02_en.EPS
Fig. 6-2:
6.4
DOK-INDRV*-SI*-VRS**-FK01-EN-P
Dual-Channel Structure
All safety-relevant data are transmitted and processed by two
independent channels. The basic control unit in the drive represents the
first monitoring channel, the control system on the optional module
represents the second channel.
I/O10n
Selection
Channel 2 I1..4n
Safety technolgy
optional module
Power
section
Cross data
comparison
Selection
Channel 1
Encoder
system
Drive control
I1..4
O10
I10
DF0016v2.EPS
Fig. 6-3:
Note:
DOK-INDRV*-SI*-VRS**-FK01-EN-P
When one or more safety functions are also activated, an additional cross
data comparison is carried out using the selection.
DOK-INDRV*-SI*-VRS**-FK01-EN-P
Dynamization
The purpose of dynamization is to detect static error conditions, so-called
"sleeping errors" in the safety-relevant circuits. Dynamization occurs
automatically at specified intervals; the user can not notice this.
Dynamization of the inputs
I1
I1n
I/O30
Safety technology
funct. 2
I1
I1n
I/O30
I1
I1n
I/O30
Channel 1
Axis 1
Channel 2
Channel 2 (Master)
Channel 1
Axis 2
Channel 2
Channel 2 (Slave)
Channel 1
Axis 3
Channel 2
Channel 2 (Slave)
DF0044v1.EPS
Fig. 6-4:
Dynamization of the interrupting
circuits
Both the control section in standard design and the optional module
"safety technology I/O" have their own interrupting circuits.
Within the drive, the activation of an interrupting circuit is cyclically
checked.
6.5
DOK-INDRV*-SI*-VRS**-FK01-EN-P
The transition to safety related stopping process in the case of error takes
place according to the settings in parameters P-0-0117, Activation of NC
reaction on error and P-0-0119, Best possible deceleration.
Note:
6.6
Normal mode
Operating mode
selection switch
Operating mode
selection switch+
enabling control
Special mode
motion
Special mode
stopping process
Enabling control
DC0003v1.EPS
Fig. 6-5:
Status diagram
DOK-INDRV*-SI*-VRS**-FK01-EN-P
DOK-INDRV*-SI*-VRS**-FK01-EN-P
Fig. 6-6:
NM:
SM:
SS:
SOS:
SRS:
SA:
SD:
SI:
SP:
SBM:
:
:
Off
Off
NM
SM
SM
SM
SM
SM
SM
SM
SM
SM
-
Off
On
On
On
On
On
On
NM
Normal mode
Special mode
Safety related standstill (no torque)
Safety related operation stop (control loops are active)
Safety related reduced speed
Safely monitored acceleration/deceleration ramp
Safety related direction of motion
Safety related limited increment
Safety related limited absolute position
Safety related brake management
Input for control element is not queried
No input for control element available (max. 4 inputs)
Special mode
with
motion
Position
Position
Position
On
Off
On
Off
On
Off
Safety
switch 1
selection switch
Drive interlock
Special mode
with
SS or SOS
stopping process Safety related
stopping process
SOS + SBM
Normal
mode
On
On
Position
Safety
switch 2
On
Off
Activated
Off
Activated
Activated
Activated
Position
Home
switch
Off
Off
Off
Off
Off
On
Off
Off
Position
Drive
interlock
Operating mode
DL0001v2.EPS
DOK-INDRV*-SI*-VRS**-FK01-EN-P
Processing and
error reaction
Selection and
feedback of
safety related
functions
Control
section
Safety
related
action
Power
section
I/O
Channel 1
Processor A
I/O
Channel 2
Processor B
Channel 1
Channel 2
Fig. 6-7:
DOK-INDRV*-SI*-VRS**-FK01-EN-P
Processing and
error reaction
Control
Control
section
S
E
R
C
O
S
I/O
Channel 1
S
E
R
C
O
S
Safety
related
action
Power
section
Channel 1
Processor A
I/O
Channel 2
Processor B
Channel 1
Channel 2
Safety
technology
active
Safety
technology
active
DF0017v1.EPS
->
->:
Fig. 6-8:
Note:
6.7
DOK-INDRV*-SI*-VRS**-FK01-EN-P
"Safety technology
I/O" optional
module
O10
I/O10n
In
DA0002v4.EPS
Channel 1:
O10 (control section)
Channel 2:
I/O10n (O10, 24 V driver is active on "Safety technology I/O"
optional module)
Fig. 6-9:
Safe status message to a safety PLC
Note:
DOK-INDRV*-SI*-VRS**-FK01-EN-P
DANGER
Control
O10
+24 V
section
"Safety technology
I/O" optional module
I/O10n
0V
Control
section
"Safety technology
I/O" optional module
I10
I/O20
Channel 1:
O10 (control section)
Channel 2:
I/O10n (24 V input and driver for relay contact are active on
"Safety technology I/O" optional module)
Fig. 6-10: Activation of a door locking device
DOK-INDRV*-SI*-VRS**-FK01-EN-P
The axes report the attainment of the safety related status and permit the
safety master to activate the safety status output (O10/O10n), e.g. for a
door locking device.
Note:
All axes of a hazard zone must be interconnected via I/O20 using a bus.
Note:
DOK-INDRV*-SI*-VRS**-FK01-EN-P
6.8
Examples of Application
Overall View
Functionality and connections for integrated safety technology on
IndraDrive drive controller
Combination of safety
functions - configurable
using parameters
Mastercommunication
interface (1)
Connection
per drive
I1
I2n
Enabling
control
Switch for drive
interlock
I3
Configuirable for
the inputs
Controlelements
I2
Safety Switch 1
Process
I1n
Operating mode
selection switch
I3n
I4
I4n
Safety Switch 2
Home switch
connection for safety related absolute
position required
REF
Input/Outputacknowledgement
I/O20
NC/PLC superordinate control
Dynamization
I/O30
O10
I/O10
+24 V
Alternative 2
Door locking device
O10
I10n
I/O10n
O10n
I10
0V
DF0034v7.EPS
1:
DOK-INDRV*-SI*-VRS**-FK01-EN-P
Note:
IndraDrive
Control section
+24 V
Power
section
Locking device
Channel 1
O10
Safety related
control of a door
locking device
Category 3
closed
I/O10n
Position switch 1
Channel 2
Channel 2
I10
0V Channel 1
(NM)
Ch2
Operating mode
selection switch,
e.g. from
machine control
panel via PLC
Ch1
Forced
dynamization
Channel 2
I/O30
Normal mode
Demands of conrols
NC program run
enablement
NC command value
limitation
0V
Safety related
standstill
Category 3
Special mode_n
Special mode
I1n
Channel 2
I1
Channel 1
DF0035v5.EPS
Fig. 6-12:
DOK-INDRV*-SI*-VRS**-FK01-EN-P
Position switch 2
IndraDrive
open
Control section
+24 V
Locking device
Power
section
Channel 1
O10
Safety related
control of a door
locking device
Category 3
closed
I/O10n
Position switch 1
Channel 2
Channel 2
I10
0V
Channel 1
Operation mode
selection switch
(NM)
(SM)
Ch2
Ch1
Forced
dynamization
Channel 2
I/O30
Safety related
standstill
Demands of controls
Category 3
NC program
run enablement
Special mode_n
NC command
value limitation
Special mode
I1n
Channel 2
I1
Channel 1
DF0079v2.EPS
Fig. 6-13:
with
position
DOK-INDRV*-SI*-VRS**-FK01-EN-P
Forced
dynamization
Power
section
Channel 2
I/O30
1 2 3
Safety related
motion
Category 3
Enabling
I2
Channel 1
No enabling
I2n
Channel 2
Pressure point
DF0037v3.EPS
Fig. 6-14:
DOK-INDRV*-SI*-VRS**-FK01-EN-P
DOK-INDRV*-SI*-VRS**-FK01-EN-P
IndraDrive
Control section
Power
section
(NM)
Ch2
Ch1
Operating mode
selection switch,
e.g from
machine control
panel via PLC
Forced
dynamization
I/O30
Channel 2
Normal mode
Demands of controls
0V
Safety related
operational stop
NC program
run enablement
Special mode_n
Block command
value (0m/min)
Special mode
I1n
I1
Category 3
Channel 2
Channel 1
DF0036v6.EPS
Fig. 6-15:
DOK-INDRV*-SI*-VRS**-FK01-EN-P
IndraDrive
Position monitoring of safety
door with locking device
(see extra illustration)
Control section
(NM)
Ch2
Power
section
Ch1
M
Operation mode
selection switch,
e.g. from
machine control
panel via PLC
Forced
dynamization
Channel 2
I/O30
Demands of controls
Normal mode
Block command
value input
(0m/min)
0V
Safe
operational stop
Category 3
Special mode_n
I1n
Channel 2
Effect
of EC
Special mode
I1
Channel 1
Enable command
value input
Effect
of EC
Limit command
value input
<2m/min)
Safety related
reduced speed
Category 3
Enabling control (EC)
(simplified representation)
Enabling
Enabling_n
I2
I2n
Channel 1
Channel 2
DF0038v6.EPS
Fig. 6-16:
DOK-INDRV*-SI*-VRS**-FK01-EN-P
DOK-INDRV*-SI*-VRS**-FK01-EN-P
IndraDrive
Position monitoring of safety
door with locking device
(see extra illustration)
Control section
(NM)
Ch2
Ch1
Power
section
M
Operating mode
selection switch,
e.g. from
machine control
panel via PLC
Forced
dynamization
Channel 2
I/O30
Demands of controls
Block command
value input
(0m/min)
Normal mode
0V
Safety related
standstill
Category 3
Special mode_n
I1n
Channel 2
Effect
of EC
Special mode
I1
Channel 1
Enable command
value input
Effect
of EC
Limit command
value input
<2m/min)
Satey related
reduced speed
Category 3
Enabling control (EC)
(simplified representation)
Enabling
Enabling_n
I2
Channel 1
I2n
Block command
value input
(0m/min)
Safety related
drive interlock
Drive interlock
Drive interlock
switch
Channel 2
Drive interlock_n
I3
Category 3
Channel 1
I3n
Channel 2
DF0039v6.EPS
Fig. 6-17:
DOK-INDRV*-SI*-VRS**-FK01-EN-P
IndraDrive
Control section
(NM)
Ch2
Operating mode
selection switch,
e.g. from
machine control
panel via PLC
Ch1
Power
section
M
Forced
dynamization
Channel 2
I/O30
Normal mode
0V
Safety related
stopping process
Demands of controls
Category 3
Block command
value input
(0 m/min)
Special mode_n
Effect
of EC
Special mode
I1n
I1
Channel 1
Effect
of EC
Enable command
value input
Limit command
value input
(<2 m/min)
Channel 2
Safety related
reduced speed /
limited increment
Category 3
Enabling
control (EC)
simplified
representation
Enabling
Enabling_n
I2
I2n
Channel 1
Channel 2
Switching of
monitoring from
speed to increment
Safety
switch S1
Selection of speed
jogging or increment jogging
Safety related
limited increment
I3
Safety related
limited increment_n I3n
Channel 1
Channel 2
DF0040v6.EPS
Fig. 6-18:
DOK-INDRV*-SI*-VRS**-FK01-EN-P
IndraDrive
Control section
(NM)
Ch2
Ch1
Operating mode
selection switch,
e.g. from
machine control
panel via PLC
power
section
M
Forced
dynamization
Channel 2
I/O30
Normal mode
Demands of controls
Blockcommand
value input
(0 m/min)
0V
Safety related
operational stop
Category 3
Special mode_n
I1n
Channel 2
Effect of
enabling
Special mode
I1
Enable command
value input
Channel 1
Effect of
enabling
Limit command
value input
Safety rel. red. speed
Safety related
jog button
Category 3
I2
Channel 1
Enabling
I2n
Channel 2
Enabling_n
Fig. 6-19:
Note:
For information about the safety related jog keys, please see
"Command Device with Automatic Reset (Safety Related Jog
Button)".
DOK-INDRV*-SI*-VRS**-FK01-EN-P
DOK-INDRV*-SI*-VRS**-FK01-EN-P
Danger zone A
Antrieb A2
Drive A2
M
M
3~
3~
Danger zone B
Antrieb A2
Drive B2
M
M
3~
3~
Drive A1A1
Antrieb
Drive
B1A1
Antrieb
M
3~
M
3~
Door locking
device
Antrieb
Drive
A3A3
Antrieb
Drive
B3A3
M
3~
M
3~
Door locking
device
Door closed in
normal mode
Door opened
in normal mode
Mains
I/O10 I/O20
Power supply
device
~
=
I/O20
I/O20
I/O10 I/O20
I/O20
I/O20
Drive A1
Safety
Master
Drive A2
Safety
Slave
Drive A3
Safety
Slave
Drive B1
Safety
Master
Drive B2
Safety
Slave
Drive B3
Safety
Slave
I1,I2,I3,I4
I1,I2,I3,I4
I1,I2,I3,I4
I1,I2,I3,I4
I1,I2,I3,I4
I1,I2,I3,I4
selection/feedback
Safety function
selection/feedback
Emergency
stop
Safety function
Monitoring
module
Fig. 6-20:
DOK-INDRV*-SI*-VRS**-FK01-EN-P
+24 V
Demand 2
PLC
I1
O10
Basic device
Ixx
Inputs
I2
O2
Outputs
Demand 1
O1
+24 V
Door locking
device 1
+24 V
Door locking
device 2
I/O10n
SI-OM
SI-OM
0V
0V
Basic device
I10
DF0046v1.EPS
Fig. 6-21:
DOK-INDRV*-SI*-VRS**-FK01-EN-P
DOK-INDRV*-SI*-VRS**-FK01-EN-P
7.1
General Information
The safety technology is a dual-channel system in which a second
processor redundantly carries out the monitoring functions. The processor
uses the known data of encoder, mechanical system and scaling of the
main system and stores them in the system/parameter memory.
Changing data is not allowed any more after the safety functions have
been commissioned. They are detected and acknowledged by an
error/warning. After the system has been changed, it is necessary to
commission the safety functions again.
All direct safety technology parameters are characterized by double input
which is realized in such a way that individual parameters have to be
written by a list of two equal values. Tables are of double size, the same
table being attached as a copy. This allows a plausibility test of the data to
be carried out, also in the case of an input via SERCOS monitor.
All safety technology parameters must be write-protected by a password
to be assigned by the user. The safety technology is activated at the
same time that the password is assigned.
7.2
DOK-INDRV*-SI*-VRS**-FK01-EN-P
7.3
DOK-INDRV*-SI*-VRS**-FK01-EN-P
DOK-INDRV*-SI*-VRS**-FK01-EN-P
DOK-INDRV*-SI*-VRS**-FK01-EN-P
Using the following parameters, the set-up position range can be defined
starting at the time of selection using the enabling control for the
parameter set that is being monitored:
P-0-3243, Safety related limited increment 1
P-0-3253, Safety related limited increment 2
P-0-3263, Safety related limited increment 3
P-0-3273, Safety related limited increment 4
By means of the following parameters, the upper and lower position limits
can be defined for the respective parameter set that is monitored:
P-0-3241, Safety related limited absolute position 1, positive
P-0-3242, Safety related limited absolute position 1, negative
P-0-3251, Safety related limited absolute position 2, positive
P-0-3252, Safety related limited absolute position 2, negative
Note:
The safety related homing procedure is the prerequisite for the "Safety
related limited absolute position" safety function.
Note:
In the case of absolute encoders, the S-0-0148, C0600 Drivecontrolled homing procedure command has to be started
for safety related homing.
DOK-INDRV*-SI*-VRS**-FK01-EN-P
7.4
7.5
DOK-INDRV*-SI*-VRS**-FK01-EN-P
Completing Commissioning
At the end of commissioning, the new parameters of the safety functions
can be tested. To do this, select the safety functions one after the other
while triggering the activation of the monitors using command value
selection.
CAUTION
Note:
7.6
DOK-INDRV*-SI*-VRS**-FK01-EN-P
7.7
7.8
Note:
Note:
Modification history
DOK-INDRV*-SI*-VRS**-FK01-EN-P
Acceptance Test
8.1
Acceptance Procedure
A complete acceptance test must be carried out by authorized personnel
when commissioning the machine and for all software or hardware
modifications that are relevant to the functional safety (including
modifications made using telecommunication).
If only a few safety-relevant data have been modified, these must be
tested in a partial acceptance test.
In any case, the modifications and the execution of the test must be
logged (see "Checklist for Acceptance Test").
8.2
DOK-INDRV*-SI*-VRS**-FK01-EN-P
DL000003v01_en.WMF
Fig. 8-1:
DOK-INDRV*-SI*-VRS**-FK01-EN-P
9.1
Firmware Code
Parameter P-0-3200, Safety firmware code contains the designation of
the safety firmware version.
9.2
Errors
The error handling of the safety technology is covered by the error
handling of the standard drive.
If error occurs, the drive is decelerated in the best possible or fastest way
and then goes to safety related standstill.
9.3
Note:
Note:
DOK-INDRV*-SI*-VRS**-FK01-EN-P
9.4
Status Messages
Parameter P-0-3213, Safety technology status makes available binary
status signals for online monitoring of the safety states. By means of this
status word, the individual status signals can be optionally programmed to
existing real-time bits of the master communication or hardware I/Os or
I/O extensions.
Parameter P-0-3215, Selected safety technology mode makes
available in coded form the activated safety operating mode of the
individual monitoring channels.
Parameter P-0-3216, Active safety technology signals shows the
current status of the safety signals of the individual channels.
Parameter P-0-3217, I/O status channel 2 (optional safety technology
module) shows the current status of the inputs/outputs of the safety
module.
9.5
9.6
DOK-INDRV*-SI*-VRS**-FK01-EN-P
10
technology
Note:
DOK-INDRV*-SI*-VRS**-FK01-EN-P
Prepare a log with the following content and append it to the safetyrelevant documentation of the machine:
Control section replaced on (date)
Change counter of safety technology memory (P-0-3201) at (value)
Operating hours at last change of memory (P-0-3202) at (value)
(Date), (name), (signature)
Replacing a control section with
MMC
DOK-INDRV*-SI*-VRS**-FK01-EN-P
11
DX00003v01_ms.eps
Fig. 11-1:
DOK-INDRV*-SI*-VRS**-FK01-EN-P
DX00002v01_de.eps
Fig. 11-2:
Mark
Certificate,
(CSH01.1...-L1-...)
"Starting
lockout"
optional
module
DOK-INDRV*-SI*-VRS**-FK01-EN-P
DX00004v01_ms.eps
Fig. 11-3:
DOK-INDRV*-SI*-VRS**-FK01-EN-P
DX00001v01_de.eps
Fig. 11-4:
technology
I/O"
optional
module"
DOK-INDRV*-SI*-VRS**-FK01-EN-P
Index 12-1
12
Index
A
absolute position see limited absolute position
Appropriate use
Introduction 3-1
Appropriate uses
Uses 3-2
C
C-standards 4-4
D
drive system see electric drive system
E
electric drive system 4-4
Enabling control 4-5
Error message
plausibility 7-6
F
Fields of application 6-2
H
Hazard analysis 4-1
I
Inappropriate use 3-2
Consequences, Discharge of liability 3-1
J
Jog switch 4-5
L
limited absolute position 4-5
Limited incremental dimension 4-5
Locked separating protective device with locking device (EN 292-1) 4-6
M
Modification history 7-8
O
Operating mode switch 4-6
operational stop 4-5
P
Protective device see Locked separating protective device with locking device
(EN 292-1) see Separating protective device (EN 292-1)
DOK-INDRV*-SI*-VRS**-FK01-EN-P
12-2 Index
R
reduced speed 4-5
Replacing a control section with MMC 10-2
Replacing a control section without MMC 10-1
Replacing the Control Section 10-1
Risk management 4-1
S
Safety acceptance test
modification status 7-8
Safety categories
requirements 4-2
safety functions
safely monitored shutdown 6-6
safety related homing procedure 6-6
Safety functions
overview 6-3
safety related brake management 6-10
safety related control of a door locking device 6-11
safety related diagnostic outputs 6-10
safety related limited absolute position 6-10
safety related limited increment 6-10
safety related operational stop 6-4
safety related reduced speed 6-9
safety related standstill 6-4
Safety Functions
safety related direction of motion 6-9
safety related limited absolute end position 6-10
standstill 4-5
Starting lockout
command value selection requirements 5-2
examples of application 5-3
forced dynamization 5-2
general information 5-1
safety function 5-1
selecting the starting lockout 5-2
U
Use See appropriate use and see inappropriate use
DOK-INDRV*-SI*-VRS**-FK01-EN-P
Bosch Rexroth AG
Electric Drives and Controls
P.O. Box 13 57
97803 Lohr, Germany
Bgm.-Dr.-Nebel-Str. 2
97816 Lohr, Germany
Phone +49 93 52-40-50 60
Fax
+49 93 52-40-49 4 1
service.svc@boschrexroth.de
www.boschrexroth.com
R911297838
Printed in Germany
DOK-INDRV*-SI*-**VRS**-FK01-EN-P