PowerFlex 750-Series Safe Torque Off User Manual
Contents
1. CE European Union 2004 108 EC EMC Directive compliant with EN 61800 3 PowerFlex 750 Series AC Drive Emissions and Immunity EN 62061 Safety Function Immunity European Union 2006 42 EC Machinery Directive EN ISO 13849 1 Safety Function EN ISO 13849 2 Safety Function EN 60204 1 Safety Function EN 62061 Safety Function EN 61800 5 2 Safety Function CTick T V Australian Radiocommunications Act compliant with EN 61800 3 categories 2 and 3 Certified by T V for Functional Safety up to SILCL3 according to EN 61800 5 2 EN 61508 and EN 62061 up to Performance Level PL e and Category 4 according to EN ISO 13849 1 when used as described in this PowerFlex 750 Series Safe Torque Off User Manual publication 750 UM002 1 When product is marked refer to www rockwellautomation com products certification for Declarations of Conformity Certificates 2 Underwriters Laboratories Inc has not evaluated the safe off safe torque off or safe speed monitoring options for functional safety CE Conformity CE Declarations of Conformity are available online at www rockwellautomation com products certification The 20 750 S Safe Torque Off module is in conformity with the essential requirements of the 2006 42 EC Machinery Directive and the 2004 108 EC EMC Directive when installed and maintained in accordance with the instructions contained in this document The following standards have been applied to d2. 750 UMO02E EN P February 2012 Functional Proof Tests PFD and PFH Definitions Safety Concept Chapter 2 Performance Level and Safety Integrity Level SIL CL3 For safety related control systems Performance Level PL according to ISO 13849 1 and SIL levels according to EN 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 ISO 13849 1 EN 61508 and EN 62061 standards for complete information on requirements for PL and SIL determination 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 Safety related 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 valu
3. Environmental Specifications 34 Category Maximum Surrounding Air Temperature IP20 NEMA UL Open Type IP00 NEMA UL Open Type IP20 NEMA UL Type 1 w Hood IP20 NEMA UL Type 1 w Label IP20 NEMA UL Type 1 MCC Cabinet Flange Mount Front IP20 NEMA UL Open Type IP00 NEMA UL Open Type Back Heat Sink IP66 NEMA UL Type 4X Stand alone Wall Mount IP54 NEMA UL Type 12 Specification 0 50 C 32 122 F Frame 1 5 All Ratings 0 50 C 32 122 F Frame 6 7 All Ratings 0 40 C 32 104 F Frame 1 5 All Ratings 0 40 C 32 104 F Frame 6 7 All Ratings 0 40 C 32 104 F Frame 8 10 All Ratings 0 50 C 32 122 F Frame 2 5 All Ratings 0 50 C 32 122 F Frame 6 7 All Ratings 0 40 C 32 104 F Frame 2 7 All Ratings 0 40 C 32 104 F Frame 2 7 All Ratings Storage Temperature all const 40 70 C 40 158 F Atmosphere Important Drive must not be installed in an area where the ambient atmosphere contains volatile or corrosive gas vapors or dust If the drive is not going to be installed for a period of time it must be stored in an area where it will not be exposed to a corrosive atmosphere UV Radiation The HIM and IP54 NEMA UL Type 12 drive plastics are not UV rated Relative Humidity 5 95 non condensing Shock Operating Frame 1 6 15 g peak for 11 ms duration 1 0 ms Frame 7 10 g peak for
4. be zero for all three measurements Frames 8 10 Measure the DC bus voltage at the DC and DC TESTPOINT sockets on the front of the power module f ATTENTION Hazard of equipment damage exists if an option module is To install the Safe Torque Off option module 1 Firmly press the module edge connector into the desired port IMPORTANT The Safe Torque Off option module can be installed in any drive port However when used in an Integrated Motion application the module must be installed in port 6 2 Tighten the top and bottom retaining screws Recommended torque 0 45 Nem 4 0 lbein Recommended screwdriver T15 Hexalobular 9 654 IMPORTANT _Donot over tighten retaining screws Rockwell Automation Publication 750 UM002E EN P February 2012 23 Chapter3 Installation and Wiring 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 Safe Torque Off Option Terminal Block Specifications Wire Size Range Wire Type Strip Length Maximum Minimum 0 8 mm 0 3 mm Multi conductor shielded 10 mm 18 AWG 28 AWG cable 0 39 in Table 2 TB2 Terminal Designations Terminal Name Description SP4 SP SP 24 Volt Safety Power Us
5. is detected the safety option goes to the Safe State This includes faults related to integrity of hardware or firmware The safety reaction time is the amount of time from a safety related event as input to the system until the system is in the Safe State The safety reaction time from an input signal condition that triggers a safe stop to the initiation of the configured Stop Type is 10 ms maximum for drive Frames 1 10 Rockwell Automation Publication 750 UM002E EN P February 2012 Safety Concept Chapter 2 Considerations for Safety The achievable safety rating of an application using the safety option installed in owerFlex 750 Series drives is dependent upon many factors drive options an Ratin gs PowerFl S d dependent up y fi d p d the type of motor For applications that rely on the immediate removal of power to the actuator resulting in an uncontrolled coast to stop a safety rating up to and including SIL CL3 PL e and Category 3 can be achieved Contact Information if Safety If you experience a failure with any safety certified device contact your local Opti on Failure Occurs 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 Publicatio
6. 0 Series Safe Torque Off option module see Figure 1 disables the drive s output IGBT s by either disconnecting the power supply to the gate control driver IC or disabling the output of the gate control driver IC The system satisfies the requirements of SIL3 for safe turn off of torque IMPORTANT The 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 the PowerFlex 750 Series 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 ATTENTION In the event of the failure of two output IGBTs in the drive when Under normal operation 24V DC is applied to both the Safety Power and Safety Enable inputs of the Safe Torque Off option module If the Safety Enable or Safety Power is de energized the outputs of the gate control driver IC are disabled and IGBT firing is disabled Parameter 933 Start Inhibits will indicate that IGBTs are inhibited and the HIM will indicate that the drive is not enabled a coast to stop action Additional protective measures will need to be applied ATTENTION By itself the PowerFlex 750 Series Safe Torque Off option initiates when an application requires a different stopping action Rockwell Automation Publi
7. 11 ms duration 1 0 ms Frame 8 10 Power Core 10 g peak for 11 ms duration 1 0 ms in Cabinet w Option Bay 5 g peak for 11 ms duration 1 0 ms Shock Packaged for Shipment Frame 1 2 381 mm 15 in drop height Frame 3 4 330 mm 13 in drop height Frame 5 305 mm 12 in drop height Frame 6 10 Meets International Safe Transit Association ISTA test procedure 2B Vibration Operating Frame 1 2 1 000 mm 0 040 in displacement 2 g peak Frame 3 5 1 000 mm 0 040 in displacement 1 5 g peak Frame 6 7 1 000 mm 0 040 in displacement 1 g peak Frame 8 10 Power Core Drive in Cabinet w Option Bay 1 000 mm 0 040 in displacement 1 g peak Vibration Packaged for Shipment Sinusoidal Loose Load Frame 1 5 20 0 mm 0 8 in peak to peak 2 5 186 Hz 1 1 g peak from 5 186 20 Hz Frame 6 10 Meets ISTA 2B packaging standards Random Secured Frame 1 5 Frequency Hz PSD g2 Hz 1 0 00005 4 0 01 16 0 01 40 0 001 80 0 001 200 0 00001 Frame 6 10 Meets International Safe Transit Association ISTA test procedure 2B Rockwell Automation Publication 750 UM002E EN P February 2012 Certifications Specifications Appendix A See the Product Certification link at www rockwellautomation com products certification for Declarations of Conformity Certificates and other certifications details Certification UL us 2 Value UL Listed certified for US and Canada
8. User Manual Allen Bradley PowerFlex 750 Series Safe Torque Off Catalog Numbers 20 750 S 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 Rockwell Automation Inc with respect to use of information circuits equipment or software described in thi
9. ard 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 reset followed by a valid start command to the drive 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 Rockwell Automation Publication 750 UMO02E EN P February 2012 Description of Operation Chapter 4 Example 3 All Drives Safe Torque Off Connection with Controlled Stop Action Dual Channel Figure 4 Stop Category 1 Controlled ACLine Input Power GuardMaster PowerFlex Trojan 750 Series 24V DC Sto External E 24V DC Start Start 24V DC l Start Stop C
10. cation 750 UM002E EN P February 2012 27 Chapter4 Description of Operation Figure 1 Drive Safe Torque Off Circuitry ACLine Input Power PowerFlex 750 Series 24V DC Stop Start Start Stop Common 24V DC Common Jumpers ENABLE Installed SAFETY Removed Gate Control Power Supply Gate Control Circuit Safety gt SP Power Safety _ SE Enable 28 Rockwell Automation Publication 750 UM002E EN P February 2012 Description of Operation Chapter 4 Example 1 PowerFlex 750 Series Drives Frames 1 10 Safe Torque Off Connection with Coast to Stop Action Dual Channel Figure 2 Stop Category 0 Coast ACLine Input Power OOO PowerFlex 750 Series 24V DC Stop GuardMaster Trojan O O Start Star 24V DC Start Stop Common 24V DC Common Jumpers ENABLE Installed SAFETY Removed E Stop d Latching Button Gate Control Power Supply Gate Control Circuit A SE Sa Sp SE Iira B 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 i
11. e 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 750 UMO02E EN P February 2012 31 Chapter4 Description of Operation Notes 32 Rockwell Automation Publication 750 UMO02E EN P February 2012 Introduction General Specifications Specifications Appendix A This appendix provides general specifications for the Safe Torque Off Option module Attribute Value Standards IEC EN60204 1 1S013489 1 IEC 61508 IEC 61800 5 2 Safety category Cat 3 and PL e per EN ISO 13849 1 SIL CL3 per IEC 61508 and EN 62061 Power supply user 1 0 24V DC 10 0 8 1 1 x rated voltage PELV or SELV Power consumption 4 4 watts Safety enable SE SE 24V DC 25 mA Safety power SP SP 24V DC 45 mA Input ON Voltage min 24V DC 410 21 6 26 4V DC Input OFF Voltage max 5V Input OFF Current max 2 5 mA 5V DC Conductor type Multi conductor shielded cable Conductor size 2 0 3 0 8mm 2 28 18 AWG Strip length 10 mm 0 39 in 1 Safety outputs need additional fuse for reverse voltage protection of the control circuit Install a 6 A slow blow or 10 A fast acting fuse 2 Refer to Industrial Automation Wiring and Grounding Guidelines publication 1770 4 1 Rockwell Automation Publication 750 UM002E EN P February 2012 33 Appendix A Specifications
12. e 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 Rockwell Automation Publication 750 UM002E EN P February 2012 11 Chapter2 Safety Concept PFD and PFH Data Safe State Safety Reaction Time 12 PFD and PFH calculations are based on the equations from Part 6 of EN 61508 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 Value Drive Frames 1 7 Drive Frame 8 Drive Frame 9 Drive Frame 10 PFD 3 29E 5 3 81E 04 2 65E 4 3 56E 4 PFH 3 75E 10 4 46E 09 3 04E 9 1 h 4 09E 9 1 h SFF 99 5 98 4 98 2 98 2 DC 99 5 O 90 0 90 0 90 0 SIL CL 3 3 3 3 PL e e e e CAT 3 3 3 3 HFT 1 1002 1 1002 1 1002 1 1002 PTI Proof Test Interval 20 years 20 years 20 years 20 years 1 Without connection to external equipment The Safe State encompasses all operation that occurs outside of the other monitoring and stopping behavior defined as part of the Safe Torque Off Option module If a Safe State Fault
13. e motor ceases gt e oD Rockwell Automation Publication 750 UM002E EN P February 2012 7 Chapter1 General Description Safety of Machinery Standards The Safe Torque Off option helps to satisfy requirements in the following standards IEC 61508 2000 SIL 3 IEC 61800 5 2 2007 SIL 3 IEC 61800 3 2004 IEC 62061 2005 ISO 13849 1 2006 Performance Level e Category 3 EN 954 1 1996 Category 3 IEC 60204 1 2005 NFPA 79 2007 Rockwell Automation Publication 750 UM002E EN P February 2012 Introduction Safety Certification Rockwell Automation Publication 750 UM002E EN P February 2012 Chapter 2 Safety Concept This section describes the safety performance level concept and how the PowerFlex 750 Series drives can meet the requirements for SIL CL3 CAT 3 or PL e applications The PowerFlex 750 Series safety option is certified for use in safety applications up to and including SIL 3 according to EN 61800 5 2 EN 61508 and EN 62061 Performance Level PL e and Category 3 according to ISO 13849 1 Safety requirements are based on the standards current at the time of certification The TUV Rheinland group has approved the PowerFlex 750 Series safety option for use in safety related applications where the de energized state is considered to be the safe state All of the examples in this manual are based on achieving de energization as the safe state for typical Machine Safety and Emergency Shutdown ESD syst
14. ebruary 2012 19 Chapter3 Installation and Wiring Configure Safety Enable Safety Enable Jumper When installing the Safe Torque Off option module ensure the safety enable jumper SAFETY on the Main Control Board is removed PowerFlex 753 SAFETY Jumper Location Note Frame 8 10 drives do not have a safety enable jumper 20 Rockwell Automation Publication 750 UMO02E EN P February 2012 Installation and Wiring Chapter 3 Hardware Enable Jumper When installing the Safe Torque Off option module ensure the hardware enable jumper ENABLE on the Main Control Board is installed PowerFlex 753 ENABLE Jumper Location A INEN aO 9 G TE Rockwell Automation Publication 750 UM002E EN P February 2012 21 Chapter3 Installation and Wiring PowerFlex 755 ENABLE Jumper Location Frames 8 10 22 Rockwell Automation Publication 750 UMO02E EN P February 2012 Installation and Wiring Chapter 3 Option Module Installation installed or removed while the drive is powered To avoid damaging the drive verify that the voltage on the bus capacitors has discharged before performing any work on the drive Frames 1 7 Measure the DC bus voltage at the Power Terminal Block by measuring between the DC and DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must
15. emonstrate conformity Machinery Directive 2006 42 EC e EN ISO 13849 1 2008 Safety of machinery Safety related parts of control systems Part 1 General principles for design e EN ISO 13849 2 2008 Safety of machinery Safety related parts of control systems Part 2 Validation e EN 60204 1 2006 Safety of machinery Electrical equipment of machines Part 1 General requirements e EN 62061 2005 Safety of machinery Functional safety of safety related electrical electronic and programmable electronic control systems e EN 61800 5 2 2007 Adjustable speed electrical power drive systems Part 5 2 Safety requirement Functional EMC Directive 2004 108 EC e EN 61800 3 2004 Adjustable speed electric power drive systems Part 3 EMC requirements and specific test methods Rockwell Automation Publication 750 UM002E EN P February 2012 35 AppendixA Specifications Notes 36 Rockwell Automation Publication 750 UMO02E EN P February 2012 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products At hetp www rockwellautomation com support you can find technical manuals a knowledge base of FAQs technical and application notes sample code and links to software service packs and a MySupport feature that you can customize to make the best use of these tools For an additional level of technical phone support for installation configuration and
16. ems 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 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 e analyzing all configuration settings and choosing the proper setting to achieve the required safety rating IMPORTANT When applying Functional Safety restrict access to qualified authorized personnel who are trained and experienced the machine if the door locks while they are in the machine Additional ATTENTION When designing your system consider how personnel will exit safeguarding devices may be required for your specific application Chapter2 Safety Concept Safety Category 3 Performance Definition To achieve Safety Category 3 according to ISO 13849 1 2006 the safety related parts have to be designed such that e 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 e bas
17. er supplied power 24 volt 10 Safety Power Common 45 mA typical 24 Volt Safety Enable User supplied power 24 volt 10 Safety Enable Common 25 mA typical Shield Terminating point for wiring shields when an EMC Shield plate or conduit box is not installed Safety Input Power Supply Connection Example Common 24V 1 mi OOO Important Safe Torque Off Option Module Installation Notes Cabling e Safety input wiring must be protected against external damage by cable ducting conduit aramored cable or other means e Shielded cable is required Port Assignment e When used in an Integrated Motion application the Safe Torque Off option must be installed in port 6 e Only one safety option module can be installed at a time Multiple safety options or duplicate safety option installations are not supported Jumper Settings e Ensure the hardware enable jumper ENABLE on the main control board is installed Refer to page 21 for location If not installed the drive will fault when powered up Ensure the safety enable jumper SAFETY on the main control board is removed Frames 1 7 only Refer to page 20 for location 24 Rockwell Automation Publication 750 UMO02E EN P February 2012 Verify Operation Installation and Wiring Chapter 3 Test the safety function for proper operation after initial installa
18. ic safety principles shall be applied e asingle fault in any of its parts does not lead to a loss of safety function e asingle fault is detected at or before the next demand of the safety function or if this detection is not possible then an accumulation of faults shall not lead to a loss of the safety function e the average diagnostic coverage of the safety related parts of the control system shall be high including the accumulation of faults e the mean time to dangerous failure of each of the redundant channels shall be high e measures against common cause failure shall be applied Stop Category Definitions The selection of a stop category for each stop function must be determined by a risk assessment e Stop Category 0 is achieved with immediate removal of power to the actuator resulting in an uncontrolled coast to stop Safe Torque Off accomplishes a Stop Category 0 stop e 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 e Stop Category 2 is a controlled stop with power available to the machine actuators The stop is followed by a holding position under power 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 10 Rockwell Automation Publication
19. is revision Information Topic Page Drive Frames 1 and 10 added Throughout PFD and PFH for 20 year Proof Test Interval table updated 2 Important installation notes added 24 Environmental Specifications added 34 Compliance clarified under CE in Certifications section 35 Evaluations and Certification s are not listed in this publication 35 Please visit www rockwellautomation com products certification for certification details Rockwell Automation Publication 750 UM002E EN P February 2012 3 Summary of Changes 4 Rockwell Automation Publication 750 UM002E EN P February 2012 General Description Safety Concept Installation and Wiring Description of Operation Specifications Table of Contents Chapter 1 What Is the PowerFlex 750 Series Safe Torque Off Option 7 Safety of Machinery Standards less 2fccicrn ns iieav es us kouel ye 8 Chapter 2 Introd ction ao ean ce nne tas ages saa anak boeken dau EEE a 9 Safety Certificato Desa o lai ot eee il vee ines toe Meu 9 Functional Proof Tests cc eee cece cece cece ence cneeenaeees 11 PFD and PFH Definitions 0 0 cee cee eee ences 11 PFD and PFH Data o on lee c eee e eee eee eneeenaeees 12 SafelState oes roves py iee ce poe A heen wok debe 12 Safety Reaction litie lt S53 cia sos aS 32a ipanatiea tava ddgens ae paeners 12 Considerations for Safety Ratings iswcneea now geeks vaceees pede 13 Contact Information if Safety Option Fail
20. n 750 UM002E EN P February 2012 13 Chapter2 Safety Concept Notes 14 Rockwell Automation Publication 750 UMO02E EN P February 2012 Chapter 3 Installation and Wiring Installation must be in accordance with the following steps and must be carried out by competent personnel The 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 Safe Torque 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 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 i ATTENTION The following information is merely a guide for proper Rockwell Automation Publication 750 UM002E EN P February 2012 15 Chapter3 Installation and Wiring Access Drive Control Pod 1 Remove drive cover Frames 1 5 Y Squeeze locking tabs and pull out bottom of cover Pull cover down and away from the cha
21. nput circuits 13 S14 amp S21 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 will not cause loss of the safety function Rockwell Automation Publication 750 UM002E EN P February 2012 29 Chapter 4 30 Description of Operation Example 2 PowerFlex 750 Series Drives Frames 1 10 Safe Torque Off Connection with Coast to Stop Action Dual Channel Figure 3 Stop Category 0 Coast ine Input Power PowerFlex GuardMaster 750 Series rojan 24V DC Stop O Start 24V Start Stop Common A 21 521512152 24V DC Common ih ig ENABLE Installed Minotaur nstalle SAFETY R d MSR138DP ub leg emove AL Gate Control A2 XT X2 X3 X4 Y39 Y40 38 48 58 ower Suppl Lo by Ld au AC Li T 24V DC Common Gate Control 4 a SE Sd SP SE Sd Circuit Status Circuit shown with gu
22. ommon Al S21 S11 S52 12 S22 37147157 13 23 33 34 24V DC Common Minotaur Jumpers MSR138DP ENABLE Installed SAFETY Removed A2 X1 X2 X3 X4 Y39 Y40 38 48 T Gate Control 24V DC Power Supply Common ET L ate Control Circuit J SP SE Sd External SP 24V DC Common SE Sd Circuit Status Circuit shown with guard door closed and system ready for normal 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 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 th
23. s 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 consequence 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 gt eee IMPORTANT Identifies information that is critical for successful application and understanding of the product Allen Bradley Rockwell Software Rockwell Automation and PowerFlex are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Summary of Changes This manual contains new and updated information New and Updated This table contains the changes made to th
24. ssis Frames 6 7 Loosen door screws Gently pry the door open to remove Rockwell Automation Publication 750 UMO02E EN P February 2012 Installation and Wiring Frames 8 10 Remove top screws Loosen bottom screws Remove the right front cover Rockwell Automation Publication 750 UM002E EN P February 2012 Chapter 3 17 Chapter3 Installation and Wiring 2 Frame 1 Lift the chassis cover Frames 2 7 Lift the Human Interface Module HIM cradle Frame 1 Loosen the retention screw Use a screwdriver to release the chassis cover locking tabs Lift the chassis until the latch engages 18 Rockwell Automation Publication 750 UMO02E EN P February 2012 Installation and Wiring Chapter 3 Frames 2 7 Loosen the retention screw Lift the cradle until the latch engages Frames 8 10 j A S Loosen the retention screw Lift the cradle until the latch engages Rockwell Automation Publication 750 UMO02E EN P F
25. tion of the Safe Torque Off option module 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 3 Table 3 Channel Operation and Verification Safety Function Status Drive In Drive In Drive In Drive Able Not Enabled Not Enabled Not Eneabled To Run Ready State State State Safety Channel Operation Safe Torque Off Option No Power Applied Power Applied No Power Applied Power Applied Terminals SP amp SP Safety Power Safe Torque Off Option No Power Applied No Power Applied Power Applied Power Applied Terminals SE amp SE Safety Enable IMPORTANT TIP If an external fault is present on the wiring or circuitry controlling the Safety Enable or Safety Power inputs for a period of time the Safe Torque Off option will not detect this condition When the external fault condition is removed the Safe Torque Off option will allow an enable condition No tell back contact is provided on the Safe Torque Off option This is a solid state relay that uses a test pulse from the safety circuit to verify operation Rockwell Automation Publication 750 UM002E EN P February 2012 25 Chapter3 Installation and Wiring Notes 26 Rockwell Automation Publication 750 UMO02E EN P February 2012 PowerFlex 750 Series Safe Torque Off Operation Chapter 4 Description of Operation The PowerFlex 75
26. troubleshooting we offer TechConnect support programs For more information contact your local distributor or Rockwell Automation representative or visit http www rockwellautomation com support Installation Assistance If you experience a problem within the first 24 hours of installation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running United States or Canada 1 440 646 3434 Outside United States or Canada Use the Worldwide Locator at http www rockwellautomation com support americas phone_en html or contact your local Rockwell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned follow these procedures United States Contact your distributor You must provide a Customer Support case number call the phone number above to obtain one to your distributor to complete the return process Outside United States Please contact your local Rockwell Automation representative for the return procedure Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document complete this form publication RA DU002 available at http www rock
27. ure Occurs 13 Chapter 3 Access Drive Control Pod 0 cece cece cece ence ee eeeaes 16 Configure Safety EMableindsvinwalee ss abou is ah oe Mae satis elas 20 Option Module Insrallition 5234 p2crioge sheet tesciete 23 WAID Sat sarge aay arg bg TAE idea AE A a as 24 Verify Operations seien Sood eer tee ti pei eee Ea SaS 25 Chapter 4 PowerFlex 750 Series Safe Torque Off Operation 4 27 Appendix A ctairarai bree ey aetna na main et greens Teed en Cer or ee retin A ea a reer a 33 General Specification Sare reisen ators cect Soares ata o E e alaa 33 Environmental Specifications s esseesesreerrrrrrrrrrrrree 34 Certifications ssi i EEEE A E EEE 35 CE Conformity sieas reo aa A AE AAE EEE EERENS 35 Rockwell Automation Publication 750 UM002E EN P February 2012 5 Table of Contents 6 Rockwell Automation Publication 750 UM002E EN P February 2012 What Is the PowerFlex 750 Series Safe Torque Off Option Chapter 1 General Description The 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 operational safety The PowerFlex 750 Series 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 necessar
28. wellautomation com literature Rockwell Otomasyon Ticaret A S Kar Plaza Is Merkezi E Blok Kat 6 34752 erenk y stanbul Tel 90 216 5698400 www rockwellautomation com Power Control and Information Solutions Headquarters 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 NV 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 Publication 750 UM002E EN P February 2012 Supersedes Publication 750 UM002C EN P September 2011 Copyright 2012 Rockwell Automation Inc All rights reserved Printed in the U S A
29. y to generate AC power to the motor e Can be used in combination with other safety devices to satisfy the requirements of IEC 61508 IEC 61800 5 2 SIL 3 ISO 13849 1 PL e and Category 3 EN 954 1 for Safe Torque Off STO 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 in accordance with the requirements of ANSI NFPA 70 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 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 PowerFlex 750 Series 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 th
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