Copley Controls Accelnet User manual

The Accelnet & Stepnet
Plus Panels
STO Manual
16-01338
Revision 00
March 23, 2015

Accelnet & Stepnet Plus Panels STO Manual 16-01338 Rev 00
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Table of Contents
1.0 About This Manual....................................................................................................................................................4
1.1 Title, Number, Revision.............................................................................................................................................................4
1.2 Revision History........................................................................................................................................................................4
1.3 Declaration of Conformity .........................................................................................................................................................4
1.4 Original Instructions..................................................................................................................................................................4
2.0 Purpose and Scope of This Document...................................................................................................................5
2.1 Disclaimer.................................................................................................................................................................................5
3.0 Risk Assessment & Responsibility of the Installer ...............................................................................................6
4.0 Warnings....................................................................................................................................................................6
4.1 Operate drives within the specifications provided in the relevant hardware manual or data sheet. ..........................................6
4.2 Risk of electric shock................................................................................................................................................................6
4.3 Disclaimer.................................................................................................................................................................................6
4.4 Installation Overview.................................................................................................................................................................7
4.5 Definitions.................................................................................................................................................................................7
4.6 Related Documentation ............................................................................................................................................................8
4.7 Reference Standards................................................................................................................................................................9
4.8 Abbreviations and Acronyms ..................................................................................................................................................10
5.0 Introduction to the Accelnet & Stepnet Plus Panels...........................................................................................11
5.1 Product Description.................................................................................................................................................................11
5.2 Model Overview & Numbering ................................................................................................................................................11
5.3 Accelnet Plus Panel Models ...................................................................................................................................................12
5.4 Stepnet Plus Panel Models.....................................................................................................................................................12
6.0 Specifications Overview.........................................................................................................................................13
6.1 Control Modes.........................................................................................................................................................................13
6.2 Command Sources.................................................................................................................................................................13
6.3 Power Sources........................................................................................................................................................................13
7.0 STO Architecture and Function.............................................................................................................................14
7.1 STO Channel Operation .........................................................................................................................................................15
7.2 STO Function Specifications...................................................................................................................................................16
7.3 Environmental Specifications..................................................................................................................................................16
7.4 Safety Related Parameters.....................................................................................................................................................17
7.5 Regulatory Specifications .......................................................................................................................................................18
7.6 Limitations and Necessary Risk Reductions...........................................................................................................................19
7.6.1 Electrical Isolation...............................................................................................................................................................19
7.6.2 DC Brush Motors................................................................................................................................................................19
7.6.3 180 Degree Electrical Movement........................................................................................................................................19
7.6.4 Loads and Other Torque/Force Producing Sources...........................................................................................................19

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7.6.5 STO Input Signal Level.......................................................................................................................................................19
7.6.6 Control Modes and STO.....................................................................................................................................................19
7.6.7 +HV and AuxHV DC Power Supply....................................................................................................................................20
7.6.8 STO DC Power Supply.......................................................................................................................................................20
7.6.9 Wiring to the STO Inputs ....................................................................................................................................................20
7.6.10 Periodic Test Requirements..........................................................................................................................................20
8.0 Installation Using STO for Accelnet & Stepnet Plus Panels...............................................................................21
8.1 STO Overview.........................................................................................................................................................................21
8.1.1 STO Power Requirements..................................................................................................................................................21
8.1.2 STO Wiring Requirements..................................................................................................................................................21
8.1.3 STO (Safety) Cable Connector...........................................................................................................................................22
8.2 Example Wiring Diagram (SIL 3 and Cat. 3 PL d STO Implementation).................................................................................23
8.2.1 Emergency Stop: Stopping Category 1 ..............................................................................................................................23
8.2.2 Accelnet & Stepnet Plus Panels Configuration...................................................................................................................23
8.2.3 Example STO Timing .........................................................................................................................................................24
8.3 Start-Up Checklist...................................................................................................................................................................25
8.3.1 Preliminary checks .............................................................................................................................................................25
8.3.2 Start-Up Checklist...............................................................................................................................................................26
8.4 STO Status Indications ...........................................................................................................................................................27
8.4.1 Axis A & B LEDs.................................................................................................................................................................27
8.4.2 STO Circuit Status Data Objects........................................................................................................................................27
8.4.3 CME2 Control Panel...........................................................................................................................................................28
8.5 Troubleshooting......................................................................................................................................................................29
8.5.1 How to tell if the STO function is active ..............................................................................................................................29
8.5.2 How to tell if the STO function is inactive............................................................................................................................29
8.5.3 Why can’t the STO function be deactivated?......................................................................................................................29
8.5.4 Why can’t the STO function be activated?..........................................................................................................................29
8.5.5 The drive is hardware-enabled but the motors don’t move. ................................................................................................29
9.0 Maintenance.............................................................................................................................................................30
9.1 Ease of Accessibility and Replacement of Internal Parts........................................................................................................30
9.2 Periodic STO Testing Interval.................................................................................................................................................30
9.3 Periodic Testing Checklist.......................................................................................................................................................31
10.0 Muting & Suspension of Safety Functions...........................................................................................................32
10.1 STO Muting.............................................................................................................................................................................32
10.2 Muting Jumpers (STO Connector)..........................................................................................................................................32
11.0 Decommissioning ...................................................................................................................................................33

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1.0 About This Manual
1.1 Title, Number, Revision
Title
The Accelnet & Stepnet Plus Panels STO Manual
Document Number
16-01338
Current Revision
00
1.2 Revision History
Revision
Date
ECO #
Comments
AA
12/09/2014
ECO-056695
Preliminary release to DESIGN lifecycle.
Originated from 16-01168.
AB
12/30/2014
ECO-056909
Add hardware type designation and
systematic capability specification
00
03/23/2015
ECO-057405
Release to PILOT lifecycle, add page
numbers
1.3 Declaration of Conformity
The products covered by this manual comply with the EC Directives 2004/108/EC (EMC Directive), 2006/95/EC
(Low Voltage Directive), 2006/42/EC (Machinery Directive) and 2011/65/EU (RoHS Directive). The complete EC
Declaration of Conformity is available on the internet at www.copleycontrols.com.
Name and Address of the Manufacturer: Name and Address of the authorized representative:
Analogic Corporation d/b/a Copley Controls BK Medical ApS
20 Dan Road Mileparken 34, DK-2730
Canton, MA 02021 Herlev
USA Denmark
1.4 Original Instructions
This manual is considered to be “original instructions” as defined in EC Directive 2006/42/EC and the contents
have been verified by Copley Controls.
Table 1
Table 2

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2.0 Purpose and Scope of This Document
This document is intended to inform the reader about the Functional Safety features of the Accelnet & Stepnet
Plus Panel drives and to provide information on the steps required to install it into systems so that a target level of
Functional Safety performance can be achieved. The scope of this document is limited to those aspects of
Functional Safety that relate to the installation, operation, and maintenance of the Accelnet & Stepnet Plus Panel
drives.
2.1 Disclaimer
This manual contains information on the Safe Torque Off (STO) feature of the Accelnet & Stepnet Plus Panel
drives and how it may be incorporated into an industrial motion control system. While every effort has been made
to ensure the completeness and accuracy of this manual it must be emphasized that the responsibility for
functional safety in the overall system into which the drive is installed rests ultimately with the manufacturer of the
system into which the Accelnet & Stepnet Plus Panel drives are installed.
The equipment manufacturer must take into account all the aspects of the system in which the Accelnet & Stepnet
Plus Panel drives are components.
Copley Controls does not accept any liability for direct or indirect injury or damage caused by the use of
information in this document. The equipment manufacturer is always responsible for the safety of its product and
its suitability under applicable laws. Copley Controls hereby disclaims all liabilities that may result from this
document.

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3.0 Risk Assessment & Responsibility of the Installer
The STO feature of the Accelnet & Stepnet Plus Panel drives is capable of the safety integrity level (SIL) and
category/performance level (PL) stated in this manual and operates in accordance with the characteristics and
limitations described herein. But it must be noted that the drive STO function is intended to be used only as one
element of an overall safety chain and is not a complete safety function unto itself. Therefore the suitability for use
of the Accelnet & Stepnet Plus Panel drives in a given application must be determined in part by one or more risk
assessments of the overall safety of the end machine conducted in accordance with the applicable standards.
Such risk assessments normally consist of a thorough review of overall machine operation to identify potential
hazards. For each identified hazard, typical risk assessments take into account the severity of any potential injury
resulting from the hazard, the frequency of exposure of persons to the hazard and the probability that persons are
able to avoid the hazard if it were to occur. The machine designer is solely responsible for conducting any
necessary risk assessments and for the ultimate determination as to the suitability of the Accelnet & Stepnet Plus
Panel drives and the STO function for use in realizing a given overall safety function.
The installer should be experienced in motion control and functional safety.
4.0 Warnings
FAILURE TO CONSIDER THESE WARNINGS CAN RESULT
IN EQUIPMENT DAMAGE, INJURY, OR DEATH
The user must take into consideration the necessary risk reductions, installation requirements,
and other information contained in this manual in order to achieve the stated functional safety
capabilities. Failure to do so could result in equipment damage, injury, or death.
4.1 Operate drives within the specifications provided in the relevant
hardware manual or data sheet.
The information in this manual is specific to the functional safety features of the Accelnet & Stepnet Plus Panel
drives. The user must use this manual along with the Accelnet & Stepnet Plus Panels User Guide and the
datasheets for the Accelnet & Stepnet Plus Panel models for proper and safe installation and overall
commissioning of the drives.
4.2 Risk of electric shock
The Accelnet & Stepnet Plus Panel drives are made for operation from transformer-isolated, DC power supplies
that provide galvanic isolation from AC mains and meet the requirements of overvoltage category II (OVC II).
Hazardous voltages are connected to and exist within these drives under normal operating conditions. Persons
responsible for installing and commissioning these drives must be experienced in all aspects of electrical
equipment installations.
4.3 Disclaimer
There are no user serviceable parts in the Accelnet & Stepnet Plus Panel drives.
Removal of the cover or tampering with internal components will void the warranty.

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4.4 Installation Overview
This graphic shows the elements of a complete Accelnet & Stepnet Plus Panel drive installation.
The STO feature and interface to the machine-level functional safety equipment are highlighted in red to
emphasize the aspects of the installation that are addressed in this manual.
4.5 Definitions
There are certain terms used throughout this document that serve an important role in describing the operation
and behavior of the Accelnet & Stepnet Plus Panels STO feature. These terms are discussed and defined as
follows:
Activate –This term is used to refer to action taken that results in the safe state being entered. In the case of the
STO feature, the STO function is activated (made active) by making the voltage at one or both STO inputs less
than or equal to the maximum rated de-energize threshold voltage.
De-Activate –This term is used to refer to action taken that results in the safe state being exited. In the case of
the STO feature, the STO function is de-activated (made inactive) by making the voltage at both STO inputs
greater than or equal to the minimum rated energize threshold voltage.
Energize –This term refers to the application of voltage greater than or equal to the minimum rated energize
threshold voltage to an individual STO input. Note that simultaneously energizing both STO inputs results in the
STO function being de-activated.
De-Energize –This term refers to the application of voltage less than or equal to the maximum rated de-energize
threshold voltage to an individual STO input. Note that de-energizing an STO input results in the STO function
being activated.
Fig. 1

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4.6 Related Documentation
These documents have additional information on the Accelnet & Stepnet Plus Panels models and are required for
proper installation and commissioning of the drives.
All are available from the Downloads page of the Copley Controls web site:
http://www.copleycontrols.com/Motion/Downloads/index.html
Downloads > Documents > Accelnet Plus Panel:
Data Sheet
Accelnet Plus EtherCAT 1-Axis BEL
Accelnet Plus EtherCAT 2-Axis BE2
Accelnet Plus CANopen 1-Axis BPL
Accelnet Plus CANopen 2-Axis BP2
Manual
Accelnet & Stepnet Plus Panels User Guide
Absolute & Serial Encoder Guide
Using CME2
CME2 Indexer User Guide
ASCII Programmers Guide
CMO Programmers Guide
Downloads > Documents > Stepnet Plus Panel:
Data Sheet
Stepnet Plus EtherCAT 1-Axis TEL
Stepnet Plus EtherCAT 2-Axis TE2
Stepnet Plus CANopen 2-Axis TP2
Manual
Accelnet & Stepnet Plus Panels User Guide
Absolute & Serial Encoder Guide
Using CME2
CME2 Indexer User Guide
ASCII Programmers Guide
CMO Programmers Guide

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4.7 Reference Standards
ISO 13849-1: 2nd ed, 2006
Safety of machinery Safety-related parts of control systems
Part 1: General Principles for Design
ISO 13849-2: 2003
Safety of machinery
Safety-related parts of control systems —Part 2: Validation
IEC 61508-1: Ed. 2.0 2010
Functional safety of electrical/electronic/programmable electronic safety-related systems
Part 1: General requirements
IEC 61508-2: 2010, 2nd Ed.
Functional safety of electrical/electronic/programmable electronic safety-related systems
Part 2: Requirements for electrical/electronic/programmable electronic safety related systems
IEC 61800-5-1: 2007, 2nd Ed.
Adjustable speed electrical power drive systems
Part 5-1: Safety requirements –Electrical, thermal and energy
IEC 61800-5-2:2007
Adjustable speed electrical power drive systems
Part 5-2: Safety requirements –Functional

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4.8 Abbreviations and Acronyms
Acronym
Description
Safety-Related
a,b,c,d,e
Denotation of performance level (PL)
Cat
Category
CCF
Common Cause Failure
DC
Diagnostic Coverage
EMC
Electro Magnetic Compatibility
HFT
Hardware Fault Tolerance
MTTF
Mean Time to Failure
MTTFd
Mean Time to Dangerous Failure
PDS(SR)
Power Drive Systems (Safety Related)
PELV
Protected Extra Low Voltage (power supply)
PFD
Probability of Dangerous Failure upon Demand
PFH
Probability of Failure per Hour
PL
Performance Level
PWM
Pulse Width Modulation
S, S1, S2
Severity of Injury
SELV
Safety Extra Low Voltage (power supply)
SFF
Safety Failure Fraction
SIL
Safety Integrity Level
STO
Safe Torque Off
Vdc
Volts DC (Direct Current)
Copley Controls Related
BEL
Accelnet Plus Panel EtherCAT 1-Axis
BPL
Accelnet Plus Panel CANopen 1-Axis
BE2
Accelnet Plus Panel EtherCAT 2-Axis
BP2
Accelnet Plus Panel CANopen 2-Axis
TEL
Stepnet Plus Panel EtherCAT 1-Axis
TE2
Stepnet Plus Panel EtherCAT 2-Axis
TP2
Stepnet Plus Panel CANopen 2-Axis
Table 3