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Integrated safety functions

6.1

Overview of safety functions

6.1.1

General information

The application-related safety functions "Safe Torque Off" and "Safe Brake

Control" described below have been realized for personal protection in

accordance with ISO 13849-1, Category 4, PL e and IEC 62061, SIL3.

Before a safety function is selected, the drive system must be put

into the appropriate state by specifying the command value.

6.1.2

Classification of safety functions

The safety functions can be divided into the following categories:

1. Safety functions in normal operation
2. Safety functions in special mode "Safe standstill"
3. Safety functions in special mode "Safe motion"
4. Additional or auxiliary functions

IndraDrive Cs

With IndraDrive Cs and the optional safety technology modules "L3" and

"L4", it is exclusively the "Safe standstill" group of safety technology functions

with the following safety technology functions which is supported:
●

Safe Torque Off (STO)

●

Safe Brake Control (SBC; only with optional safety technology module

"L4")

●

Safe stop 1 (Emergency stop) (only in conjunction with an external,

time-delayed safety selection device)

IndraDrive Mi

With IndraDrive Mi and the optional safety technology module "L3", it is

exclusively the "Safe standstill" group of safety technology functions with the

following safety technology functions which is supported:
●

Safe Torque Off (STO)

●

Safe stop 1 (Emergency stop) (only in conjunction with an external,

time-delayed safety selection device)

IndraDrive C and IndraDrive M

With IndraDrive C and IndraDrive Mi and the optional safety technology

module "L3", it is exclusively the "Safe standstill" group of safety technology

functions with the following safety technology functions which is supported:
●

Safe Torque Off (STO)

●

Safe stop 1 (Emergency stop) (only in conjunction with an external,

time-delayed safety selection device)

IndraDrive ML

With IndraDrive ML and the optional safety technology module "L3", it is

exclusively the "Safe standstill" group of safety technology functions with the

following safety technology functions which is supported:
●

Safe Torque Off (STO)

●

Safe stop 1 (Emergency stop) (only in conjunction with an external,

time-delayed safety selection device)

DOK-INDRV*-SI3-**VRS**-AP06-EN-P
Rexroth IndraDrive Integrated Safety Technology "Safe Torque Off" (as of MPx-16)

Bosch Rexroth AG

49/149

Integrated safety functions

LSA Control S.L. www.lsa-control.com [email protected] (+34) 960 62 43 01

Summary of Contents for Rexroth IndraDrive M

Page 1: ... Rexroth Indramat Bosch y Aventics LSA Control S L Bosch Rexroth Sales Partner Ronda Narciso Monturiol y Estarriol 7 9 Edificio TecnoParQ Planta 1ª Derecha Oficina 14 Parque Tecnológico de Paterna 46980 Paterna Valencia Telf 34 960 62 43 01 comercial lsa control com www lsa control com www boschrexroth es ...

Page 2: ...Control Company Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 Edition 06 Application Manual R911332634 LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 3: ...P01 EN P to DOK INDRV SI3 VRS AP06 EN P 2010 10 to 2014 07 See chapter About this documentation margin al note Editions of this documentation Copyright Bosch Rexroth AG 2014 This document as well as the data specifications and other information set forth in it are the exclusive property of Bosch Rexroth AG It may not be reproduced or given to third parties without its consent Liability The specifi...

Page 4: ... 3 Protection against dangerous movements 18 3 3 4 Protection against electromagnetic and magnetic fields during operation and mounting 19 3 3 5 Protection against contact with hot parts 20 3 3 6 Protection during handling and mounting 20 3 3 7 Battery safety 20 3 3 8 Protection against pressurized systems 21 3 4 Explanation of signal words and the Safety alert symbol 22 4 System overview 23 4 1 I...

Page 5: ...rive M 59 7 1 1 STO and SBC functions L4 only when selected by means of passive safety units 59 7 1 2 STO and SBC functions L4 only when selected by means of active safety units 61 7 1 3 Safe stop 1 emergency stop function with L3 L4 option 64 7 1 4 Zone setup 65 7 2 Examples of application for IndraDrive Mi 65 7 2 1 Single channel selection 65 7 2 2 Central selection at KCU 68 7 2 3 Distributed s...

Page 6: ...ntegrated safety technology 98 9 3 3 Behavior in the Case of Non Fatal Safety Technology Errors F3xxx 99 9 3 4 Behavior in the Case of Fatal Errors F8xxx 100 9 4 Removing malfunctions maintenance measures deactivating the motors 101 9 5 Replacing drive components 101 9 5 1 General information 101 9 5 2 Replacing the Motor 101 9 5 3 Replacing the brake 102 9 5 4 Replacing drive components of IndraD...

Page 7: ...5 E Stop function 137 12 3 6 Safety zones 139 12 4 Technical data of inputs and outputs 141 12 4 1 Digital inputs safety technology L options 141 12 4 2 Digital Outputs Safety Technology L Options 142 13 Service and support 143 Index 145 Bosch Rexroth AG DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 IV 149 Table of Contents LSA Control S L...

Page 8: ...ices with integrated safety technology Tab 1 1 Record of revisions Means of representation in this documentation To facilitate reading this documentation the table below contains the means of representation and notations of recurring terms What How For example Important facts which are to be highlighted in the body text Boldface With the safety function Safe parking axis the following monitoring f...

Page 9: ...tion contains information on mounting and maintenance on proper and safe operation and on the decommissioning of the integrated safety technology Safe Motion of IndraDrive Cs IndraDrive Mi and IndraDrive M IndraDrive ML IndraDrive C with control sections of the Cxx02 type is addressed to persons who mount operate and maintain IndraDrive Cs IndraDrive Mi and IndraDrive M IndraDrive ML IndraDrive C ...

Page 10: ... PRxx EN P 318790 ML Drive Systems with HMU05 Project Planning Manual Hxx05 PRxx EN P 344279 Drive Controllers Control Sections CSB01 CSH01 CDB01 Project Planning Manual CSH PRxx EN P 295012 Control Sections CSE02 CSB02 CDB02 CSH02 Project Planning Manual Cxx02 PRxx EN P 338962 Additional Components and Accessories Project Planning Manual ADDCOMP PRxx EN P 306140 1 In the document typecodes xx is ...

Page 11: ...x EN P R911297321 Rexroth GTE Planetary Gearboxes Project Planning Manual DOK GEAR GTE PRxx EN P R911308842 1 In the document typecodes xx is a wild card for the current edition of the documentation example RE02 is the second ed ition of a Reference Book Tab 1 5 Documentations Gearboxes 1 2 4 Cables Title Kind of documentation Document typecode1 DOK CONNEC Material number R911 Rexroth Connection C...

Page 12: ... Application Manual SI3 VRS APxx EN P 332634 Integrated Safety Technology Safe Motion as of MPx 18 Application Manual SI3 SMO VRS APxx EN P 338920 Rexroth IndraMotion MLD Libraries as of MPx 17 Reference Book MLD SYSLIB2 RExx EN P 332627 Rexroth IndraMotion MLD Libraries as of MPx 18 Reference Book MLD SYSLIB3 RExx EN P 338916 Rexroth IndraMotion MLD as of MPx 17 Application Manual MLD2 VRS APxx E...

Page 13: ...sch Rexroth AG DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 10 149 LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 14: ...nges are permitted It is not permitted to decompile software products or alter source codes Damaged or faulty products may not be installed or put into operation Make sure that the products have been installed in the manner described in the relevant documentation 2 1 2 Areas of Use and Application Drive controllers made by Rexroth are designed to control electrical motors and monitor their operati...

Page 15: ... This includes for example operation under water under extreme temperature fluctuations or extremely high maximum temperatures Furthermore Drive controllers may not be used in applications which have not been expressly authorized by Rexroth Please carefully follow the specifications outlined in the general Safety Instructions Components of the Rexroth IndraDrive system are products of category C3 ...

Page 16: ... several devices or systems interconnected for a defined purpose and on a defined site which however are not intended to be placed on the market as a single functional unit Machine A machine is the entirety of interconnected parts or units at least one of which is movable Thus a machine consists of the appropriate machine drive elements as well as control and power circuits which have been assembl...

Page 17: ...amage injury electric shock or even death 3 2 2 Requirements for safe use Read the following instructions before initial commissioning of the components of the electric drive and control system in order to eliminate the risk of injury and or property damage You must follow these safety instructions Rexroth is not liable for damages resulting from failure to observe the safety instructions Read the...

Page 18: ...plication are met The instructions for installation in accordance with EMC requirements can be found in the section on EMC in the respective application documentation The machine or installation manufacturer is responsible for compliance with the limit values as prescribed in the national regulations The technical data connection and installation conditions of the components are specified in the r...

Page 19: ...when working on power installations Before switching on the equipment grounding conductor must have been permanently connected to all electric components in accordance with the connection diagram Even for brief measurements or tests operation is only allowed if the equipment grounding conductor has been permanently connected to the points of the components provided for this purpose Before accessin...

Page 20: ...ctors is allowed each having the same cross section as the outer conductors Cross section outer conductor Minimum cross section equipment grounding conductor Leakage current 3 5 mA 1 equipment grounding conductor 2 equipment grounding conductors 1 5 mm2 16 AWG 10 mm2 8 AWG 2 1 5 mm2 16 AWG 2 5 mm2 14 AWG 2 2 5 mm2 14 AWG 4 mm2 12 AWG 2 4 mm2 12 AWG 6 mm2 10 AWG 2 6 mm2 10 AWG 10 mm2 8 AWG 16 mm2 6...

Page 21: ...mplete safety Until the integrated monitoring functions become effective it must be assumed in any case that faulty drive movements will occur The extent of faulty drive movements depends upon the type of control and the state of operation Dangerous movements Danger to life risk of injury serious injury or property damage A risk assessment must be prepared for the installation or machine with its ...

Page 22: ... electric drive and control system and their supply leads If the use of these devices cannot be avoided check the machine or installation at initial commissioning of the electric drive and control system for possible malfunctions when operating such high frequency remote control and radio equipment in its possible positions of normal use It might possibly be necessary to perform a special electrom...

Page 23: ... accordance with the respective safety regulations the manufacturer of the machine or installation must take measures to avoid injuries caused by burns in the final application These measures can be for example Warnings at the machine or installation guards shieldings or barriers or safety instructions in the application documentation 3 3 6 Protection during handling and mounting Risk of injury by...

Page 24: ...zed media such as compressed air hydraulics oil cooling liquids and cooling lubricants Improper handling of the connected supply systems supply lines or connections can cause injuries or property damage Risk of injury by improper handling of pressurized lines Do not attempt to disconnect open or cut pressurized lines risk of explosion Observe the respective manufacturer s operating instructions Be...

Page 25: ...ON is used to alert the reader to personal injury hazards DANGER In case of non compliance with this safety instruction death or serious injury will occur WARNING In case of non compliance with this safety instruction death or serious injury could occur CAUTION In case of non compliance with this safety instruction minor or moderate injury could occur NOTICE In case of non compliance with this saf...

Page 26: ...nderstanding of complex subjects Improved diagnostics Simplified certification Easy commissioning Independent of control units Comparison with conventional safety technology A drive and control system with integrated safety technology differs from systems with conventional safety technology by the fact that the safety functions are directly integrated in the intelligent drives in the form hardware...

Page 27: ...4 1 Schematic diagram of IndraDrive with integrated safety technology STO Safe Torque Off and SBC Safe Brake Control The safety functions Safe Torque Off and Safe Brake Control do not require any measuring system 4 1 3 Risk assessment Before a machine can be placed on the market the manufacturer of the machine must carry out a risk assessment in accordance with the Machinery Directive 2006 42 EC i...

Page 28: ...ns which comply with SIL1 SIL2 or SIL3 of IEC 62061 The safety related parts of the IndraDrive Mi range with the option L3 are suited for applications up to SIL3 of IEC 62061 and up to Category 4 PL e of ISO 13849 i e the optional safety technology modules of the IndraDrive Mi range allow implementing safety functions which comply with SIL1 SIL2 or SIL3 of IEC 62061 The safety related parts of the...

Page 29: ...ol sections of the IndraDrive M IndraDrive C range can be equipped with the optional module L3 STO Safe Torque Off The optional module L3 equips IndraDrive M IndraDrive C with integrated safety technology which provides the user with safe torque off IndraDrive ML The Cxx02 5 control sections of the IndraDrive ML range can be equipped with the optional module L3 STO Safe Torque Off The optional mod...

Page 30: ...parts of control units according to ISO 13849 1 Category 4 PL e and IEC 62061 SIL 3 as required in EN 1010 1 printing and paper converting machines EN 12415 turning machines and EN 12417 machining centres Control functions in the case of an error according to IEC 60204 1 homogeneous redundancy 4 2 2 Integrated safety technology as IndraDrive platform solution Characteristics of IndraDrive Cs The t...

Page 31: ...1 Bosch Rexroth AG DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 28 149 System overview LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 32: ...he different characteristics of the drive connection box KCU02 the distributed drive controller KMS02 and the distributed servo drive KSM02 Fig 4 3 Type code KCU02 To employ the integrated safety technology Safe Torque Off L3 it is necessary to use at least the design 2 or higher of the drive connection box DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off...

Page 33: ... Bosch Rexroth AG DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 30 149 System overview LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 34: ... DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 Bosch Rexroth AG 31 149 System overview LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 35: ... MPB 17V10 Characteristics of IndraDrive M IndraDrive C The following type codes show the different characteristics of the control sections of IndraDrive C IndraDrive M Fig 4 6 Type code CSB02 Bosch Rexroth AG DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 32 149 System overview LSA Control S L www lsa control com comercial lsa control com ...

Page 36: ...2 DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 Bosch Rexroth AG 33 149 System overview LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 37: ...Px 18V06 IndraDrive M Cxx02 x control sections As of MPx 18V06 Characteristics of IndraDrive ML The following type codes show the different characteristics of the control sections of IndraDrive ML Bosch Rexroth AG DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 34 149 System overview LSA Control S L www lsa control com comercial lsa control ...

Page 38: ... 5 DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 Bosch Rexroth AG 35 149 System overview LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 39: ... 5 Bosch Rexroth AG DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 36 149 System overview LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 40: ...electrical electronic programmable electronic safety related systems Tab 4 2 Standards relevant to components 4 3 3 Standards relevant to machinery Standard Title ISO 12100 Safety of machinery General principles for design Risk assessment and risk reduction IEC 60204 1 Safety of machinery Electrical equipment of machines IEC 62061 Safety of machinery Functional safety of safety related electrical ...

Page 41: ...ve Tab 4 4 EC Directives 4 4 Overview of functions and characteristics 4 4 1 Characteristics of integrated safety technology Introduction This documentation describes the characteristics Safe Torque Off pure hardware solution optional safety technology module L3 and Safe Torque Off and Safe Brake Control pure hardware solution optional safety technology module L4 of the integrated safety technolog...

Page 42: ...dule L3 it is exclusively the Safe standstill group of safety technology functions with the following safety technology functions which is supported Safe Torque Off Safe stop 1 Emergency stop only in conjunction with an external time delayed safety selection device IndraDrive C and IndraDrive M With IndraDrive C IndraDrive Mi and the optional safety technology module L3 it is exclusively the Safe ...

Page 43: ...ified according to IEC 61508 IEC 61800 5 2 IEC 62061 and ISO 13849 1 IndraDrive Mi For using the optional safety technology module L3 the IndraDrive Mi system has been certified according to IEC 61508 IEC 61800 5 2 IEC 62061 and ISO 13849 1 IndraDrive C IndraDrive M For using the optional safety technology module L3 the IndraDrive C IndraDrive M system has been certified according to IEC 61508 IEC...

Page 44: ... Mission Time 175 200 h 20 years 175 200 h 20 years Proof Test interval 175 200 h 20 years 175 200 h 20 years MTTFd channel 1 200 years 200 years DCavg 99 99 Test interval 1 h 1 h 1 The specified safety characteristics are achieved under the conditions mentioned in the Project Planning Manual see Am bient and operating conditions With the IndraDrive Mi system the PFH value of the drive connection ...

Page 45: ...t be available for all components which have an influence on the safety function if necessary procure the PFH value from the component manufacturer 1 External component 2 Only for safety zone with at least one IndraDrive Mi with L3 op tion Fig 4 12 Formula to calculate PFH for a safety zone The following conditions restrictions apply to the general use of the formula for PFH calculation for a safe...

Page 46: ...tates were realized in the system Dual channel structure Comparison of the states of both channels Dynamization of static states These measures ensure that a single error cannot cause the safety functions to be lost The installation or machine manufacturer has to determine in how far this is sufficient for an existing installation or machine by a risk assessment according to annex I of the Directi...

Page 47: ...unction via OSSD outputs The active safety unit tests its outputs on its own The OSSD Output Signal Switching Device is that part of a safe selection unit which has been connected to the machine control and which goes to the OFF state when the safe selection unit triggers during the intended operation When the safety functions are selected via an active safety unit the dynamization pulses of the O...

Page 48: ...ion or deselection tDmin tPH tP 90 Minimum sampling ratio of the selection signals tBounce 400 ms Maximum bounce time for a selection or deselection φ Phase shift of the test pulses on both channels No requirement Tab 5 1 Limit values of the dynamization pulses of the OSSD outputs Fig 5 2 Example of dynamized selection signals The figure below illustrates in schematic form the interconnection of a...

Page 49: ...he selection When the selection of the safety functions takes place via a passive safety unit the drive generates the dynamization pulses and makes them available via the dynamization channel A and dynamization channel B outputs These two outputs allow supplying the isolated selection contacts of the passive safety unit The figure below illustrates in schematic form the interconnection of a passiv...

Page 50: ... L3 L4 If more than 25 drives are to be operated at a safety unit several safety zones must be set up DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 Bosch Rexroth AG 47 149 Functional principle of integrated safety technology LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 51: ...sch Rexroth AG DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 48 149 LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 52: ...election device IndraDrive Mi With IndraDrive Mi and the optional safety technology module L3 it is exclusively the Safe standstill group of safety technology functions with the following safety technology functions which is supported Safe Torque Off STO Safe stop 1 Emergency stop only in conjunction with an external time delayed safety selection device IndraDrive C and IndraDrive M With IndraDriv...

Page 53: ...on is active power is not removed from the motor de energize the motor s drive before working on it Features The safety function Safe Torque Off STO has the following features When the optional safety technology module L4 is used and the safety function Safe Torque Off STO is selected the Safe Brake Control SBC is automatically activated Corresponds to stop category 0 according to IEC 60204 1 Is s...

Page 54: ...llel Online dynamization of the outputs and interrupting circuits Short reaction time 18 ms 108 ms with IndraDrive ML The state of safety function Safe Torque Off is displayed via parameter P 0 0106 Operating status STO SBC Pertinent parameters The following parameters are used in conjunction with the safety function Safe Torque Off P 0 0101 Configuration STO SBC P 0 0106 Operating status STO SBC ...

Page 55: ...dynamization of the selection signals is carried out in the deselected state Monitoring takes place so that dynamization is carried out at the latest after 1 hour in the deselected state normal operation For this purpose the time in the deselected state is added in the drive and only reset by dynamization i e an interim selection does not cause monitoring to be reset Monitoring takes place indepen...

Page 56: ...que Off can be optionally selected via one channel or via two channels In the case of IndraDrive Mi selection via one channel is not allowed The selection of the safety function is detected when a 0 signal is detected on both selection inputs The selection can alternatively be made by means of active or passive safety units See also Examples of application In the case of the safety option L4 the s...

Page 57: ...haft is aligning Synchronous motor example For a 6 pole synchronous motor the motion can be a maximum of 30 degrees For a directly driven ball screw e g 20 mm per revolution this corresponds to a one time maximum linear motion of 1 67 mm When an asynchronous motor is used the short circuits in two separate circuits of the power section have almost no effect because the exciter field breaks down wh...

Page 58: ...ynamization of the safety function selection takes place alternatively by means of the OSSD dynamization of the active safety unit or the dynamization outputs at the X49 terminal connector of the optional safety technology module L4 in the case of control by passive safety units It is possible to set up a zone by connecting up to 25 drives in parallel Only self holding electrically releasing brake...

Page 59: ...dard drive functions A safety function is selected via an N C N C combination i e a 0 signal at both inputs is evaluated as the selection of the safety function Therefore the dynamization of the external selection channels can only take place in the deselected state normal operation Internal dynamizations are carried out independent of the selection For the dynamization of the safety function sele...

Page 60: ...ameter P 0 0101 Configuration STO SBC it is possible to select whether the drive is to react to the error with the fatal error F8027 STO SBC while drive enabled or the fatal warning E8027 STO SBC while drive enabled The warning is automatically cleared when drive enable is removed the error must be cleared by the user The diagnostic messages are recorded in S 0 0375 Diagnostic numbers list Lethal ...

Page 61: ...ore working on it As the safety function Safe Brake Control cannot be deactivated it is only allowed to operate self holding electrically releasing brakes at drives with the optional safety technology module L4 If an electrically clamping brake is configured in parameter P 0 0525 Holding brake control word the transition command error C0256 Safety technology configuration error is generated when t...

Page 62: ...7 1 STO function and SBC function only IndraDrive Cs with L4 with du al channel wiring and passive safety unit The assignment of the dynamization signals can be selected as desired DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 Bosch Rexroth AG 59 149 Examples of application LSA Control S L www lsa control com comercial lsa control com 34 9...

Page 63: ...other potentials Short circuit with 24 V Short circuit with ground See also EN 61800 5 2 2007 table D 1 In the case of single channel wiring between the passive safety unit and connector X49 of the L option the internal structure of the passive safety unit too must meet the requirements of the safe wiring The application engineers are free to choose any dynamization signal Bosch Rexroth AG DOK IND...

Page 64: ...y IndraDrive Cs with L4 with ac tive safety unit plus plus switching outputs Plus minus switching safety unit When the safety function is selected by means of a plus minus switching safety unit the following errors must be detected by the OSSD outputs Short circuit of the plus switching selection signal against 24 V Short circuit of the minus switching selection signal against 0 V DOK INDRV SI3 VR...

Page 65: ...e safety function is selected by means of a safety unit the short circuit with 24 V must be detected by the OSSD output Bosch Rexroth AG DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 62 149 Examples of application LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 66: ... made Short circuits with other potentials Short circuit with 24 V Short circuit with ground See also EN 61800 5 2 2007 table D 1 When the wiring between the active safety unit and connector X49 of the L option is a single channel wiring the OSSD output must have been designed with serial redundancy in accordance with SIL3 DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology...

Page 67: ...nction or the NC stop of the control unit and select the STO function after a fixed time that has been set is over The selection must always take place after the time that has been set independent of the state of the axis Fig 7 6 SS1 function including SBC with dual channel wiring and passive safety unit Bosch Rexroth AG DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology S...

Page 68: ...plication for IndraDrive Mi 7 2 1 Single channel selection In the case of IndraDrive Mi selection via one channel is not allowed DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 Bosch Rexroth AG 65 149 Examples of application LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 69: ...f IndraDrive Mi Bosch Rexroth AG DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 66 149 Examples of application LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 70: ...f IndraDrive Mi DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 Bosch Rexroth AG 67 149 Examples of application LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 71: ...cted by means of a plus plus switching safety unit the following errors must be detected by the OSSD outputs Short circuit of the selection signals with 24 V Short circuit between the two selection signals Bosch Rexroth AG DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 68 149 Examples of application LSA Control S L www lsa control com comer...

Page 72: ...ors must be detected by the OSSD outputs Short circuit of the plus switching selection signal against 24 V Short circuit of the minus switching selection signal against 0 V DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 Bosch Rexroth AG 69 149 Examples of application LSA Control S L www lsa control com comercial lsa control com 34 960 62 43...

Page 73: ...s switching outputs Bosch Rexroth AG DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 70 149 Examples of application LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 74: ... fixed time that has been set is over The selection must always take place after the time that has been set independent of the state of the axis The figure below shows KCU02 as a zone beginner The E Stop signal is wired to X50 of KCU02 and is transmitted to the zone nodes via the hybrid cable Fig 7 13 SS1 function via KCU02 with dual channel wiring and passive safety unit DOK INDRV SI3 VRS AP06 EN...

Page 75: ...nd passive safety unit The assignment of the dynamization signals can be selected as desired Bosch Rexroth AG DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 72 149 Examples of application LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 76: ...ety unit plus minus switching outputs Plus plus switching safety unit When the safety function is selected by means of a plus plus switching safety unit the following errors must be detected by the OSSD outputs Short circuit of the selection signals with 24 V Short circuit between the two selection signals DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off ...

Page 77: ...rol unit and select the STO function after a fixed time that has been set is over The selection must always take place after the time that has been set independent of the state of the axis The figure below shows KMS02 as a zone beginner The E Stop signal is wired to a digital input X37 alternative X38 of KMS02 and can be transmitted to another node of the same safety zone via the hybrid cable Bosc...

Page 78: ...ansmitting the selection signals Drive 2 does not feature L3 option Connector RBS0023 at X141 is not required here because in the case of devices of the KMS02 KSM02 type without L3 option X103 1 internally transmits the selection signals to X103 2 Selection in safety zone 2 is made via a passive safety unit at KMS02 drive 3 The E Stop function of the drive was used here as well to extend the STO D...

Page 79: ...e selection signals with connector RBS0023 or for transmitting new selection signals with cable RKB0033 Connector RBS0023 and cable RKB0033 are described in the Appendix see chapter 12 3 4 Connectors and cables for safety technology on page 136 Bosch Rexroth AG DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 76 149 Examples of application LS...

Page 80: ...sive safety unit Drive 4 Node of safety zone 2 the selection signals are transmitted by drive 3 via connector RBS0023 at X141 Fig 7 18 Example of zone setup with two safety zones and E Stop selection DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 Bosch Rexroth AG 77 149 Examples of application LSA Control S L www lsa control com comercial l...

Page 81: ...y modules L2 and L3 L4 at an active safety unit are integrated the axes must be interconnected as follows Fig 7 19 Mixed Operation of Safety Options L2 and L3 L4 via an Active Safety Unit Plus Minus Switching The circuit illustrated above makes the following demands on the active safety unit which is used Bosch Rexroth AG DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology ...

Page 82: ... L3 or L4 must be output A cyclic test for optional safety technology modules L2 must be made in accordance with the requirement The outputs of the safety unit must be designed for the number of nodes of a safety zone DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 Bosch Rexroth AG 79 149 Examples of application LSA Control S L www lsa contr...

Page 83: ...d L3 L4 via Safety Switching Device Passive Safety Unit The circuit illustrated above makes the following demands on the passive safety unit which is used No more than 15 axes with the optional safety technology modules L2 L3 L4 may be combined in a safety zone The two outputs of the passive safety unit which are used to control the L3 L4 options must meet the requirements of the SIL or Performanc...

Page 84: ... via a passive safety unit in which drives with the optional safety modules L2 and L3 L4 are integrated and single channel wiring of the L3 L4 option are not allowed Fig 7 21 Inadmissible Mixed Operation of the Safety Options L2 and L3 L4 with Single Channel Selection via Safety Switching Device Passive Safety Unit DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe To...

Page 85: ...sch Rexroth AG DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 82 149 LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 86: ...S02 types the control section and power section are combined In the case of drive controllers of the IndraDrive Mi KSM02 type the control section power section and motor are combined By the interaction of hardware and software components IndraDrive provides the Integrated Safety Technology The mechanical parts of power transmission such as gear motor and those of the safety devices brakes fall dow...

Page 87: ...so Functional Description of firmware Firmware types 8 2 3 Required controller configuration General information To use the integrated safety technology of Rexroth IndraDrive controllers the drive controller has to be configured equipped with the corresponding optional safety technology module Optional safety technology module L3 Using the Safe Torque Off function requires the optional safety tech...

Page 88: ... L3 or L4 Optional safety technology module L4 Using the Safe Torque Off and Safe Brake Control function requires the optional safety technology module L4 The optional module can be ordered for the following controllers IndraDrive Cs Basic HCS01 1E W00 A0 B IndraDrive Cs Economy HCS01 1E W00 A0 E IndraDrive Cs Advanced HCS01 1E W00 A0 A For pin assignments and technical data of the optional safety...

Page 89: ... specified for the brake even in the case of an error The safety function does not provide any protection against overvoltage The brake current in the activated state must be between 0 1 A and 1 25 A Mechanical system When using the L4 option only friction surface brakes are allowed as motor holding brakes It is not allowed to operate form fitting brakes as motor holding brakes The static holding ...

Page 90: ...re 8 4 1 IndraDrive Cs Commissioning the Safe Torque Off and Safe Brake Control functions optional safety technology modules L3 L4 Overview The Safe Torque Off and Safe Brake Control functions are preferably commissioned by means of the IndraWorks commissioning software or manually The following commissioning steps describe the commissioning procedure on the basis of IndraWorks 12V04 For commissio...

Page 91: ...become active or not Step 1 Connecting and wiring the Safe Torque Off and Safe Brake Control function L4 only The connection and wiring of the Safe Torque Off and Safe Brake Control function depends on the option used to make the selection at the drive The Examples of application chapter shows the different options of selection and wiring The inputs and outputs at the connector X49 of the optional...

Page 92: ...ected brake in this dialog configure self holding as the holding brake type when using the optional safety technology module L4 because only electrically releasing brakes are allowed with the optional module L4 P 0 0525 Holding brake control word Step 3 Configuring the safety function As of MPx17V08 it is possible to configure the diagnostic message output and the error reaction of the L options T...

Page 93: ...tialization of the axis and before drive enable is set for the first time When the L option is selected by external components which output invalid selection states during initialization Limited diagnostic message should be parameterized The corresponding parameter is P 0 0101 Configuration STO SBC Step 4 Activating deactivating the safety function Before selecting the safety functions Safe Torque...

Page 94: ... external force influences together with danger for persons or machines are to be expected with the safety function Safe Torque Off e g due to the weight of the load in the case of a vertical axis this motion must be safely prevented by additional measures e g by a mechanical brake or a weight compensation In this case all cases of operation occurring in the application must be taken into account ...

Page 95: ...e dependances of the wiring of the optional safety technology module KCU02 KSM02 KMS02 as zone beginner KSM02 KMS02 as zone node Selection via a passive safety unit Dynamization outputs Dyn_Ch1 and Dyn_Ch2 X49 6 and X49 5 X141 8 and X141 12 Connector RBS0023 at X141 Hybrid cable at X103 1 X103 2 Selection inputs SI_Ch1 and SI_Ch2 X49 3 and X49 1 X141 1 and X141 2 24V supply X49 4 X141 4 0V supply ...

Page 96: ... initialization of the axis and before drive enable is set for the first time for this purpose select Limited diagnostic message When the L option is selected by external components which output invalid selection states during initialization Limited diagnostic message should be parameterized The corresponding parameter is P 0 0101 Configuration STO SBC Step 4 Activating deactivating the safety fun...

Page 97: ...f external force influences together with danger for persons or machines are to be expected with the safety function Safe Torque Off e g due to the weight of the load in the case of a vertical axis this motion must be safely prevented by additional measures e g by a mechanical brake or a weight compensation In this case all cases of operation occurring in the application must be taken into account...

Page 98: ... wiring type single channel or dual channel plus plus switching or plus minus switching The dynamization outputs Dyn_Ch1 X49 6 and Dyn_Ch2 X49 5 in the case of selection via a passive safety unit The selection inputs SI_Ch1 X49 3 and SI_Ch2 X49 1 always The 24V supply of the X49 connector X49 4 in the case of selection via a passive safety unit The 0V supply of the X49 connector X49 2 always Step ...

Page 99: ...ve controlled stopping process The safety function Safe Torque Off is automatically activated after the booting process It cannot be deactivated 8 5 Control unit requirements Optional safety technology mod ules L3 and L4 The control unit is subject to the following requirements in conjunction with the optional safety technology modules L3 and L4 Before selecting the safety function shut down the d...

Page 100: ...he diagnostic system S 0 0095 Diagnostic message S 0 0375 List of diagnostic numbers S 0 0390 Diagnostic message number P 0 0009 Error number up to MPx18 P 0 0478 Logbook event P 0 0479 Logbook time stamp Axis or device configuration A drive controller consists of several components power section control section firmware each of them has its own identifier in the form of a parameter see also Funct...

Page 101: ...ions Description of the status display dialog in IndraWorks 13 The dialog described below is displayed for devices with optional safety technology module L4 For devices with optional safety technology module L3 only STO is displayed instead of STO SBC the information content status information is identical for both optional modules The STO SBC status field of the IndraWorks Diagnostics dialog can ...

Page 102: ... 7 SMO Error reaction F3 tolerance time then the drive goes torque free and the output stage is locked via two channels If the F3 error reaction is not complete after the time period entered in P 0 3263 0 7 SMO Error reaction F3 tolerance time then the error message F7050 Timeout standstill or F8350 Timeout standstill is generated if the F3 error reaction is configured the same as the F7 error rea...

Page 103: ...h the corresponding setting in P 0 0118 Power supply configuration the power supply is disconnected in the case of fatal errors Fatal Safety Technology Errors When a fatal safety technology error occurs the safety technology immediately locks the output stage via two channels in the case of an error in the output stage interlock possibly via one channel only STO and if available and configured swi...

Page 104: ...cure the machine against accidental movements and against unauthorized operation Wait to allow the electric systems to discharge and then disconnect all electrical connections Before dismounting them secure the motor and if necessary the fan unit against falling or moving before unfastening the mechanical connections 9 5 Replacing drive components 9 5 1 General information When replacing drive com...

Page 105: ...xes with indirect distance measuring system via the motor encoder will loose the position data reference when the motor is replaced This position data reference to the machine coordinate system must therefore be reestablished after replacement 9 5 3 Replacing the brake Dangerous movements Danger to persons from falling or dropping axes WARNING While the brake is replaced secure the axis by a block...

Page 106: ...s place them on a conductive surface Control sections and optional cards may only be stored or shipped in conductive packaging Limited number of insertions and removals Risk of damage from frequent installation and removal NOTICE A control section optional card may only be installed and removed a maximum of 20 times DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe T...

Page 107: ...on is the reverse of removal 9 5 5 Replacing the controller Overview A controller of the IndraDrive range consists of the components power section control section and programming module control panel incl firmware The control section can be configured with additional components Bosch Rexroth AG DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16...

Page 108: ...g parameters or updating upgrading the drive firmware IndraMotion Service Tool IMST additionally analyzes drive systems connected via cross communication CCD Further information on IndraMotion Service Tool IMST and IndraDrive Service Tool IDST is described in the separate documentation Rexroth IndraDrive Service Tools IMST IDST DOK IM MLD IMSTIDSTV13 RE EN P mat no R911342652 How to proceed when r...

Page 109: ...e replaced by a device of identical type This is the only way to ensure that the originally configured functions can be used in unchanged form 9 Connect device according to machine circuit diagram Putting drive controller and ma chine into ready for operation state 1 Restore control voltage 2 Put machine into ready for operation state according to machine manufacturer s instructions 3 Activate saf...

Page 110: ...en loaded for the drive The replacement of the device must be recorded in the machine logbook For this purpose the data of the following safety technology parameters must be accordingly documented and checked for correctness these data can be queried via the control panel in the SMO Info menu for IndraDrive Mi the data must be read e g by means of the IndraDrive Service Tool IDST via the Controlle...

Page 111: ...arameter values saved after initial commissioning to controller Control master Load axis specific parameter values according to list parameters S 0 0192 IDN list of all backup operation data and P 0 0195 IDN list of retain data replacement of devices saved after initial commissioning With active Safe Motion initial or serial commissioning of the drive controller is required after the programming m...

Page 112: ...ct and hazard analysis must contain a risk assessment of the process of decommissioning On the basis of this impact and hazard analysis decommission the drive or component see also IEC 61508 1 2010 7 17 DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 Bosch Rexroth AG 109 149 Decommissioning Drive Components LSA Control S L www lsa control co...

Page 113: ...ch Rexroth AG DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 110 149 LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 114: ...OK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 Bosch Rexroth AG 111 149 Declarations of conformity LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 115: ...afe Torque Off and SBC Safe Brake Control and L3 STO Safe Torque Off Fig 11 1 Declaration of conformity for the optional safety technology modules L4 STO Safe Torque Off and SBC Safe Brake Control and L3 STO Safe Torque Off Bosch Rexroth AG DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 112 149 Declarations of conformity LSA Control S L www...

Page 116: ... the English language with signatures as of July 2014 If you have access to the Bosch Rexroth Intranet please download the declaration of conformity here otherwise please contact your responsible sales partner DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 Bosch Rexroth AG 113 149 Declarations of conformity LSA Control S L www lsa control c...

Page 117: ...nery Directive for the optional safety technology module L3 STO Safe Torque Off Fig 11 3 Declaration of conformity for the optional safety technology module L3 STO Safe Torque Off Bosch Rexroth AG DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 114 149 Declarations of conformity LSA Control S L www lsa control com comercial lsa control com 3...

Page 118: ...signatures as of July 2014 If you have access to the Bosch Rexroth Intranet please download the declaration of conformity here otherwise please contact your responsible sales partner DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 Bosch Rexroth AG 115 149 Declarations of conformity LSA Control S L www lsa control com comercial lsa control co...

Page 119: ...tional safety technology module L3 STO Safe Torque Off Fig 11 5 Declaration of conformity for the optional safety technology module L3 STO Safe Torque Off in the distributed servo drives KSM02 and the distributed drive controllers KMS02 Bosch Rexroth AG DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 116 149 Declarations of conformity LSA Co...

Page 120: ...e available in the English language with signatures as of July 2014 If you have access to the Bosch Rexroth Intranet please download the declaration of conformity here otherwise please contact your responsible sales partner DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 Bosch Rexroth AG 117 149 Declarations of conformity LSA Control S L www...

Page 121: ...uccessfully completed Bosch Rexroth will declare conformity with the Machinery Directive for the optional safety technology module L3 STO Safe Torque Off in the HMU05 drive controllers For the status quo please contact our service department Bosch Rexroth AG DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 118 149 Declarations of conformity L...

Page 122: ...ogy Safe Torque Off When the dynamization outputs do not work check the power supply connection The polarity might possibly have been reversed 12 2 IndraDrive Cs 12 2 1 X49 Optional Safety Technology L3 or L4 View Connectio n Signal name Function 1 SI_Ch2 Input for selection of channel 2 2 0V Power supply of inputs outputs 3 SI_Ch1 Input for selection of channel 1 4 24V Power supply of inputs outp...

Page 123: ...otor power by for example mechanically securing the vertical axes adding external braking arrester clamping mechanisms ensuring sufficient equilibration of the vertical axes Lethal electric shock by live parts with more than 50 V WARNING The input of the motor temperature evaluation is not galvanically isolated from the housing If the voltage applied to the input is impermissibly high e g because ...

Page 124: ... X6 4 output for controlling the motor holding brake Tab 12 3 Function pin assignment Motor holding brake selection Maximum current carrying capacity of outputs X6 1 25 A Rbr min Ubr max 1 25 A Rbr min Minimum allowed resistance of the motor holding brake Ubr max Maximum supply voltage of the motor holding brake If Ubr max 24 V 5 25 2 V this results in Rbr min 20 16 Ω applicable to all operating a...

Page 125: ...ake current monitoring unit signals an error Connection diagram Fig 12 1 Connection of motor temperature monitoring and motor holding brake Bosch Rexroth AG DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 122 149 Project planning LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 126: ...rs part of basic accessory HAS01 L L DC bus For connection to supply unit via contact bars part of basic accessory HAS01 X1 Module bus Keep ribbon cable in parking position when there is no connection to neighboring device X29 1 X29 2 Multi Ethernet Signals are looped through X49 Safety technology L3 Safe Torque Off X50 E Stop E Stop input X52 Status messages For exchanging status messages X53 42 ...

Page 127: ...ent Function Function Signal Connectio n Technical data Selection channel 1 SI_Ch1 3 chapter 12 4 1 Digital inputs safety technology L options on page 141 Selection channel 2 SI_Ch2 1 Dynamization output channel 1 Dyn_Ch1 6 chapter 12 4 2 Digital Outputs Safety Technology L Options on page 142 Dynamization output channel 2 Dyn_Ch2 5 Power supply of isolated inputs and outputs 24V 4 DC 19 2 30 V Th...

Page 128: ...Connection cable AWG 20 16 Allowed input voltage V 3 30 Input voltage H V 15 30 Input current H mA 2 15 Input voltage L V 0 5 Input current L mA 0 0 5 Input resistance kΩ 2 5 1 Exclusively use the 24 V output for the E Stop input in conjunc tion with the jumper from X50 3 to X50 4 Maximum power rat ing 15 mA 2 Exclusively use the 0 V output for the E Stop input in conjunc tion with the jumper from...

Page 129: ...Connection cable AWG Voltage range V 0 24 10 Voltage level H V 15 n s Voltage level L V n s 5 Output current mA n s 500 Conductor color of the ready made cable RKH Tab 12 8 Function Pin Assignment Properties 12 3 2 KSM02 connection points Position of connection points Use ready made hybrid cables and terminal connectors by Rexroth for X103 1 and X103 2 X107 programming module is only accessible af...

Page 130: ...Digital Inputs Outputs Fig 12 2 X37 and X38 View Connectio n Signal name Function X37 1 Uext External supply 19 30 V max 1 A connected to X38 1 X37 2 I O_3 Dig I O configurable X37 3 0 Vext Reference potential external supply connected to X38 3 X37 4 I O_1 Dig I O configurable can be used as probe X37 5 PE For cable shield DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology...

Page 131: ...d as probe inputs The outputs and Uext are internally supplied with isolated 24 V 20 This allows connecting sensors directly without additional external 24V supply to KSM02 KMS02 if their total current consumption X37 and X38 is smaller than 100 mA If more current is required in total you have to supply in addition 24V externally via the connections X38 1 or X37 1 Uext Each of the short circuit pr...

Page 132: ... 3 30 On V 15 Off V 5 Input current mA 2 15 Input resistance kΩ 6 3 Sampling frequency kHz Depending on firmware Control delay μs 20 100 1 cycle time of position control Pulse width tPuls probe μs 4 Measuring accuracy tx probe μs 1 Tab 12 11 Digital Inputs DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 Bosch Rexroth AG 129 149 Project plann...

Page 133: ...Min Typ Max Output voltage ON with external supply V Uext 0 5 24 Uext Output voltage ON without external supply V 19 2 21 28 8 Output voltage OFF V n s n s 2 1 Output current OFF mA n s n s 0 05 Allowed output current per output with external supply mA n s n s 500 Allowed output current total or per group with external supply mA n s n s 1000 Allowed output current per output without external suppl...

Page 134: ...ectly at the relay coil X103 1 X103 2 Connection Point Hybrid Cable High electrical voltage Danger to life by electric shock WARNING Do not remove connectors when the component has been powered Do not plug in connectors when the component has been powered Wait at least 30 minutes after switching off the supply voltages to allow discharging A Codings of the connection points to prevent the hybrid c...

Page 135: ...2 KMS02 at a KCU02 Always connect the hybrid cable of KCU02 to the connection point X103 1 of the first KSM02 KMS02 of a drive line Hybrid cables contain power lines and control lines Always route hybrid cables in such a way that the hybrid cables are protected against external damage in accordance with EN 61800 5 1 and EN 61800 5 2 Notes on Operation Do not remove connectors when the component ha...

Page 136: ...one node Short circuit to X141 11 input voltage 0 6 V Release brake Short circuit to X141 9 input voltage 24 V 20 4 24V n c Power supply of the outputs 5 SI_Ch1_In n c 6 0V_In 0V2 7 SI_Ch2_In n c 8 Dyn_Ch1 n c Dynamization output Ch1 3 9 24V_ZBr 24V_Br Internal interface only 24 V for zones and release brake function 10 0V 0V2 Connected to X103 2 9 11 GND_Zone GND For safety zone node function 12 ...

Page 137: ...r cuit between the two signal wirings must be excluded Tab 12 14 Function pin assignment properties Technical data Function Signal Connection Technical data Selection channel 1 SI_Ch1 1 chapter 12 4 1 Digital inputs safety technology L options on page 141 Selection channel 2 SI_Ch2 2 Dynamization output channel 1 Dyn_Ch1 8 chapter 12 4 2 Digital Outputs Safety Technology L Options on page 142 Dyna...

Page 138: ...M02 chapter X37 X38 Digital Inputs Outputs on page 127 X103 1 X103 2 connection point of hybrid cable See description of KSM02 chapter X103 1 X103 2 Connection Point Hybrid Cable on page 131 X141 safety technology See description of KSM02 chapter X141 safety technology Safe Torque Off and service input Release brake on page 133 The open loop characteristic does not feature the release brake input ...

Page 139: ...nal names of safety technology in brackets 5 1 SI_Ch1_In SI_Ch1 7 2 SI_Ch2_In SI_Ch2 6 10 SI_0V_In SI_0V 11 3 GND_SI Zone_Br KSM KMS without optional safety technology can be operated within a safety zone without the connector RBS0023 because the signals are directly transmitted to the next safety zone node via X103 1 and X103 2 2 7 3 11 4 n c 5 1 6 10 7 2 8 n c 9 n c 10 6 11 3 12 n c Tab 12 18 Fu...

Page 140: ...n The E Stop function is wired at KCU02 and transmitted to KSM02 KMS02 via the hybrid cable The E Stop signal is amplified in each KSM02 KMS02 Assigning and transmitting E Stop signals When a KSM02 KMS02 device has been configured as a safety zone beginner X141 3 n c P 0 0249 2 and an E Stop signal has been assigned to this KSM02 KMS02 via an I O X37 X38 this E Stop signal ist transmitted to the K...

Page 141: ...signment list P 0 0223 E Stop input P 0 0008 Activation E Stop function 1 Switch position when P 0 0223 E Stop input not entered in any element of P 0 0300 default state 2 Switch position when X141 equipped with cable RKB0033 or open P 0 0249 2 zone beginner 3 Switch position when X141 equipped with connector RBS0023 P 0 0249 1 zone node Fig 12 8 E Stop zone setup The E Stop zone setup is independ...

Page 142: ... table of E Stop zone setup See also Functional Description of firmware E Stop function 12 3 6 Safety zones Safety zone A safety zone consists of a safety zone beginner and one or several safety zone nodes The example shows a drive system with 2 safety zones DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 Bosch Rexroth AG 139 149 Project pla...

Page 143: ... the individual safety zones SI Zone 1 SI Zone 2 Safety zones X49 X141 Connection points of safety technology Fig 12 10 Safety zones Safety zone beginner A Monitoring electronics in KCU H49 Diagnostic display for safety technology signals Fig 12 11 Safety zone beginner KCU Two options for signal input Bosch Rexroth AG DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe...

Page 144: ...quipped with the connector RBS0023 KSM KMS without optional safety technology do not require the connector because for these devices the signals are directly transmitted to the next safety zone node via X103 1 and X103 2 KSM KMS without optional safety technology are not safety zone nodes and do not react to safety technology signals 12 4 Technical data of inputs and outputs 12 4 1 Digital inputs ...

Page 145: ...l Data Unit Min Max Supply voltage Uext V 19 2 30 Current consumption Iext mA 700 Output voltage ON V 18 2 30 Output voltage OFF V 5 Output current ON mA 350 Allowed energy content of connected inductive loads e g relay coils only allowed as single pulse mJ 400 Short circuit protection Available Overload protection Available Tab 12 23 Digital Outputs Safety Technology L Options Bosch Rexroth AG DO...

Page 146: ...aining can be found on our internet sites Service worldwide Outside Germany please contact your local service office first For hotline numbers refer to the sales office addresses on the internet Preparing information To be able to help you more quickly and efficiently please have the following information ready Detailed description of malfunction and circumstances resulting in the malfunction Type...

Page 147: ...ch Rexroth AG DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 144 149 LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 148: ... Hybrid cable Connection 131 I Inappropriate use 12 Consequences exclusion of liability 11 IndraDrive Conceptual overview 24 Inputs Digital isolated 127 Installation Control section 102 Optional card 102 Integrated safety technology Dynamization 44 Functional principle 43 Isolated inputs outputs 127 K KCU02 Connection points 123 Type code 29 KMS02 Connection points 134 Safety technology 135 Type c...

Page 149: ...ing IndraDrive Mi 93 Deactivating IndraDrive C M ML 96 Deactivating IndraDrive Cs 90 Deactivating IndraDrive Mi 93 L3 119 124 X49 119 124 Safe Torque Off STO 50 Safe Torque Off Safe Brake Control L4 119 Safety characteristics Total PFH value of a safety zone 42 Safety functions Classification 49 Overview 49 Safe Brake Control 54 Safe Torque Off 50 Safety functions in special mode Safe standstill 5...

Page 150: ... outputs 127 X49 Safe Torque Off 119 124 Safe Torque Off Safe Brake Control 119 X50 E Stop input 125 X52 Status messages 126 X103 1 Hybrid cable 131 X103 2 Hybrid cable 131 X141 Safety technology Safe Torque Off 133 Service input release brake 133 DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 Bosch Rexroth AG 147 149 Index LSA Control S L ...

Page 151: ...Bosch Rexroth AG DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 148 149 LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 152: ...DOK INDRV SI3 VRS AP06 EN P Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 Bosch Rexroth AG 149 149 LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 153: ...s and Controls P O Box 13 57 97803 Lohr Germany Bgm Dr Nebel Str 2 97816 Lohr Germany Tel 49 9352 18 0 Fax 49 9352 18 8400 www boschrexroth com electrics DOK INDRV SI3 VRS AP06 EN P LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

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