Rockwell Automation 20-750-ATEX User Manual
User Manual
PowerFlex 750-Series ATEX Option Module
Catalog Number 20-750-ATEX
Original Instructions
Important User Information
IMPORTANT
Read this document and the documents listed in the additional resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to
familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws,
and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required
to be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be
impaired.
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 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 consequence.
Identifies information that is critical for successful application and understanding of the product.
Labels may also be on or inside the equipment to provide specific precautions.
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.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).
Allen-Bradley, Rockwell Software, Rockwell Automation, PowerFlex, and TechConnect are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Table of Contents
Preface
Safety Concepts
Installation and Wiring
What Is the PowerFlex 750-Series ATEX Option Module? . . . . . . . . . . . . 5
Catalog Numbers for ATEX and 11-Series I/O Option Modules . . . . . . 5
Catalog Numbers for Spare Terminal Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ATEX Directive 94/9/EC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Motor Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Chapter 1
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ATEX Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Thermostat Trip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Positive Temperature Coefficient (PTC) Trip . . . . . . . . . . . . . . . . . . 10
Risk Assessment Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safe State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Hardware Fault Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety Reaction Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Contact Information If Safety Option Failure Occurs . . . . . . . . . . . . . . . 12
Chapter 2
Perform a Risk Assessment of the Operational Environment. . . . . . . . . 13
Perform a Safety Analysis of the Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Access the Drive Control Pod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Remove the Drive Cover for Frame 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Remove the Drive Cover for Frames 2…5. . . . . . . . . . . . . . . . . . . . . . . 15
Remove the Drive Cover for Frames 6 and 7 . . . . . . . . . . . . . . . . . . . . 16
Remove the Drive Cover for Frames 8…10. . . . . . . . . . . . . . . . . . . . . . 17
Configure the Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
S1 Switch Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Safety Enable Jumper Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
ATEX Option Module and 11-Series I/O Option Module
without a Safety Option Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ATEX Option Module and 11-Series I/O Option Module
with a Safety Option Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Assemble the ATEX and 11-Series I/O Option Modules . . . . . . . . 21
Connect the Thermal Sensor Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Cabling Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installation Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Install the ATEX Option Module Assembly. . . . . . . . . . . . . . . . . . . . . . . . 23
Safe Torque-off Option Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Connecting the ATEX Option with a
Safe Torque-off Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Safe Speed Monitor Option Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Connecting the ATEX Option with a
Safe Speed Monitor Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Reset the Drive after an SSM Fault Detection . . . . . . . . . . . . . . . . . . . . . . 27
Interface Without a Safety Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Rockwell Automation Publication 750-UM003B-EN-P - July 2013 3
Table of Contents
Chapter 3
Verify Operation
ATEX Monitoring
Specifications and Certifications
Index
Verify Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Description of Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Motors with Thermostatic Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Functional Proof Testing for Systems with Thermostat Contacts . 30
Motors with Positive Temperature Coefficient (PTC) Devices. . . . . . . 30
Functional Proof Testing for Systems with PTC Devices. . . . . . . . . 31
Over-temperature Functional Proof Test . . . . . . . . . . . . . . . . . . . . . . . 31
Short-circuit Functional Proof Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Functional Proof Testing Without a Test Fixture . . . . . . . . . . . . . . . . . . . 32
Chapter 4
Parameter 41 [ATEX Sts] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
ATEX Fault Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
ATEX Configuration Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Restart the Drive after an Over-temperature Fault. . . . . . . . . . . . . . . . . . . 35
Appendix A
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
11-Series I/O Option Module Terminal Block Specifications . . . . . . . . 37
Environmental Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4 Rockwell Automation Publication 750-UM003B-EN-P - July 2013
Preface
IMPORTANT
The PowerFlex® 750-Series ATEX option module and the 11-Series I/O option
module for PowerFlex 750-Series AC Drives are safety system components of the
equipment and protective systems intended for use in potentially explosive
atmospheres (ATEX). Perform a risk assessment and safety analysis of the
operating atmosphere and the ATEX system components (PowerFlex 750-Series
drive, motor, ATEX option module, and 11-Series I/O option module) before
you begin this ATEX installation. See Installation and Wiring on page 13
Read and understand this user manual before you begin to design and install
your ATEX system.
.
What Is the PowerFlex 750-Series ATEX Option Module?
Catalog Numbers for ATEX and 11-Series I/O Option Modules
The ATEX option module with the 11-Series I/O option module enables a
PowerFlex 750-Series drive to be used in ATEX installations. The ATEX option
module helps to eliminate the risk of explosion due to an over-temperature
condition in an ATEX approved motor. In an ATEX installation, the motor is
installed in a potentially explosive atmosphere, while the drive is installed outside
of the potentially explosive atmosphere. See Figure 1 on page 9
WARNING: Risk of Explosion.
Do not install the PowerFlex 750-Series drive in a potentially explosive
atmosphere.
A drive installed in a potentially explosive atmosphere can cause an explosion.
This table lists the catalog numbers for the ATEX option module and the
compatible 11-Series I/O option modules.
ATEX Option Module Cat. No. 11-Series I/O Option Module Cat.
20-750-ATEX
No.
20-750-1132D-2R 115V AC digital input
20-750-1133C-1R2T 24V DC digital input
20-750-1132C-2R 24V DC digital input
.
Description
2 relay outputs, digital
2 transistor, 1 relay outputs, digital
2 relay outputs, digital
Catalog Numbers for Spare Terminal Plugs
This table contains the catalog numbers for the 11-Series I/O option module
spare terminal plug kits.
Cat. No. Spare Terminal Plug Kit
SK-R1-SCRWTB-EIO Screw-down terminal plugs spare kit (set of three)
SK-R1-SPRGTB-EIO Spring-clamp terminal plugs spare kit (set of three)
Rockwell Automation Publication 750-UM003B-EN-P - July 2013 5
Preface
ATEX Directive 94/9/EC
The PowerFlex 750-Series drives, together with the ATEX and 11-Series I/O
option modules, are compliant safety devices under the ATEX directive
94/9/EC, and satisfy requirements for use in Group II, Category 2, (GD)
applications with ATEX approved motors as described below:
• Group II – The motor is installed in a potentially explosive atmosphere
that is not in a mine.
• Category 2 – The motor is likely to be exposed to an explosive atmosphere.
A high level of protection is required.
• GD – The explosive atmosphere consists of a mixture of (G) gas vapors and
(D) dust that can cause an explosion.
Certification of the drive for the ATEX group and category on its nameplate is
based on installation, operation, and maintenance according to this user manual
and to the requirements found in the drive user manual and installation
instructions, and the instruction manual for the motor.
ATT EN TI ON : In addition to the procedures in the standard installation and user
manuals for the ATEX certified drive with an ATEX certified motor, you must
follow all additional instructions in this PowerFlex 750-Series ATEX Option
Module User Manual. Equipment damage and/or personal injury can result if all
additional instructions in this user manual are not followed.
6 Rockwell Automation Publication 750-UM003B-EN-P - July 2013
Preface
FLAMEPROOF Exd ENCLOSURE
EExd I/IIB Tamb C to C
II 2 G/D
I M2 Sira ATEX
MFG. BY ROCKWELL AUTOMATION
0518
Motor Requirements
• The motor must be manufactured under the guidelines of the ATEX
directive 94/9/EC. The motor must be installed, operated, and
maintained according to the instructions of the motor manufacturer.
• Only motors with nameplates marked for use on an inverter power source,
and labeled for specific hazardous areas, can be used in hazardous areas on
inverter (variable frequency) power.
• When the motor is rated ATEX Group II, Category 2 for use in gas
environments (category 2G), the motor must be of flameproof
construction, EEx d (according to EN 50018) or Ex d (according to
EN 60079-1 or IEC 60079-1). Group II motors are marked with a
temperature or a temperature code.
• When the motor is rated ATEX Group II, Category 2 for use in dust
environments (category 2D), the motor must be protected by an enclosure
(according to EN 50281-1-1, or according to
IEC 61241-1: Ex tD). Group II motors are marked with a temperature.
• The motor over-temperature signal is supplied to the drive by one of two
methods:
– A normally closed contact (open during over temperature condition)
compatible with the digital (logic) input circuitry of the drive. If
multiple sensors are required in the motor, the connection at the drive
must be the result of all required contacts wired in series.
– A positive temperature coefficient (PTC) type of thermal sensor. Refer
to Appendix A
for specifications.
• Refer to all product markings for additional cautions.
• Typical motor markings are contained on a motor certification nameplate
similar to the sample below.
Rockwell Automation Publication 750-UM003B-EN-P - July 2013 7
Preface
Additional Resources
These documents contain additional information concerning related products
from Rockwell Automation.
Resource Description
PowerFlex 750-Series AC Drives Installation Instructions,
publication 750-IN001
PowerFlex 750-Series AC Drives Programming Manual,
publication 750-PM001
PowerFlex 750-Series AC Drives Technical Data,
publication 750-TD001
PowerFlex 750-Series Safe Torque Off User Manual,
publication 750-UM002
Safe Speed Monitor Option Module for PowerFlex
750-Series AC Drives Safety Reference Manual,
publication 750-RM001
Industrial Automation Wiring and Grounding Guidelines,
publication 1770-4.1
Product Certifications website, http://www.ab.com Provides declarations of conformity, certificates, and other
Provides detailed information for installing the drive.
Provides detailed information on the following:
• I/O, control, and feedback options
• Parameters and programming
• Faults, alarms, and troubleshooting
Provides detailed information on the following:
• Drive specifications
• Option specifications
• Fuse and circuit breaker ratings
Provides information for the safe torque-off option that
can be used as a component in a safety control system.
Provides information for the safe speed monitor option
that can be used as a component in a safety control
system.
Provides general guidelines for installing a Rockwell
Automation® industrial system.
certification details.
You can view or download publications at
http://www.rockwellautomation.com/literature/
. To order paper copies of
technical documentation, contact your local Allen-Bradley distributor or
Rockwell Automation sales representative.
8 Rockwell Automation Publication 750-UM003B-EN-P - July 2013
Safety Concepts
PowerFlex 750-Series Drive
Power to the Motor
Thermal Sensor Input to the Drive
Poten tially Expl osive At mosphere
ATEX Certified Motor
Chapter 1
Introduction
The PowerFlex 750-Series ATEX option module, installed in a PowerFlex
750-Series drive equipped with an 11-Series I/O option module, provides an
ATEX compliant safety function. This ATEX compliant function provides a safe
turn-off for equipment installed in a potentially explosive atmosphere according
to European Council Directive 94/9/EC.
The overall system includes an ATEX certified motor installed in a potentially
explosive atmosphere. The motor is equipped with a thermal sensor connected to
the ATEX option input. Do not install the drive in a potentially explosive
atmosphere. See Figure 1
WARNING: Risk of Explosion.
Do not install the PowerFlex 750-Series drive in a potentially explosive
atmosphere.
A drive installed in a potentially explosive atmosphere can cause an explosion.
Figure 1 - Basic ATEX Application
.
The ATEX option module monitors the thermal sensor in the motor. When the
thermal sensor reaches its trip point, the drive initiates a safe torque-off function
and removes torque-producing power from the motor. The ATEX safety
function has a safety integration level (SIL) capability limit of 1 according to
IEC 61508.
Rockwell Automation Publication 750-UM003B-EN-P - July 2013 9
Chapter 1 Safety Concepts
ATEX+
ATEX–
High Voltage
Possible
Isolation Safe Low Voltage
EnC
EnNOThermal
Sensor Type
Switch
Safety
Configuration
Switch
Latch
Relay Driver
Safe Shutdown
Signal
Reset Signal
Or
Field wiring to thermal sensor.
See Connect the Thermal
Sensor Wires on page 22.
Safety configuration switch to configure the
safety path for use with a safety option. See
Configure the Hardware on page 18.
Terminals EnC and EnNO must be wired correctly
when a safety option is present in the drive. See the
important statements on page 25 and page 26.
ATEX trip signals pass through an
isolation barrier to protect the drive
in case of a motor insulation fault.
See ATEX Monitoring on page 33
.
Thermal sensor-type switch selects
between PTC and thermostatictype thermal sensors. See S1 Switch
Location on pa ge 18.
An ATEX trip latches the drive into a
safe state until a reset sequence takes
place. See Restart the Drive after an
Over-temperature Fault on page 35.
For installations that do not have the safe
torque-off or safe speed monitor safety opti ons
present, the ATEX safety function uses the
safety signal on the backplane. See Interface
Without a Safety Option on page 27.
ATEX Function
The PowerFlex 750-Series ATEX option module can be configured to support
ATEX certified motors equipped with either a thermostat or a PTC-type
thermal sensor.
ATT EN TI ON : Risk of electric shock. If a motor insulation fault occurs, high
voltage can be present at the ATEX terminal block and wiring. Be sure that all
drive covers are installed when power is applied to the drive.
Thermostat Trip
When the circuit is configured to trip with a thermostat, the ATEX option
module supports a normally-closed, dry-contact thermostat. The safe off
function initiates when the ATEX option module detects that the contact is
open. This can be the result of a broken wire, or an over-temperature condition in
the motor.
Positive Temperature Coefficient (PTC) Trip
When the circuit is configured to trip with a PTC-type thermal sensor, the
ATEX option module supports sensors with characteristics according to
DIN 44081/DIN 440. The ‘Mark A’ measuring circuit on the ATEX option
module is designed in accordance to IEC 60947-8 or EN 60947-8. This circuit
trips when the motor temperature has reached its trip point, or an open-wire/
short-circuit condition is detected in the sensor circuit.
10 Rockwell Automation Publication 750-UM003B-EN-P - July 2013
Loss of voltage to the measuring circuit also initiates the safe off function. This
voltage is sourced internally by the ATEX option module.
Figure 2 - ATEX Circuitry
Safety Concepts Chapter 1
IMPORTANT
IMPORTANT
Risk Assessment Data
The PFD and PFH values in Ta b l e 1 were calculated based on equations in
IEC 61508. This table shows the worst case calculated values for drive frames
1…10 with a proof test interval of 20 years.
A proof test is not defined in this user manual. A proof test interval of 20 years
is used for the calculations here, signifying the product life span is 20 years.
These values show the SIL1 consumption of the ATEX safety function to be
approximately 30%. The safety calculations represent the local ATEX safety path
from the input of the ATEX daughter card to the device that disables
heat-producing power.
Table 1 - PFD and PFH for 20-year Proof Test Interval for Frames 1…10
Attribute Value
Safety integrity level (SIL) 1
Hardware fault tolerance (HFT) 0
Proof test inter val (PTI) 20
Probability of failure on demand (PFD) <3.09E-02
Probability of failure per hour (PFH) <3.53E-07
Safe State
Hardware Fault Tolerance
Safety Reaction Time
The safe state includes all operation that occurs outside of the other monitoring
and stopping behavior defined as part of the ATEX option module. The ATEX
safety function, as provided by the ATEX option module, places the drive in a
safe state by removing the power from the gate firing circuits of the output power
devices (IGBTs).
Hardware fault tolerance is the minimum number of faults that can cause a loss of
the safety function as defined by IEC 61508-2. The overall ATEX function has a
hardware fault tolerance of zero.
If one fault occurs in the safety path, the safety function can become
compromised.
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 trigger to the initiation of the
ATEX safety function is 30 ms (maximum) for PowerFlex 750-Series drives,
frames 1…10.
Rockwell Automation Publication 750-UM003B-EN-P - July 2013 11
Chapter 1 Safety Concepts
Contact Information If Safety Option Failure Occurs
If you experience a failure with any safety-certified device, contact your local
Rockwell Automation distributor to do the following:
• 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.
• Request a failure analysis (if necessary) to determine the probable cause of
the failure.
12 Rockwell Automation Publication 750-UM003B-EN-P - July 2013
Chapter 2
Installation and Wiring
You must follow the installation steps described in this installation and wiring
section. The installation and wiring steps must be performed by qualified drive
installation personnel. The PowerFlex 750-Series ATEX option module with an
11-Series I/O module are part of an ATEX safety control system.
ATT EN TI ON : Only qualified personnel familiar with adjustable frequency AC
drives and associated machinery should plan or implement the installation,
start-up, and subsequent maintenance of the system. Failure to comply may
result in personal injury and/or equipment damage.
ATT EN TI ON : The following information is 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. Personal injury and/or equipment damage can
occur if codes are ignored during installation.
Perform a Risk Assessment of the Operational Environment
Perform a Safety Analysis of the Motor
Access the Drive Control Pod
Before you begin the installation, perform a risk assessment to compare the
ATEX option specifications with the potentially explosive atmosphere where you
want to install the system. See Safety Concepts on page 9
The ATEX safety system includes the thermal sensor in the motor and the wiring
to the ATEX daughter card. Ve ri fy Op er ati on on p ag e 29
functionally test the system from the input to the ATEX daughter card, but these
tests do not verify the thermal sensor response or the wiring from the motor.
Follow the motor manufacturer's recommendations for safe use of the motor in
ATEX installations and possible functional test procedures.
Different frame sizes have different ways to access the control pod. Follow the
steps for your frame size to access the control pod:
• Remove the Drive Cover for Frame 1 on page 14
• Remove the Drive Cover for Frames 2…5 on page 15
• Remove the Drive Cover for Frames 6 and 7 on page 16
.
gives methods to
• Remove the Drive Cover for Frames 8…10 on page 17
Rockwell Automation Publication 750-UM003B-EN-P - July 2013 13
Chapter 2 Installation and Wiring
Remove the Drive Cover for Frame 1
Follow the steps in this section to remove the drive cover for frame 1.
1. Squeeze the locking tabs and pull out the bottom of the cover.
2. Pull the cover down and away from the chassis.
3. Lift the chassis cover.
a. Loosen the retention screw.
b. Use a screwdriver to release the chassis-cover locking tabs.
c. Lift the chassis until the latch engages.
14 Rockwell Automation Publication 750-UM003B-EN-P - July 2013
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