Safe-Off Option for PowerFlex® 700S Phase II AC
Contents
1. 0 400 480V Frames 9 13 2 None 600V Frames 1 4 2 None 600 690V Frames 5 and6 G 600 690V Frames 9 13 2 None PowerFlex 700L 400 480V Frames 3A and 3B 6 Liquid Cooled 600 690V Frames 3A and 3B 1 TUV Report No 968 EZ 189 00 05 2 TUV Report No 968 EL 328 00 05 3 TUV Report No 968 EZ 230 00 06 4 TUV Certificate No 968EZ 189 00 05 5 TUV Certificate No 968 EZ 230 00 06 Installation and Wiring Installation and Wiring Installation must be in accordance with the following steps and must be carried out by competent personnel The DriveGuard Safe 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 Off option specifications and all foreseeable 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 ATTENTION The following information is merely a guide for proper 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 ignored2. Allen Bradley Drive 1 Safe Off Option for PowerFlex 700S Phase II AC Drives and PowerFlex 700L Liquid Cooled AC Drives User Manual 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 Avww 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 Rockwell Automation Inc with respect to use of information circuits equipment or software d
3. Figure 1 Drive Safe Off Circuitry AC Line Input Power PowerFlex 700S 700L 24V DC Stop Star Start Stop Common 24V DC Common Gate Control Power Supply Safe Safety Channel Gate Control Circuit Common Safety Channel Enable Description of Operation 19 Example 1 PowerFlex 700S Drives Frames 1 6 Safe Off Connection with Coast to Stop Action Dual Channel Figure 2 Stop Category 0 Coast AC Line Input Power PowerFlex 700S 700L 24V DC sep al ne i Start Stop Common 24V DC Common 31113723 Gate Control RL Power Supply 132 11424 U 24V DC Common Gate Control Circuit 4 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 off circuit and drive Opening the guard door will switch the input circuits S13 S14 amp S21 S22 to the Minotaur monitoring safety relay unit The output circuits 13 14 amp 23 24 will cause the Safe 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
4. 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 20 Description of Operation Example 2 PowerFlex 700S Drives Frames 9 13 and PowerFlex 700L Drives Frames 3A and 3B Safe Off Connection with Coast to Stop Action Dual Channel Figure3 Stop Category 0 Coast AC Line Input Power PowerFlex 700S 700L GuardMaster 24V DC rolen o Stop M Stop _L O Start Start Start Stop Common 24V DC l Cr 24V DC Common Al S21 S11 S52 S22 37 47 57 13 23 833 834 I ened Gate Control Minotaur J Power Supply MSR138DP oa VP a Safe Ae X1 X2 X3 X4 Y39 Y40 38 48 58 14 24 24V DC II Common en eee NG Gate Control Circuit 4 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 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
5. D 2 24V Common 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 14 Installation and Wiring Configure Hardware Enable Ensure that Jumper P22 on the Main Control Board is set to HW Enable Pins 2 and 4 Jumper P22 413 a HW Enable i No HW Enable pih q i 50 o wo O Fy Important In addition to the correct jumper setting enable circuitry must be connected to I O Terminals 13 and 16 Refer to the PowerFlex 700S Phase II Control User Manual publication 20D UMO006 for wiring examples Installation and Wiring 15 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 2 Set Par 147 FW Functions En Bit 14 Digital Outs to 1 True Set Par 845 Dig Outl Sel Par 850 Dig Out2 Sel or Par 855 R
6. of Operation Supplemental Information PowerFlex 700S Certification PowerFlex 700L Certification RIBBES a e ar JS es Iron J i fic fino Jiro gt D General Description General Description The DriveGuard Safe Off option when used with other safety components helps provide protection according to EN 954 1 1997 Category 3 for safe off and protection against restart The DriveGuard Safe 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 Off Option The DriveGuard Safe 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 AC power to the motor e Can be used in combination with other safety devices to satisfy the requirements of EN 954 1 Category 3 for safe off and help protect against restart 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 This option should not be used as a control for starting and or stopping the drive ATTENTION Electrical Shock Hazard Verify that all sources of AC and DC power are deenergized and locked out or tagged out
7. ard analysis of the system The external wiring has to meet the requirements for fault exclusions according to Annex D 5 2 Table D 4 of EN ISO 13849 2 The user manual Safe Off Option for PowerFlex 700L AC Drive has to be considered Der Pr fbericht Nr 968 EZ 230 00 06 vom 2006 06 27 ist Bestandteil dieses Zertifikates Der Inhaber eines f r den Pr fgegenstand g ltigen Genehmigungs Ausweises ist berechtigt die mit dem Pr fgegenstand berein stimmenden Erzeugnisse mit dem abgebildeten Pr fzeichen zu ver sehen The test report no 968 EZ 230 00 06 dated 2006 06 27 is an integral part of this certificate The holder of a valid licence certificate for the product tested is authorized to affix the test mark shown opposite to products which are identical with the product tested T V Rheinland Industrie Service GmbH Gesch ftsfeld ASI Automation Software und informatonstechnalogie o www rockwellautomation com Power Control and Information Solutions Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation SA NV Vorstlaan Boulevard du Souverain 36 1170 Brussels 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 Publication 20D UM007D EN P Decemb
8. during installation Installation and Wiring Option Board Installation 6 and PowerFlex 700L Frames 3A and 3B 1 Remove the I O Control Cassette from the drive PowerFlex 700S Frames 1 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 Task Description Q PowerFlex 700S shown VVVVVIVAY Sal al Oe N Ea 6 Installation and Wiring PowerFlex 700S Frames 9 13 1 Remove the I O Control Cassette from the drive Description Open the door of the power structure and carefully disconnect the three 3 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 Task Swing the flange and cassette away from the control frame Remove the cassette Typical Frames 10 13 Installation and Wiring All Frames PowerFlex 700S and PowerFlex 700L 2 Remove the screws securing the interior cassette cover to gain access to the Main board 15 pin position 3 Remove the 2 pin shunt jumper from the 16 Installation and Wiring Important If the DriveGuard Safe Off option is removed from the drive this jumper must be reinstalled or the drive will not run 4 Remove the exterior cassette cov
9. e 20 HIM 28 10 20 COMM COM Module 20B_ DB1 Internal Dynamic Brake VY Use marker to note Power Module Front addition of DriveGuard Bottom Covers Removed Safe Off option Installation and Wiring 13 Wiring Important points to remember about wiring e 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 Table 1 DriveGuard Safe Off Option Terminal Block Specifications Wire Size Range Torque Maximum Minimum Maximum Recommended 1 5 mm 0 14 mm 0 25 N m 0 22 N m 16 AWG 26 AWG 2 2 Ib in 1 9 Ib in 1 Maximum minimum that the terminal block wil accept these are not recommendations Table 2 Wire Types Minimum Wire Type s Description Insulation Rating Unshielded Per US NEC or applicable 300V national or local code 60 degrees C Shielded Multi conductor shielded cable 0 750 mm2 18AWG 140 degrees F such as Belden 8770 or equiv 3 conductor shielded Table 3 DriveGuard Safe Off Option Terminals Description No Signal Description ea amp 1 24V DC Connections for user supplied power nassen to energize coil ban cove unser
10. er 2006 363068 P03 Supersedes 20D UM007C EN P October 2006Copyright 2006 Rockwell Automation Inc All rights reserved Printed in USA
11. ers to access the grounding plate 00000000000 III ZIED 40000000 Installation and Wiring 5 Install the 16 pin stacker connector 200000008 S S S S Ss Ss S 0 8 1 1 N m 7 0 10 0 Ib in 7 Install and tighten mounting screws Installation and Wiring 10 Install the exterior cassette covers 8 009009909 Installation and Wiring 11 9 Install the inside front cover 10 Reinstall the cassette in the drive 11 Record the modification on the Field Installed Option label PowerFlex 700S Frames 1 6 FIELD INSTALLED OPTIONS Use marker to note addition of DriveGuard Safe Off option 12 Installation and Wiring PowerFlex 700S Frames 9 13 Use marker to note addition of DriveGuard Safe Off option FIELD INSTALLED OPTIONS Firmware F Date Firmware E Date 20 HIM HIM 28 410 vo 20 COMM COM Module 208_ DB1 Internal Dynamic Brake Frame 10 shown PowerFlex 700L Frames 3A and 3B Input Power Filter Bay Module Bay fel Pe Qa Power Module Bay Door Cutaway Sa FIELD INSTALLED OPTIONS Firmware Date Firmware Dat
12. escribed 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 that can cause an explosion in a hazardous environment which may N WARNING Identifies information about practices or circumstances lead to personal injury or death property damage or economic loss Important Identifies information that is critical for successful application and understanding of the product 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 the hazard and recognize the consequences drive or motor to alert people that dangerous voltage may be present Burn Hazard labels may be located on or inside the equipment e g drive or motor to alert people that surfaces may be at dangerous temperatures Shock Hazard labels may be located on or inside the equipment e g PowerFlex PLC and DriveGuard are registered trademarks of Rockwell Automation Inc DriveExplorer DriveExecutive and SCANport are trademarks of Rockwell Automation Inc Summary of Changes Manual Updates The following changes apply to revision D December 2006 of this manual Added a new wiring diagram for Safe Off Connection wit
13. ficate for the product tested is authorized to affix the test mark shown opposite to products which are identical with the product tested TUV Industrie Service GmbH f Gat Datum Date Firmenstempel Company seal Unterschrift Signature 24 Supplemental Information PowerFlex 700L Certification TUV T V Rheinland Group T V Rheinland Industrie Service GmbH Automation Software und Informationstechnologie ZE RTI F KAT Nr No 968 EZ 230 00 06 CERTIFICATE Pr fgegenstand Safety function Safe standstill within Zertifikatsinhaber Rockwell Automation Product tested the Adjustable Frequency AC Drive License holder 6400 West Enterprise Drive Hersteller USA Mequon WI 53092 Manufacture United States of America Typbezeichnung Verwendungszweck Safety relevant applications Type designation Intended application Safety Function Safe stand Allen Bradley PowerFlex 700L AC Drive se al Frames 3A and 38 400 V 480 V 600 V 690 V category 3 Pr fgrundlagen EN 954 1 1996 Codes and standards forming EN ISO 13849 2 2003 the basis oftesting EN 60204 1 1997 EN 50178 1997 EN 61800 3 2004 Pr fungsergebnis The safety function Safe standstill fulfils the requirements for Test results category 3 according EN 954 1 Besondere Bedingungen The possibility of the small movement of the motor resulting from Specific requirements simultaneous IGBT failures must be taken into account during the haz
14. h Coast to Stop 20 Action Dual Channel for PowerFlex 700S High Horse Power AC Drives Frames 9 13 and PowerFlex 700L Liquid Cooled AC Drives Frames 3A and 3B The following changes apply to revision C October 2006 of this manual Change See Page Added PowerFlex 700L Liquid Cooled AC Drive Frame 3A and 3B Throughout information manual Added Attention message to advise that the drive may provide energy for 3 and 17 up to 180 of rotation in a 2 pole motor in the event two output IGBTs in the drive fail and the DriveGuard Safe Off option has controlled the drive outputs to a safe state Added an Important message to advise that the DriveGuard Safe Off 17 option does not eliminate dangerous voltages at the drive output The following changes apply to revision B August 2005 of this manual Added 400 500V and 600 690V Frame 9 13 drives to EN 954 1 Category 3 approval Updated the option board installation instructions to include frames 9 13 6 and 12 soc i Summary of Changes Table of Contents Section General Description u o Q D What Is the DriveGuard Safe Off Option Safety of Machinery Standards Evaluation Certification by TUV Rheinland Group Installation and Wiring Option Board Installation Wiring Configure Hardware Enable Configure Digital Outputs Linking Parameters Verify Operation Description
15. in accordance with the requirements of ANSI NFPA 70E Part II 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 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 General Description 3 drive when the DriveGuard Safe 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 ATTENTION In the event of the failure of two output IGBTs in the Safety of Machinery Standards The DriveGuard Safe Off option satisfies requirements in the following machine safety standards e EN 954 1 1996 Safety of Machinery Safety related parts of control systems Part 1 General Principles for design e EN ISO 13849 2 2003 Safety of Machinery Safety related parts of control systems Part 2 Validation Evaluation Certification by TUV Rheinland Group TUV Report on Safety TUV fs Drive Rating Function _ Certification PowerFlex 700S Phase Il 208 240V Frames 1 6 m m 400 480V Frames 1 6 1 2
16. ly Out3 Sel to option 0 User Select Link Par 846 Dig Outl Data Par 851 Dig Out Data or Par 856 Rly Out3 Data to Par 324 Fault Status 2 See Linking Parameters below Set Par 847 Dig Outl 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 Outl 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 Using the HIM keypad enter 846 850 or 856 and press the Enter key The parameter value screen will appear Press ALT and then View Sel Next press the Up or Down Arrow to change Present Value to Defined Link Press the Enter key 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 To remove a link repeat the steps above and change the source parameter to zero 0 16 Installation and Wiring Ve
17. n with guard door closed and system ready for normal operation Operating Principle This is a dual channel system with monitoring of the safe 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 will issue a Stop command to the drive and cause a 22 Description of Operation controlled deceleration After the programmed delay the timed output circuits 47 48 amp 57 58 will cause the Safe 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 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 Supplemental Information 23 Supplemental Information PowerFlex 700S Certification TUV T V Rheinland Group TUV Industrie Service GmbH Automation Software und Informationstechnologie Nr No 968 EZ 189 00 05 ZERTIFIKAT CERTIFICATE Pr fgegenstand Adjustable Frequency AC Drive Zertifikatsinhaber Rockwell Automation Product tested License h
18. older 6400 West Enterprise Drive Hersteller USA Mequon WI 53092 Manufacture United States of America Typbezeichnung Type designation Verwendungszweck Safety relevant applications Intended application Safety Function Safe stand still according to EN 954 1 Allen Bradley PowerFlex 700S AC Drive category 3 Frame 1 2 3 4 5 6 240 V 400 V 480 V and corresponding DC input voltage ratings Frame 5 6 600 V 690 V and corresponding DC input voltage ratings Pr fgrundlagen EN 954 1 1996 Codes and standards forming EN ISO 13849 2 2003 the basis of testing EN 60204 1 1997 EN 50178 1997 EN 61800 3 1996 amp A11 2000 Pr fungsergebnis Test results The safety function Safe standstill meets the requirements for category 3 according EN 954 1 Besondere Bedingungen Specific requirements Fault exclusion for the external wiring has to be made according to EN ISO 13849 2 The user manual Safe Off Option for PowerFlex 700S AC Drive has to be considered A 2005 02 25 Der Pr fbericht Nr 968 EZ 189 00 05 vom 2005 02 25 ist Bestandteil dieses Zertifikates Der Inhaber eines f r den Pr fgegenstand g ltigen Genehmigungs Ausweises ist berechtigt die mit dem Pr fgegenstand bereinstimmen den Erzeugnisse mit dem abgebildeten Pr fzeichen zu versehen The test report no 968 EZ 189 00 05 dated 2005 02 25 is an integral part of this certificate The holder of a valid licence certi
19. rify Operation Test the safety function for proper operation after initial installation of the DriveGuard Safe Off option Retest the safety function at the intervals determined by the safety analysis described on page 4 Verify that both safety channels are functioning according to Table 4 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 Off Option No Power Power Applied No Power Power Applied Terminals 1 amp 2 Applied Applied PowerFlex 700S 700L No Power No Power Power Applied Power Applied Enable Input Applied Applied Description For Verification Safe 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 A Description of Operation 17 Description of Operation The DriveGuard Safe Off option see Figure 1 disables the drive s output IGBT s by disconnecting the gate control power supply When used in combination with a second safety channel the Enable input the system satisfies the requirements of EN 954 1 Category 3 for safe turn off of torque producing energy at the output of the drive Important The DriveGuard Safe Off option does not eliminate dangerous voltages at the drive output Input power
20. to the drive must be turned off and safety procedures followed before performing any electrical work on the drive or motor ATTENTION In the event of the failure of two output IGBTs in the drive when the DriveGuard Safe 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 Under normal drive operation the Safe Off relay is energized the enable input is energized and gate control power is available to the gate control eircuit 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 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 954 1 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 ATTENTION By itself the DriveGuard Safe Off option initiates a coast to stop action Additional protective measures will need to be applied when an application requires a different stopping action Description of Operation
21. to trip and the motor will coast to stop After the programmed delay the timed output circuits 57 58 will cause the Safe Off option circuit to trip To restart the drive the Minotaur safety relay must first be reset followed by a valid start command to the drive 24V DC Description of Operation 21 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 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 Off Connection with Controlled Stop Action Dual Channel Figure 4 Stop Category 1 Controlled AC Line Input Power Al PowerFlex 700S 700L GuardMaster 24V DC Trojan Stop O Start Start Start Stop Common I Tr 24V DC Common 1S21 511 552 512 522 37 47 57 Gate Control A PBBP yr Minotaur Power Supply MSR138DP hs 2 X1 X2 X3 X4 Y39 Y40 38 48 58 24V bo LI bt Ld Common i 2 4 Thi Gate Control Circuit Common Enable Circuit Status Circuit show
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