DriveGuard Safe Torque Off Option for PowerFlex 700S/700L AC
Contents
1. 30 Rockwell Automation Publication 20D UM007G EN P March 2012 Description of Operation Chapter 3 Connection Examples Example 1 PowerFlex 700S Drives Frames 1 6 Safe Torque Off Connection with Coast to Stop Action Dual Channel Figure 2 Stop Category 0 Coast AC Line Input Power PowerFlex 700S 700L 24V DC Stop Stop I O Star Start i Stop Common 24V DC Common 23 Gate Control cy tees Power Supply Bay KE Safe i 24 Vv 24V DC a lt Common Gate Control Circuit A amp Common Enable Circuit Status Circuit shown with guard door closed and system ready for normal drive operation Operating Principle This is a dual channel system with monitoring of the Safe Torque Off circuit and drive Opening the guard door will switch the input circuits S13 S14 amp 21 S22 to the Minotaur monitoring safety relay unit The output circuits 13 14 amp 23 24 will cause the Safe Torque Off option and drive Enable circuit to trip and the motor will coast to stop To restart the drive the Minotaur safety relay must first be reset followed by a valid start command to the drive Fault Detection A single fault detected on the Minotaur safety input circuits will result in the lock out of the system at the next operation and wi2. 21 Rockwell Automation Publication 20D UM007G EN P March 2012 Chapter2 Installation and Wiring 9 Install the inside front cover 0 8 1 1 Nem 7 0 10 0 Ibein 10 Reinstall the cassette in the drive 11 Record the modification on the Field Installed Option label 22 Rockwell Automation Publication 20D UM007G EN P March 2012 Installation and Wiring Chapter 2 PowerFlex 700S Frames 1 6 FIELD INSTALLED OPTIONS E Date a Date 20 HIM HIM 2810 vo 20 COMM COM Module 208_ DB1 Internal Dynamic Brake Use marker to note addition of DriveGuard Safe Torque Off option PowerFlex 700S Frames 9 14 Use marker to note addition of DriveGuard Safe Torque Off option FIELD INSTALLED OPTIONS Firmware Date Firmware E Date 20 HIM HIM 28 10 vo 20 COMM COM Module 20B_ DB1 Internal Dynamic Brake Frame 10 shown Rockwell Automation Publication 20D UM007G EN P March 2012 23 Chapter2 Installation and Wiring PowerFlex 700L Frames 3A and 3B Input Power Filter Bay Module Bay o Re Q Power Module m Bay Door Cutaway ae O ansaa u Ho me Perg FIELD INSTALLED OPTIONS Firmware
3. 33 Chapter 3 34 Description of Operation Operating Principle This is a dual channel system with monitoring of the Safe Torque Off circuit and drive Opening the guard door will switch the input circuits S11 S12 amp 21 S22 to the Minotaur monitoring safety relay unit The output circuits 13 14 will issue a Stop command to the drive and cause a controlled deceleration After the programmed delay the timed output circuits 47 48 amp 57 58 will cause the Safe Torque Off option and the drive Enable circuit to trip If the motor is rotating when the trip occurs it will coast to stop To restart the drive the Minotaur safety relay must first be reset followed by a valid start command to the drive Fault Detection A single fault detected on the Minotaur safety input circuits will result in the lock out of the system at the next operation and will not cause loss of the safety function If the Safe Torque Off option sticks ON the motor will stop on command due to the enable input The system cannot be reset when this fault condition exists Rockwell Automation Publication 20D UM007G EN P March 2012 C coast to stop action dual channel connection example frames 1 6 31 connection example frames 3A 3B 32 connection example frames 9 13 32 controlled stop action dual channel connection example 33 D digital output configuration 27 DriveGuard Safe Torque Off option description
4. 7 operation 29 F functional proof tests 13 H hardware enable configuration 26 important safety considerations 10 L linking parameters 27 machine safety standards 8 Index 0 option board pre installation instructions 15 terminal block specifications 25 wiring 25 P performance level 12 PFD data 12 definition 12 PFH data 12 definition 12 probability of a dangerous failure occurring per hour PFH definition 12 probability of failure on demand PFD definition 12 S safety category 3 definition 11 safety certifications 9 safety function operation verification 28 SIL safety integrity level 12 stop category 0 definition 11 stop category 1 definition 11 T Terminal Block 1 0 25 TUV Report on Safety Function amp TUV Certification 9 Rockwell Automation Publication 20D UM007G EN P March 2012 35 Index Ww wiring option board 25 36 Rockwell Automation Publication 20D UM007G EN P March 2012 Index Notes Rockwell Automation Publication 20D UM007G EN P March 2012 37 Index Notes 38 Rockwell Automation Publication 20D UM007G EN P March 2012 U S Allen Bradley Drives Technical Support Tel 1 262 512 8176 Fax 1 262 512 2222 Email support drives ra rockwell com Online www ab com support abdrives PN 124644 Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwa
5. 8770 or equiv 3 conductor shielded Table 3 DriveGuard Safe Torque Off Option Terminals Description No Signal Description 1 24V DC Connections for user supplied power 2 24V Common to energize coil 33 3 mA typical 55 mA maximum 3 Monitor N C Normally closed contacts for 4 Common N c Monitoring relay status Maximum Resistive Load 250V AC 30V DC 50 VA 60 Watts Maximum Inductive Load 250V AC 30V DC 25 VA 30 Watts ASSEMBLY ar m ID LABEL 3 BAR CODE LABEL ine te an Sol Rockwell Automation Publication 20D UM007G EN P March 2012 25 Chapter2 Installation and Wiring Configure Hardware Enable Ensure that Jumper P22 on the Main Control Board is set to HW Enable Pins 2 and 4 gt E pom Ao Jumper P22 I i 31 HW Enable g No HW Enable mih a g u OL O f i IMPORTANT In addition to the correct jumper setting enable circuitry must be connected to 1 0 Terminals 13 and 16 For wiring examples refer to the following p
6. Input Applied Applied Applied Applied Description For Verification Safe Torque Off Option Closed Open Closed Open Monitor Contact Terminals 3 amp 4 PowerFlex 700S 700L Bit 16 0 Bit 16 0 Bit 16 1 Bit 16 0 Drive Inhibits Bit 1 1 Bit 1 1 Bit 1 0 Bit 1 0 Param 156 Bits 1 amp 16 28 Rockwell Automation Publication 20D UM007G EN P March 2012 Chapter 3 Description of Operation DriveGuard Safe Torque Off Operation The DriveGuard Safe Torque Off option disables the drive s output IGBT s by disconnecting the gate control power supply see Figure 1 When used in combination with a second safety channel the Enable input the system satisfies the requirements of EN ISO 13849 1 PL d Category 3 for safe turn off of torque producing energy at the output of the drive IMPORTANT The DriveGuard Safe Torque Off option does not eliminate dangerous voltages at the drive output Input power to the drive must be turned off and safety procedures followed before performing any electrical work on the drive or motor drive when the DriveGuard Safe Torque Off option has controlled the drive outputs to the off state the drive may provide energy for up to 180 of rotation in a 2 pole motor before torque production in the motor ceases N ATTENTION In the event of the failure of two output IGBTs in the Under normal drive operation the Safe Torque Off relay is energized the enable input is energized and gat
7. carefully disconnect the three cables that connect to the main board Loosen the thumb screw that holds the metal flange in place Loosen the screws on the face of the cassette Remove the cassette Task C Swing the flange and cassette away from the control frame Typical Frames 10 14 Rockwell Automation Publication 20D UM007G EN P March 2012 17 Chapter2 Installation and Wiring PowerFlex 700S All Frames and PowerFlex 700L Frame 3 2 Remove the screws securing the interior cassette cover to gain access to the Main board LVUVVUVUVVY IMPORTANT _ fthe DriveGuard Safe Torque Off option is removed from the drive this jumper must be reinstalled or the drive will not run 18 Rockwell Automation Publication 20D UM007G EN P March 2012 Chapter 2 Installation and Wiring 4 Remove the exterior cassette covers to access the grounding plate 799999990 4 LLL 2 o _ we M mv rN 19 Rockwell Automation Publication 20D UM007G EN P March 2012 Chapter2 Installation and Wiring 5 Install the 16 pin stacker connector 7 0 10 0 Ibein 7 Install and tighten mounting screws GO00000080 20 Rockwell Automation Publication 20D UM007G EN P March 2012 20000000 Chapter 2 Installation and Wiring 8 Install the exterior cassette covers 00990999 _499009490424099999098
8. option has controlled the drive outputs to the off state the drive may provide energy for up to 180 of rotation in a 2 pole motor before torque production in the motor ceases Safety of Machinery Standards The DriveGuard Safe Torque Off option meets the following council directives and the requirements of the following machine safety standards EN 61800 5 2 2007 Adjustable Speed Electrical Power Drives Systems Part 5 2 Safety Requirements Functional EN ISO 13849 1 2008 Safety of Machinery Safety related parts of control systems Part 1 General Principles for Design EN 62061 2005 Safety of Machinery Functional safety of safety related electrical electronic and programmable electronic control systems EN 60204 1 2006 Safety of Machinery Electrical equipment of machines Part 1 General Requirements IEC 61508 Part 1 7 1998 2000 and 2010 Functional safety of electrical electronic programmable electronic safety related systems Rockwell Automation Publication 20D UM007G EN P March 2012 Safety Certifications General Description Chapter 1 The T V Rheinland group has approved the DriveGuard Safe Torque Off option for use in safety related applications where the de energized state is considered to be the safe state All of the examples related to I O included in this manual are based on achieving de energization as the safe state for typical Machine Safety and Emergency Shutdown ESD systems Evaluat
9. requirements of SIL CL2 according to EN 61800 5 2 IEC 61508 and EN 62061 Performance Level PL d and Category 3 according to EN ISO 13849 1 IMPORTANT This option is suitable for performing mechanical work on the drive system or affected area of a machine only It does not provide electrical safety For electrical maintenance on the drive and or motor equipment must be electrically disconnected from the power source The Safe Torque Off option should not be used for non safety related stopping of the drive Rockwell Automation Publication 20D UM007G EN P March 2012 7 Chapter 1 General Description gt gt BB ATTENTION Electrical Shock Hazard Verify that all sources of AC and DC power are de energized and locked out or tagged out in accordance with the requirements of ANSI NFPA 70E Part Il ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged before performing any work on the drive Measure the DC bus voltage at the DC and DC terminals or test points refer to your drive s User Manual for locations The voltage must be zero ATTENTION In Safe Torque Off mode hazardous voltages may still be present at the motor To avoid an electric shock hazard disconnect power to the motor and verify that the voltage is zero before performing any work on the motor ATTENTION In the event of the failure of two output IGBTs in the drive when the DriveGuard Safe Torque Off
10. E Date Firmware F Date 20 HIM 28 10 20 COMM COM Module 208 DB1 Internal Dynamic Brake De Use marker to note Power Module Front addition of DriveGuard Bottom Covers Removed Safe Torque Off option 24 Rockwell Automation Publication 20D UM007G EN P March 2012 Installation and Wiring Chapter 2 Wiring Important points to remember about wiring Always use tinned copper wire e Wire with an insulation rating of 600V or greater is recommended e Control wires should be separated from power wires by at least 0 3 meters 1 foot e All control wires should be shielded cable with the shield earthed on one end of the cable Table 1 DriveGuard Safe Torque Off Option Terminal Block Specifications Wire Size Range Torque Maximum Minimum Maximum Recommended 1 5 mm 0 14 mm 0 25 Nem 0 22 Nem 16 AWG 26 AWG 2 2 Ibein 1 9 Ibein 1 Maximum minimum that the terminal block will accept these are not recommendations Table 2 Wire Types Minimum Wire Type s Description Insulation Rating Unshielded Per US NEC or applicable NOT RECOMMENDED 300V national or local code 60 degrees C Shielded Multi conductor shielded cable 0 750 mm2 18AWG 1140 degrees F such as Belden
11. User Manual Allen Bradley o Drive i Safe Torque Off Option for PowerFlex 700S Phase II AC Drives and PowerFlex 700L Liquid Cooled AC Drives Catalog Number 20D P2 DG01 Original Instructions Allen Bradley Rockwell Software Automation Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment Safety Guidelines for the Application Installation and Maintenance of Solid State Controls Publication SGI 1 1 available from your local Rockwell Automation sales office or online at http www rockwellautomation com literature describes some important differences between solid state equipment and hard wired electromechanical devices Because of this difference and also because of the wide variety of uses for solid state equipment all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable In no event will Rockwell Automation Inc be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation Rockwell Automation Inc cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by R
12. e control power is available to the gate control circuit If either of these inputs is de energized the gate control circuit is disabled and the STS Status indicator on the drive will change to a yellow flashing light When the enable input is de energized parameter 156 Start Inhibits bit 1 No Enable is set to 1 When the Safe Torque Off relay is de energized parameter 156 Start Inhibits bit 16 GateShutDown is set to 1 If both inputs are de energized only bit 1 No Enable will be set to 1 because it takes precedence To meet EN ISO 13849 1 PL d Category 3 operation both safety channel inputs to the drive must be de energized to safely turn off output to the motor Refer to the following examples for details a coast to stop action Additional protective measures will need to be N ATTENTION By itself the DriveGuard Safe Torque Off option initiates applied when an application requires a different stopping action Rockwell Automation Publication 20D UM007G EN P March 2012 2 wo Chapter3 Description of Operation Figure 1 Drive Safe Torque Off Circuitry AC Line Input Power PowerFlex 700S 700L 24V DC Stop Start Start Stop Common 24V DC Common Gate Control Power Supply Safe Off Option a Safety _ 2 mn Channel 1 AV Ar Gate Control Circuit A Common Safet Channel Enable
13. erformance Level and Safety Integrity Level SIL CL2 12 PFD and PFH Definitions sseeresesrrsrrrsrrsrrrrrrrrr srt 12 PFD and PFA Dita u 2 rar 12 PFD and PFH for 20 year Proof Test Interval 12 Functional Proof Iests sssssrererrererrrrrrrrrrrrrr srt 13 Contact Information if Safety Option Failure Occurs 13 Installation and Wiring Pre Installation Instructions 0 00sec cece cece cence eens 15 Option Board Installation 2cccccceeeeeeeneenn 16 PowerFlex 700S Frames 1 6 and PowerFlex 700L Frames GIET e Bo Bice u een nee FINER TE AGA 16 PowerFlex 700S Frames 9 l4 sssseessresrrrrererrrer rr ret 17 PowerFlex 700S All Frames and PowerFlex 700L Frame 3 18 PowerFlex 700S Frames 1 6 0 0 00 ccc c cece cee ce eee eeeee 23 PowerFlex 700S Frames 9 14 cc ccc ennnen eee cee nnn 23 PowerFlex 700L Frames 3A and 3B 0 cece cece cece es 24 MWY TEU Bs ke Ses wees seca ne deg ere age HN i ded 25 Configure Hardware Enable 22222cccceeneneenn 26 Configure Digital Outputs 222 22222020 27 Linking Parameters sa o en essen es Anson ee 27 Verify Operations sssseesesrereererrererrer rer ere ees 28 Rockwell Automation Publication 20D UM007G EN P March 2012 5 Table of Contents Chapter 3 Index Description of Operation DriveGuard Safe Torque Off Operation sssserseossrrea 29 Connection Examples arsar ie e ENA AE R
14. i 31 Example 1 PowerFlex 700S Drives Frames 1 6 Safe Torque Off Connection with Coast to Stop Action Dual Channele Golan E E ils ck ad a Oa 31 Example 2 PowerFlex 700S Drives Frames 9 14 and PowerFlex 700L Drives Frames 3A and 3B Safe Torque Off Connection with Coast to Stop Action Dual Channeli 3 202 8a da oat ae Gag een 32 Example 3 All Drives Safe Torque Off Connection with Controlled Stop Action Dual Channels iy ae ats ana rn 33 Rockwell Automation Publication 20D UM007G EN P March 2012 Chapter 1 General Description The DriveGuard Safe Torque Off option when used with other safety components helps provide protection to meet the requirements for SIL CL2 and Category 3 or PL d class applications Safety requirements are based on the standards current at the time of certification The DriveGuard Safe Torque Off option is just one component in a safety control system Components in the system must be chosen and applied appropriately to achieve the desired level of operator safeguarding What Is the DriveGuard Safe Torque Off Option The DriveGuard Safe Torque Off option e Is designed to help safely remove power from the gate firing circuits of the drive s output power devices IGBT s This helps prevent the drive s output power devices from switching in the pattern necessary to generate rotation at the motor e Can be used in combination with other safety devices to satisfy the Safe Torque Off
15. ion Certification by T V Rheinland Group TUV Report on Safety Function amp TUV Drive Rating Certification PowerFlex 700S 208 240V and 400 480V TUV Certificate No 01 205 5195 12 Phase II Frames 1 6 TUV Report No 968 EZ 189 01 09 600 690V Frames 5 and 6 400 480V and 600 690V TUV Certificate No 01 205 5195 12 Frames 9 14 TUV Report No 968 EZ 189 02 12 PowerFlex 700L 400 480V and 600 690V TUV Report and Certificate No Liquid Cooled Frames 3A and 3B 968 EZ 230 00 06 Certifications Online TUV Certificate No 01 205 0667 09 TUV Report No 968 EZ 230 02 09 See the Product Certifications link at http ab com for Declarations of Conformity Certificates and other certifications details Rockwell Automation Publication 20D UM007G EN P March 2012 Chapter 1 General Description Important Safety Considerations The system user is responsible for e the set up safety rating and validation of any sensors or actuators connected to the system e completing a system level risk assessment and reassessing the system any time a change is made e certification of the system to the desired safety performance level e project management and proof testing e programming the application software and the safety option configurations in accordance with the information in this manual e access control to the system including password handling e analyzing all configuration settings and choosing the
16. ll not cause loss of the safety function Rockwell Automation Publication 20D UM007G EN P March 2012 31 Chapter3 Description of Operation 32 Example 2 PowerFlex 700S Drives Frames 9 14 and PowerFlex 700L Drives Frames 3A and 3B Safe Torque Off Connection with Coast to Stop Action Dual Channel Figure 3 Stop Category 0 Coast AC Line Input Power PowerFlex 700S 700L GuardMaster 24V DC Trojan Stop Start Start Stop Common 24V DC l 24V DC Common At 82151155812522 37 Gate Control Minotaur MSR138DP Power Supply T 24V DC Common ALIAL EAE LJ Gate Control Circuit Common Enable Circuit Status Circuit shown with guard door closed and system ready for normal drive operation Operating Principle This is a dual channel system with monitoring of the Safe Torque Off circuit and drive Opening the guard door will switch the input circuits S11 S12 amp S21 S22 to the Minotaur monitoring safety relay unit The output circuits 13 14 amp 23 24 cause the drive Enable circuit to trip and the motor will coast to stop After the programmed delay the timed output circuits 57 58 will cause the Safe Torque Off option circuit to trip To restart the drive the Minotaur safety relay must first be re
17. low 69 low 80 Rockwell Automation Publication 20D UM007G EN P March 2012 General Description Chapter 1 Functional Proof Tests The functional safety standards require that functional proof tests be performed on the equipment used in the system Proof tests are performed at user defined intervals and are dependent upon PFD and PFH values IMPORTANT Your specific application determines the time frame for the proof test interval Contact Information if Safety Option Failure Occurs If you experience a failure with any safety certified device contact your local Rockwell Automation distributor With this contact you can e return the device to Rockwell Automation so the failure is appropriately logged for the catalog number affected and a record is made of the failure e request a failure analysis if necessary to determine the probable cause of the failure Rockwell Automation Publication 20D UM007G EN P March 2012 13 Chapter 1 General Description Notes 14 Rockwell Automation Publication 20D UM007G EN P March 2012 Chapter 2 Installation and Wiring Pre Installation Instructions Installation must be in accordance with the following steps and must be carried out by competent personnel The DriveGuard Safe Torque Off option is intended to be part of the safety related control system of a machine Before installation a risk assessment should be performed that compares the DriveGuard Safe Torque Off option
18. ockwell Automation Inc with respect to use of information circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations WARNING Identifies information about practices or circumstances that can cause an explosion in a hazardous environment which may lead to personal injury or death property damage or economic loss ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you identify a hazard avoid a hazard and recognize the consequences SHOCK HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that dangerous voltage may be present BURN HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that surfaces may reach dangerous temperatures PE RP IMPORTANT Identifies information that is critical for successful application and understanding of the product Allen Bradley Rockwell Software Rockwell Automation and TechConnect are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Summary of Changes This man
19. proper setting to achieve the required safety rating IMPORTANT When applying Functional Safety restrict access to qualified authorized personnel who are trained and experienced will exit the machine if the door locks while they are in the machine Additional safeguarding devices may be required for your specific application N ATTENTION When designing your system consider how personnel 10 Rockwell Automation Publication 20D UM007G EN P March 2012 General Description Chapter 1 Safety Category 3 Performance Definition To achieve Safety Category 3 according to EN ISO 13849 1 2008 the safety related parts have to be designed such that the safety related parts of machine control systems and or their protective equipment as well as their components shall be designed constructed selected assembled and combined in accordance with relevant standards so that they can withstand expected conditions well tried safety principles shall be applied a single fault in any of its parts does not lead to a loss of safety function some but not all faults will be detected the accumulation of undetected faults can lead to loss of safety function short circuits in the external wiring of the safety inputs is not one ofthe faults that can be detected by the system therefore according to DIN EN ISO 13549 2 these cables must be installed so as to be protected against external damage by cable ducting or armor Stop Categor
20. s ALT and then View Sel Next press the Up or Down Arrow to change Present Value to Defined Link Press the Enter key 4 Press the Enter key to select the Link field Using the HIM keypad enter 324 as the Source Parameter Number and press the Enter key The linked parameter can now be viewed two different ways by repeating the steps above and selecting Preset Value or Define Link If an attempt is made to edit the value of a linked parameter Parameter is Linked will be displayed indicating that the value is coming from a source parameter and cannot be edited 5 To remove a link repeat the steps above and change the source parameter to zero 0 Rockwell Automation Publication 20D UM007G EN P March 2012 27 Chapter2 Installation and Wiring Verify Operations Test the safety function for proper operation after initial installation of the DriveGuard Safe Torque Off option Retest the safety function at the intervals determined by the safety analysis described on page 15 Verify that both safety channels are functioning according to Table 4 below Table 4 Channel Operation and Verification Drive In Drive In Drive In Drive Able Safety Function Status Safe State Stopped State Stopped State To Run Safety Channel Operation Safe Torque Off Option No Power Power No Power Power Terminals 1 amp 2 Applied Applied Applied Applied PowerFlex 700S 700L No Power No Power Power Power Enable
21. set followed by a valid start command to the drive Rockwell Automation Publication 20D UM007G EN P March 2012 Description of Operation Chapter 3 Application Considerations When the hazard analysis for the overall machine determines the need for external mechanical brakes or other stopping means the external means shall be activated after the removal of power for Stop Category 0 If the Safe Torque Off option sticks ON the motor will stop on command due to the enable input The system cannot be reset when this fault condition exists Example 3 All Drives Safe Torque Off Connection with Controlled Stop Action Dual Channel Figure 4 Stop Category 1 Controlled AC Line Input Power Al A2 24V DC Common PowerFlex 700S 700L GuardMaster Trojan O Star Start Stop Common 24V DC L l 24V DC Common S14 S52 S12 S22 37 47 57 13123 833 534 A y Na Gate Control Minotaur Power Supply MSR138DP N Safe i xp x3 x4 3940 38 48 58 14 b L v Gate Control Circuit 4 Common Enable Circuit Status Circuit shown with guard door closed and system ready for normal operation Rockwell Automation Publication 20D UM007G EN P March 2012
22. specifications and all foresecable operational and environmental characteristics of the machine to which it is to be fitted A safety analysis of the machine section controlled by the drive is required to determine how often the safety function should be tested for proper operation during the life of the machine installation Rockwell Automation Inc cannot assume responsibility for the compliance or the noncompliance to any code national local or otherwise for the proper installation of this equipment A hazard of personal injury and or equipment damage exists if codes are ignored during installation N ATTENTION The following information is merely a guide for proper Rockwell Automation Publication 20D UM007G EN P March 2012 15 Chapter 2 16 Installation and Wiring Option Board Installation PowerFlex 700S Frames 1 6 and PowerFlex 700L Frames 3A and 3B 1 Remove the I O Control Cassette from the drive Task Description Q Open the door of the power structure and disconnect the cables that connect to the main board Loosen the screws on the face of the cassette Remove the cassette PowerFlex 700S shown VRVUVVV Rockwell Automation Publication 20D UM007G EN P March 2012 Installation and Wiring Chapter 2 PowerFlex 700S Frames 9 14 1 Remove the I O Control Cassette from the drive Description Open the door of the power structure and
23. systems can be classified as operating in either a Low Demand mode or in a High Demand Continuous mode e Low Demand mode where the frequency of demands for operation made on a safety related system is no greater than one per year or no greater than twice the proof test frequency e High Demand Continuous mode where the frequency of demands for operation made on a safety related system is greater than once per year or greater than twice the proof test interval The SIL value for a Low Demand safety related system is directly related to order of magnitude ranges of its average probability of failure to satisfactorily perform its safety function on demand or simply average probability of failure on demand PFD The SIL value for a High Demand Continuous mode safety related system is directly related to the probability of a dangerous failure occurring per hour PFH PFD and PFH Data These PFD and PFH calculations are based on the equations from Part 6 of IEC 61508 and show worst case values This table provides data for a 20 year proof test interval and demonstrates the worst case effect of various configuration changes on the data PFD and PFH for 20 year Proof Test Interval Attribute Test Result Frames 1 6 Test Result Frames 9 14 PFDay 5 28 x 10 2 14 x 107 PFH 6 00 x 1010 1 h 2 64 x 109 1 h calculated according to IEC 61508 calculated according to IEC 61508 MTTFp High 4023 years High 11415 years DC
24. ual contains new and updated information New and Updated Information The following changes apply to this revision ofthe manual Change See Page Added Original Instructions to the front cover Updated the Important statement regarding the proper use of the Safe Z Torque Off option Updated the information in the Evaluation Certification by TUV Rheinland 9 Group table to support frame 5 and 6 and frames 9 14 drives Updated the information in the PFD and PFH for 20 year Proof Test 12 Interval table to support frame 9 14 drives Added steps for installing the Safe Torque Off option board in frame i 9 14 drives Added frames 9 14 drives to wiring diagram example 2 er Rockwell Automation Publication 20D UM007G EN P March 2012 3 Summary of Changes 4 Rockwell Automation Publication 20D UM007G EN P March 2012 Chapter 1 Chapter 2 Table of Contents General Description What Is the DriveGuard Safe Torque Off Option 7 Safety of Machinery Standards sssserserrererrrrrrrer rer rar 8 Safety Gertificationssa Au a 2 CSUN bl Aha Aaaa 9 Evaluation Certification by T V Rheinland Group 9 Certifications Online 06 0 cece cece eee cence eee ens 9 Important Safety Considerations 0 0 0 e cece eee eee eee 10 Safety Category 3 Performance Definition 00005 11 Stop Category Definitions ssssereeserrererrerrrrer rer rasa 11 P
25. ublications e PowerFlex 700S Phase II Drive Frames 1 6 Installation Instructions publication 20D INO24 e PowerFlex 700H and 700S Drive Frames 9 14 Installation Instructions publication PFLEX INO06 26 Rockwell Automation Publication 20D UM007G EN P March 2012 Installation and Wiring Chapter 2 Configure Digital Outputs Digital Output 1 and 2 TB2 Terminals 3 4 and 5 and Relay Output 3 TB2 Terminals 6 7 and 8 can be configured to activate external logic in the event the safety enable diagnostic routine results in an F45 Enable Health fault 1 Set Par 147 FW Functions En Bit 14 Digital Outs to 1 True 2 Set Par 845 Dig Outl Sel Par 850 Dig Out2 Sel or Par 855 Rly Out3 Sel to option 0 User Select 3 Link Par 846 Dig Out Data Par 851 Dig Out2 Data or Par 856 Rly Out3 Data to Par 324 Fault Status 2 See Linking Parameters below 4 Set Par 847 Dig Out Bit Par 852 Dig Out2 Bit or Par 857 Rly Out3 Bit to 12 Par 324 Bit 12 EnableHealth status Linking Parameters Use the following procedure to establish a link between Par 846 Dig Out Data Par 851 Dig Out2 Data or Par 856 Rly Out3 Data and Par 324 Fault Status 2 1 Using the drive s Human Interface Module HIM select Parameter from the Main Menu and press the Enter key 2 Using the HIM keypad enter 846 850 or 856 and press the Enter key The parameter value screen will appear 3 Pres
26. ukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation Pegasus Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 www rockwellautomation com Publication 20D UM007G EN P March 2012 Supersedes 20D UMO07F EN P September 2011 Copyright 2012 Rockwell Automation Inc All rights reserved Printed in USA
27. y Definitions The selection of a stop category for each stop function must be determined by a risk assessment Stop Category 0 is achieved with immediate removal of power to the actuator resulting in an uncontrolled coast to stop Sce Description of Operation Example 1 on page 31 and Example 2 on page 32 Stop Category 1 is achieved with power available to the machine actuators to achieve the stop Power is removed from the actuators when the stop is achieved See Description of Operation Example 3 on page 33 IMPORTANT When designing the machine application timing and distance should be considered for a coast to stop Stop Category 0 or Safe Torque Off For more information regarding stop categories refer to EN 60204 1 Rockwell Automation Publication 20D UM007G EN P March 2012 11 Chapter 1 General Description 12 Performance Level and Safety Integrity Level SIL CL2 For safety related control systems Performance Level PL according to EN ISO 13849 1 and SIL levels according to IEC 61508 and EN 62061 include a rating of the system s ability to perform its safety functions All of the safety related components of the control system must be included in both a risk assessment and the determination of the achieved levels Refer to the EN ISO 13849 1 IEC 61508 and EN 62061 standards for complete information on requirements for PL and SIL determination PFD and PFH Definitions Safety related
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