AC Drives and Safety circuits
Contents
1. KOO Lo ose Drive T No Drive Safe oft Input Power OS Se GuardMaster rive I ype No Drive sate o pecececeee Trojan Other Output contactor for NFPA79 Emergency Stop SS PowerFlex 70 f Wetatetet AC Drive KS os lus 24V DC lt gt 4 OS wesereces K lt Ke 674 alo lt gt OS lt 4 LK St eseo oe sto 9p ESES 130584033 ae EE __ o Start Start Gate Control Power Supply gt Jaz 24V DC A1 S21 S11 S52 S12 S22 37 47 57 13 23 S33 834 BPP YS x Minotaur KA Ki MSR138DP Bee yes 3940 ke K2 A2 X1 X2 X3 X4 38 48 58 14 24 Y2 Y1 X n Gate 2 Control y a Ly A Circuit ag SLA K2 i e Digin Com t O Enable K1 H 24V DC H Com NG i Pi GAK e Gate triggers safety function e Contactor Drive Enable and Safe Off open after time delay AA k2 e Automatic reset when gate closes e Monitored output Drive requires new start command after safety relay reset Contactor shown for NFPA79 and Category 3 operation Circuit Operation The gate will trigger the safety function When triggered the safety relay outputs Terminals 13 to 14 and 23 to 24 open This immediately removes 24vdc from the d2. z Drive Type Drive with Safe Off Option P poe i GuardMaster Other Output contactor for NFPA79 Emergency Stop _ i Sel Trojan X S PowerFlex 70 se 24V DC AC Drive i i alo i S 24VDC e SI alo s 4 oO op Stop l e stark Start Gate Control Power Supply A1 S21 S11 S52 S12 S22 37 47 57 13 23 S33 S34 k Safe Off Option VH N So 1 Minotaur K H MSR138DP 2 SPRY AF eon L 3 A2 X1 x2 X3 x4 39 40 38 48 58 14 24 Y2 Y1 b TFA E eee T IDAS S7 Gate S gt Control w a oy e JDigin Com Circuit 7 JE 24V DC Com i Com Enable i i Gate triggers safety function Contactor Drive Enable and Safe Off open after time delay K1 Automatic reset when gate closes Monitored output Drive requires new start command after safety relay reset sai Contactor shown for NFPA79 purposes not required for Category 3 certification M J Circuit Operation The gate will trigger the safety function When triggered the safety relay outputs Terminals 13 to 14 and 23 to 24 open This immediately removes 24vdc from the drive Start Stop input The result is the drive stop signal is asserted an
3. j A S21 S13 31 13 23 X7 K KIT Minotaur 9 of an oa E MSR9OT g fe fot me k EStor J 9 lean Latching J A2 S22 S14 32 14 24 x2 Bi gt Button i Gate P re na Control w Ly J ircuit 7 Ke Circuit SF Lae H b Digin Com O e Enable KI 24V DC RG i m Com K Drive with no Safe off Function Gate triggers safety function amp contactors open E Stop triggers safety function and opens contactors WA k2 Automatic reset when gate closes Monitored output Drive requires new start command after safety relay reset Contactor Shown for NFPA79 and Category 3 operation M Circuit Operation The gate will trigger the safety function When triggered the safety relay outputs Terminals 13 to 14 and 23 to 24 open This immediately removes 24vdc from the drive Enable the drive Start Stop inputs and both contactor coils K1 amp K2 The result is the drive is disabled a stop signal is asserted the contactors open and the motor will coast to stop The N O auxiliary contact of K1 and K2 open to prevent a drive Start before the contactors close The N C auxiliary contacts are monitored by the safety relay at terminals X1 amp X2 When the gate is restored and satisfies the safety relay inputs the safety relay is reset The safety relay outputs are energized restoring 24vdc to the drive Enable input the coils of the contactors and the Drive Not Stop A start command must be issued to the drive to re
4. Overview This example shows how to provide Stop and protection against restart Category 3 per EN954 1 ona drive with a safe off feature The contactors can also satisfy the NFPA79 Emergency Stop requirements Gate Example Stop Type Category 0 Coast AG Ling Safety Level EN954 1 Cat 3 ee Drive Type Drive with Safe Off Option a PowerFlex 70 i N Other Output contactor for NFPA79 Emergency Stop AC Drive i 24VDC Stop Start e Start Gate GuardMaster Gate Control Trojan 24V DC Power Supply lt c j OOOO Ea gt a Sod See Se ar rece KS e585 1 21 S13 13 23 X Safe Off Option L 08 eee NS Se lt 6 pan Minotaur ane KZ T MSROT 4 Ne Se lt 3 58 NP es lt 3 58 NPs races RR ee wo I NS z os S a gt E Stop A i Latching T A2 s22 s14 32 14 24 x2 Y J Button H re S08 aces S80 iF Ko e et A gt gt Ke i gt Cx cece ce ESS Bi 2 2 gt BS BS Gate ara e com Control i Digin Com Circuit ek T Com Gate triggers safety function contactor remains closed E Stop triggers safety function and opens con
5. 54 1 IMPORTANT The option is suitable for performing mechanical work on the drive system or affected area of a machine only It does not provide electrical safety e Safety Relay Reset The examples in this document use an automatic reset scheme for the safety relay The use of a manual or automatic reset should be dictated by the application Related Publications e DriveGuard User Manual for the Safe Off Option Interfacing AC Drives with Safety Relays Rev04 doc 1 Application Note Interfacing AC Drives with Safety Relays Stop Type Category 0 Coast Safety Level EN954 1 Category 3 Drive Type Drive without Safe off option Other Output contactor for NFPA79 Emergency Stop operation Overview This example shows how to provide Stop and protection against restart Category 3 per EN954 1 ona drive without a safe off feature The contactors can also satisfy the NFPA79 Emergency Stop requirements Gate Example Stop Type Category 0 Coast Safety Level EN954 1 Cat 3 AC Ling 5 Input Power Drive Type No Drive Safe off ee f Other Output contactor for NFPA Emergency Stop AC Drive gt 24V DC sth Stop e a il Start A a Gate GuardMaster hf Gate Contro Trojan Power Supply l iz
6. Application Note Interfacing AC Drives with Safety Relays Purpose e The intent of this document is to provide typical examples of how to interface AC Drives with safety relays This document will not describe machine guarding safety or risk assessment which are covered in our safety business documentation References e NFPA79 Electrical Standards for Industrial Machinery e EN954 1 Safety of Machinery safety related parts of a control system Part 1 General Principles for Design Stop Categories e Stop Category 0 Coast Immediate removal of power to the motor With immediate removal of power to the motor the motor will coast to stop The time required to stop motion is dependent on the load inertia and speed as well as the friction in the mechanical power transmission equipment used in the system e Stop Category 1 Controlled Controlled Stop then removal of power to the motor A ramp to stop will be used to control the mechanical power transmission to rest then power is removed from the motor The time required to bring the mechanical system to rest is dependent upon load inertia and speed as well as the regenerative dissipation capacity of the drive Component Descriptions e Gate Interlock The Trojan gate interlock uses direct opening contacts When the gate is opened the contacts in the interlock are forced open by non resilient components e g not by springs A redundant two set of double break contacts are desig
7. d a ramp to stop is issued Once the time delay in the safety relay expires the safety relay time delayed contacts Terminals 37 to 38 47 to 48 amp 57 to 58 open The 24vdc is then removed from the contactor K1 coil the drive Enable input as well as the Safe Off Option The N O auxiliary contact of K1 open to prevent a drive Start before the contactor closes The N C auxiliary contacts of K1 and the Safe Off Option are monitored by the safety relay at terminals Y1 amp Y2 Note The time delay of the safety relay must be greater than the deceleration ramp time of the drive otherwise a coast stop will occur when the timer expires Interfacing AC Drives with Safety Relays Rev04 doc 11 Application Note Interfacing AC Drives with Safety Relays When the gate is restored and satisfies the safety relay inputs the safety relay is reset terminals 39 amp 40 are N C The safety relay outputs are energized restoring 24vdc to the drive Enable input the coil of the contactor K1 and the Drive Start Stop A start command must be issued to the drive to restart If the Safe off monitor contact is in an abnormal state as monitored by the safety relay X1 amp X2 the safety relay will prevent operation at the next cycling of the safety circuit Other Considerations Note The hardware enable jumper in the drive must be removed if the Safe Off Option is installed If not the drive will fault F111 when a start command is issued I
8. inals 39 amp 40 are N C The safety relay outputs are energized restoring 24vdc to the drive Enable input the Safe Off Option and the Drive Start Stop A start command must be issued to the drive to restart If the Safe off monitor contact is in an abnormal state as monitored by the safety relay X1 amp X2 the safety relay will prevent operation at the next cycling of the safety circuit Interfacing AC Drives with Safety Relays Rev04 doc 9 Application Note Interfacing AC Drives with Safety Relays Other Considerations Note The hardware enable jumper in the drive must be removed if the Safe Off Option is installed If not the drive will fault F111 when a start command is issued Interfacing AC Drives with Safety Relays Rev04 doc 10 Application Note Interfacing AC Drives with Safety Relays Stop Type Category 1 Controlled Safety Level EN954 1 Category 3 Drive Type Drive with Safe Off Option Other Output contactor for NFPA79 Emergency Stop operation Overview This example shows how to provide Controlled Stop and protection against restart Category 3 per EN954 1 on a drive with a safe off feature The contactors can also satisfy the NFPA79 Emergency Stop requirements KAAAAAAA LIISI ae aes ae LAA AAA AS LIISIS 24V DC Gate Example Stop Type Category 1 Controlled Safety Level EN954 1 Cat 3 oye
9. ned to ensure that at least one signal is sent to the safety relay when the gate is opened e E Stop When the E Stop button is pressed the safety function is activated Drive goes to safe state When a contactor is used it is opened by the E Stop circuit The E stop button must utilize direct opening contacts The button must latch to an open state when the contacts open i e you must not be able to tickle the contacts without latching the button The button must be a red with a yellow background e Contactor Provides electromechanical disconnection of the motor from the drive Its normally closed mechanically linked contacts are monitored by the safety relay to help ensure that the contactor has dropped out before the next resetting of the safety relay e Start Stop Pushbuttons The Start and Stop pushbuttons are used to turn the drive on and off They are also symbolic of the non safety related parts of the machine control system These buttons can be replaced by a programmable control system e Generic Drive Describes a drive that does not contain a Safe off option e The PowerFlex Safe Off Option Board o Is designed to safely remove power from the gate firing circuits of the Drives output power devices IGBT s This prevents then from switching in the pattern necessary to generate AC power to the motor o Can be used in combination with other safety devices to meet the Stop and protection against restart requirements of EN9
10. nterfacing AC Drives with Safety Relays Rev04 doc 12
11. rfacing AC Drives with Safety Relays Stop Type Category 0 Coast Safety Level EN954 1 Category 3 Drive Type Drive with Safe Off Option Other Overview This example shows how to provide Stop and protection against restart Category 3 per EN954 1 ona drive with a safe off feature AC Line Input Power Gate Example Stop Type Category 0 Coast f Safety Level EN954 1 Cat 3 PowerFlex70 5 Drive Type Drive with Safe off Option AC Drive 24VDC g Stop GuardMaster e a J Start Trojar 24V DC Gate Control Power Supply O D Aj o reek I SO 2S oe A1 S21 S13 31 13 23 X1 1 Minotaur MSRST cates lt gt SOSER iTi neas S S OS Safe Off Option Ma 53 ei S Ox sects eee rae Oe o eee lss va soe ox S OS va x ee oS A2 s22 814 32 14 24 x2 Al ae 33s oe statatat Ma 58 oe tas YS 24V DC Com Behe seen fatatat LX Lee Gate i ge Control a Ly __ Digin Com Circuit v Com Enable NX i A Gate triggers safety function Automatic reset when gate clo
12. rive Start Stop input The result is the drive stop signal is asserted and a ramp to stop is issued Once the time delay in the safety relay expires the safety relay time delay contacts Terminals 47 to 48 amp 57 to 58 open The 24vdc is then removed from the drive enable as well as both contactor coils K1 amp K2 The N O auxiliary contact of K1 and K2 open to prevent a drive Start before the contactors close The N C auxiliary contacts are monitored by the safety relay at terminals Y1 amp Y2 Note The time delay of the safety relay must be greater than the deceleration ramp time of the drive otherwise a coast stop will occur when the timer expires Interfacing AC Drives with Safety Relays Rev04 doc 4 Application Note Interfacing AC Drives with Safety Relays When the gate is restored and satisfies the safety relay inputs the safety relay is reset terminals 39 amp 40 are N C The safety relay outputs are energized restoring 24vdc to the drive Enable input the coils of the contactors and the Drive Start Stop A start command must be issued to the drive to restart Other Considerations The safe off jumper in the drive must be installed when the Safe Off Option is not present Drives with hardware enable feature Use of hardware enable is not required for this example but in general is recommended when the drive is interfaced with a safety relay Interfacing AC Drives with Safety Relays Rev04 doc 5 Application Note Inte
13. rt command will now restart the drive Interfacing AC Drives with Safety Relays Rev04 doc 7 Application Note Interfacing AC Drives with Safety Relays If the Safe off monitor contact is in an abnormal state as monitored by the safety relay X1 amp X2 the safety relay will prevent operation at the next cycling of the safety circuit Other Considerations Note The hardware enable jumper in the drive must be removed if the Safe Off Option is installed If not the drive will fault F111 when a start command is issued Interfacing AC Drives with Safety Relays Rev04 doc 8 Application Note Interfacing AC Drives with Safety Relays Stop Type Category 1 Controlled Safety Level EN954 1 Category 3 Drive Type Drive with Safe Off Option Other Overview This example shows how to provide Controlled Stop and protection against restart Category 3 per EN954 1 on a drive with a safe off feature Gate Example Stop Type Category 1 Controlled GuardMaster Safety Level EN954 1 Cat 3 Trojan a AC Line Dri
14. ses e Monitored output a Drive requires new start command after safety relay reset M cane Circuit Operation The gate will trigger the safety function When triggered the safety relay outputs Terminals 13 to 14 and 23 to 24 open This immediately removes 24vdc from the drive Enable the Safe Off Option relay and the drive Start Stop input The result is the drive is disabled a stop signal is asserted the Safe Off Option goes to a safe state off and the motor will coast to stop When the gate is restored and satisfies the safety relay inputs the safety relay is reset The safety relay outputs are energized restoring 24vdc to the drive Enable input the Safe Off Option relay and the Drive Start Stop A start command must be issued to the drive to restart If the Safe off monitor contact is in an abnormal state as monitored by the safety relay X1 amp X2 the safety relay will prevent operation at the next cycling of the safety circuit Other Considerations Note The hardware enable jumper in the drive must be removed if the Safe Off Option is installed If not the drive will fault F111 when a start command is issued Interfacing AC Drives with Safety Relays Rev04 doc 6 Application Note Interfacing AC Drives with Safety Relays Stop Type Category 0 Coast Safety Level EN954 1 Category 3 Drive Type Drive with Safe Off Option Other Output contactor for NFPA79 Emergency Stop operation
15. start When the E Stop is activated the safety function is triggered and performs the same as the gate triggered function Restoration of the E Stop also recovers in the same manner as the gate restoration Interfacing AC Drives with Safety Relays Rev04 doc 2 Application Note Interfacing AC Drives with Safety Relays If the contactors N C auxiliary contacts are in an abnormal state as monitored by the safety relay X1 amp X2 the safety relay will prevent operation at the next cycling of the safety circuit Other Considerations The safe off jumper in the drive must be installed when the Safe Off Option is not present Drives with hardware enable feature Use of hardware enable is not required for this example but in general is recommended when the drive is interfaced with a safety relay Interfacing AC Drives with Safety Relays Rev04 doc 3 Application Note Interfacing AC Drives with Safety Relays Stop Type Category 1 Controlled Safety Level EN954 1 Category 3 Drive Type Drive without Safe off option Other Output contactor for NFPA79 Emergency Stop operation Overview This example shows how to provide Controlled Stop and protection against restart Category 3 per EN954 1 on a drive without a safe off feature The contactors can also satisfy the NFPA79 Emergency Stop requirements Gate Example Stop Type Category 1 Controlled Safety Level EN954 1 Cat 3 AC Line Gate
16. tactor Automatic reset when gate closes Monitored output Drive requires new start command after safety relay reset Contactor shown for NFPA79 purposes not required for Category 3 certification AN R Enable i u Pi Circuit Operation The gate will trigger the safety function When triggered the safety relay outputs Terminals 13 to 14 and 23 to 24 open This immediately removes 24vdc from the drive Enable the Safe Off Option relay and the drive Start Stop input The result is the drive is disabled a stop signal is asserted the Safe Off Option goes to a safe state off and the motor will coast to stop The contactor K1 stays energized When the gate is restored and satisfies the safety relay inputs the safety relay is reset The safety relay outputs are energized restoring 24vdc to the drive Enable input the Safe Off Option relay and the Drive Not Stop A start command must be issued to the drive to restart When the E Stop is activated the safety function is triggered and performs the same as the gate The E Stop also removes power from the contactor coil which opens the contactor and disconnects the motor from the drive The auxiliary contacts open the circuit to the drive Start Stop to prevent a drive Start before the contactor closes Upon restoring the E Stop and gate is in normal condition the safety relay resets and the contactor is energized closing the main poles and auxiliary contacts A sta
17. ve Type Drive with Safe Off Option input Power t a S PowerFlex 70 l AC Drive 24VDC o o T Stop t San Start 24V DC A 821 81 5521812 822 13747157 13 23 S33 s34 aan hit Sey S Minotaur MSR138DP Safe Off Optior See A A2 X x2 x3 x4 39 40 38 48 58 14124 v2 v7 2 dia 3 oe arg fy i Y 7 o 4 24V DC Com Gate i pe Control y Gg Ly Digin Com Circuit Com Enable i Ni wy Gate triggers safety function Drive Enable and Safe Off open After safety relay time delay Automatic reset when gate closes ie Monitored output Drive requires new start command after safety relay reset Ke J Circuit Operation The gate will trigger the safety function When triggered the safety relay outputs Terminals 13 to 14 and 23 to 24 open This immediately removes 24vdc from the drive Start Stop input The result is the drive stop signal is asserted and a ramp to stop is issued Once the time delay in the safety relay expires the safety relay time delayed contacts Terminals 37 to 38 47 to 48 amp 57 to 58 open The 24vdc is then removed from the drive Enable input as well as the Safe Off Option The Safe Off Option goes to a safe state off Note The time delay of the safety relay must be greater than the deceleration ramp time of the drive otherwise a coast stop will occur when the timer expires When the gate is restored and satisfies the safety relay inputs the safety relay is reset term
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