Rockwell Automation 20C-DG01 User Manual
User Manual
PowerFlex 700H AC Drive Safe Torque Off Option
Catalog Number 20C-DG01
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
your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/
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 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.
available from
) describes some
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.
IMPORTANT
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.
Identifies information that is critical for successful application and understanding of the product.
Summary of Changes
This manual contains new and updated information.
New and Updated Information
This table contains the changes made to this revision.
Topic Page
All instances of the term “Safe-Off” are changed to the term “Safe
Torque Off”
Added applicable machinery safety standards to Safety and
Machinery Standards.
Removed Safety Certificate Examples and provided new link to
online certificates.
Added new Important Safety Considerations section. 9
Added new PL d/Category 3 Performance Definition section. 10
Added new Stop Category Definitions section. 10
Added new System Performance Level and Safety Integrity Level
(SIL) section.
Added new PFD and PFH Definitions section. 11
Added new PFD and PFH Data section. 12
Added an Index. 25
Throughout
manual
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8
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Rockwell Automation Publication 20C-UM001B-EN-P - June 2011 3
Summary of Changes
4 Rockwell Automation Publication 20C-UM001B-EN-P - June 2011
Table of Contents
Summary of Changes
Overview
Installation and Wiring
New and Updated Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Chapter 1
What is the Safe Torque Off Option?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety of Machinery Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Certified Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Certifications Online . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Important Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
PL d/Category 3 Performance Definition . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Stop Category Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
System Performance Level and Safety Integrity Level (SIL) . . . . . . . . . . 11
PFD and PFH Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
PFD and PFH Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Functional Proof Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Contact Information if Safety Option Failure Occurs . . . . . . . . . . . 12
Chapter 2
Safe Torque Off Option Board Installation. . . . . . . . . . . . . . . . . . . . . . . . . 14
Wire the Safe Torque Off Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fault/Alarm Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Installation Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Verify Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Safe Torque Off Option Board (20C-DG01) Removal . . . . . . . . . . . . . . 23
Index
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Rockwell Automation Publication 20C-UM001B-EN-P - June 2011 5
Table of Contents
6 Rockwell Automation Publication 20C-UM001B-EN-P - June 2011
Chapter
1
Overview
The PowerFlex 700H control board, 24V DC Digital Input with Analog I/O
(20C-DA1-A) board, and the Safe Torque Off option board (20C-DG01), when
used with other safety components, helps provide a hardware-based safe torque
off to prevent torque on the motor shaft.
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 operator safeguarding.
What is the Safe Torque Off Option?
The Safe Torque Off option is designed to 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 sequence necessary to
generate torque in the motor.
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 de-energized and locked out or tagged out 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 completely before servicing. Check 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 be zero for all
three measurements.
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.
Rockwell Automation Publication 20C-UM001B-EN-P - June 2011 7
Chapter 1 Overview
Safety of Machinery Standards
Certified Equipment
The Safe Torque Off option is compliant with the following safety standards:
• EN 60204-1:2006 Safety of Machinery – Electrical equipment of
machines – Part 1: General Requirements
• EN ISO 13849-1:2008 Safety of Machinery – Safety-related parts of
control systems - Part 1: General Principles for Design
• EN ISO 13849-2:2003 Safety of Machinery – Safety-related parts of
control systems – Part 2: Validation
• EN 61800-5-2:2007 Adjustable Speed Electrical Power Drives Systems –
Part 5-2 Safety Requirements: Functional
• EN 62061:2005 Safety of Machinery, Functional safety of safety-related
electrical, electronic and programmable electronic control systems
• IEC 61508 Parts 1…7: 1998 and 2000 Functional Safety of electrical/
electronic/programmable electronic control systems
The Safe Torque Off option for the following PowerFlex 700H AC drives has
been evaluated to meet the safety parameters for SIL 2 according to IEC 61508
and PL d/category 3 according to EN ISO 13849-1.
• 400/480V Frames 9-14
• 600/690V Frames 9-14
Note: The TUV certification stamp is only included on the drive data nameplate
label when the Safe Torque Off option board is factory installed.
Certifications Online
See the Product Certifications link at http://ab.com for Declarations of
Conformity, Certificates, and other certifications details.
8 Rockwell Automation Publication 20C-UM001B-EN-P - June 2011
Overview Chapter 1
Important Safety Considerations
The system user is responsible for:
• the set-up, safety rating, and validation of any sensors or actuators
connected to the system.
• 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.
• project management and proof testing.
• programming the application software and the safety option
configurations in accordance with the information in this manual.
• access control to the system, including password handling.
• 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.
ATTENTION: When designing your system, consider how personnel will
exit the machine if the door locks while they are in the machine.
Additional safeguarding devices may be required for your specific
application.
Rockwell Automation Publication 20C-UM001B-EN-P - June 2011 9
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