Rockwell Automation 20D-P2-ENCO User Manual
User Manual
Safe Torque Off Option for
PowerFlex 700S Phase II AC Drives and
PowerFlex 700L Liquid-Cooled AC Drives
Catalog Number 20D-P2-DG01
Original Instructions
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
Rockwell Automation sales office or online a
t 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 this manual.
Reproduction of the contents of this manual, in whole or in part, without written
permission of Rockwell Automation, Inc. is prohibited.
Throughout this manual, when necessary we use notes to make you aware of safety
considerations.
WARNING: Identifies information about practices or
circumstances that can cause an explosion in a hazardous
environment, which may lead to personal injury or death, property
damage, or economic loss.
ATTENTION: Identifies information about practices or
circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard,
avoid a hazard, and recognize the consequences.
available from your local
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
Identifies information that is critical for successful application and
understanding of the product.
Allen-Bradley, Rockwell Software, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Summary of Changes
This manual contains new and updated information.
New and Updated Information
The following changes apply to this revision of the manual.
Change See Page…
Added “Original Instructions” to the front cover. –
Updated the Important statement regarding the proper use of the Safe
Torque Off option.
Updated the information in the Evaluation/Certification by TÜV Rheinland
Group table to support frame 5 and 6 and frames 9…14 drives.
Updated the information in the PFD and PFH for 20-year Proof Test
Interval table to support frame 9…14 drives.
Added steps for installing the Safe Torque Off option board in frame
9…14 drives.
Added frames 9…14 drives to wiring diagram example 2. 32
7
9
12
17
Rockwell Automation Publication 20D-UM007G-EN-P - March 2012 3
Summary of Changes
4 Rockwell Automation Publication 20D-UM007G-EN-P - March 2012
Chapter 1 General Description
What Is the DriveGuard Safe Torque Off Option? . . . . . . . . . . . . . . . 7
Safety of Machinery Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Safety Certifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Evaluation/Certification by TÜV Rheinland Group . . . . . . . . . . 9
Certifications Online. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Important Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Safety Category 3 Performance Definition . . . . . . . . . . . . . . . . . . . . . 11
Stop Category Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Performance Level and Safety Integrity Level (SIL) CL2. . . . . . . . . 12
PFD and PFH Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PFD and PFH Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PFD and PFH for 20-year Proof Test Interval . . . . . . . . . . . . . . . 12
Functional Proof Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Contact Information if Safety Option Failure Occurs . . . . . . . . . . . 13
Chapter 2 Installation and Wiring
Pre-Installation Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Option Board Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
PowerFlex 700S Frames 1…6 and PowerFlex 700L Frames
3A and 3B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
PowerFlex 700S Frames 9…14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
PowerFlex 700S, All Frames, and PowerFlex 700L, Frame 3 . . . 18
PowerFlex 700S Frames 1…6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
PowerFlex 700S Frames 9…14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
PowerFlex 700L Frames 3A and 3B . . . . . . . . . . . . . . . . . . . . . . . . . 24
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Configure Hardware Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Configure Digital Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Linking Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Verify Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Table of Contents
Rockwell Automation Publication 20D-UM007G-EN-P - March 2012 5
Table of Contents
Chapter 3 Description of Operation
DriveGuard Safe Torque Off Operation. . . . . . . . . . . . . . . . . . . . . . . . 29
Connection Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Example 1 - PowerFlex 700S Drives, Frames 1…6
Safe Torque Off Connection with Coast-to-Stop Action, Dual
Channel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Example 2 - PowerFlex 700S Drives, Frames 9…14 and PowerFlex
700L Drives, Frames 3A and 3B
Safe Torque Off Connection with Coast-to-Stop Action, Dual
Channel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Example 3 - All Drives
Safe Torque Off Connection with Controlled Stop Action, Dual
Channel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Index
6 Rockwell Automation Publication 20D-UM007G-EN-P - March 2012
Chapter 1
General Description
The DriveGuard Safe Torque Off option, when used with other safety
components, helps provide protection to meet the requirements for SIL CL2
and Category 3 or PL d class applications. Safety requirements are based on
the standards current at the time of certification.
The DriveGuard Safe Torque Off option is just one component in a safety
control system. Components in the system must be chosen and applied
appropriately to achieve the desired level of operator safeguarding.
What Is the DriveGuard Safe Torque Off Option?
The DriveGuard Safe Torque Off option:
• Is designed to help safely remove power from the gate firing circuits of the
drive’s output power devices (IGBT’s). This helps prevent the drive’s
output power devices from switching in the pattern necessary to generate
rotation at the motor.
• Can be used in combination with other safety devices to satisfy the Safe
Torque Off requirements of SIL CL2, according to EN 61800-5-2,
IEC 61508, and EN 62061 Performance Level PL d and Category 3
according to EN ISO 13849-1.
IMPORTANT
Rockwell Automation Publication 20D-UM007G-EN-P - March 2012 7
This option is suitable for performing mechanical work on the drive
system or affected area of a machine only. It does not provide
electrical safety. For electrical maintenance on the drive and/or motor,
equipment must be electrically disconnected from the power source.
The Safe Torque Off option should not be used for non safety-related
stopping of the drive.
Chapter 1 General Description
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 before performing any work on
the drive. Measure the DC bus voltage at the +DC and -DC terminals or
test points (refer to your drive’s User Manual for locations). The voltage
must be zero.
ATTENTION: In Safe Torque Off mode, hazardous voltages may still be
present at the motor. To avoid an electric shock hazard, disconnect
power to the motor and verify that the voltage is zero before
performing any work on the motor.
ATTENTION: In the event of the failure of two output IGBTs in the
drive, when the DriveGuard Safe Torque Off option has controlled the
drive outputs to the off state, the drive may provide energy for up to
180° of rotation in a 2-pole motor before torque production in the
motor ceases.
Safety of Machinery Standards
The DriveGuard Safe Torque Off option meets the following council
directives and the requirements of the following machine safety standards:
• EN 61800-5-2:2007 Adjustable Speed Electrical Power Drives Systems –
Part 5-2 Safety Requirements: Functional
• EN ISO 13849-1:2008 Safety of Machinery – Safety-related parts of
control systems - Part 1: General Principles for Design
• EN 62061:2005 Safety of Machinery, Functional safety of safety-related
electrical, electronic and programmable electronic control systems
• EN 60204-1:2006 Safety of Machinery – Electrical equipment of
machines – Part 1: General Requirements
• IEC 61508 Part 1-7:1998, 2000, and 2010 Functional safety of electrical
/ electronic / programmable electronic safety-related systems
8 Rockwell Automation Publication 20D-UM007G-EN-P - March 2012
General Description Chapter 1
Safety Certifications
The TÜV Rheinland group has approved the DriveGuard Safe Torque Off
option for use in safety-related applications where the de-energized state is
considered to be the safe state. All of the examples related to I/O included in
this manual are based on achieving de-energization as the safe state for typical
Machine Safety and Emergency Shutdown (ESD) systems.
Evaluation/Certification by TÜV Rheinland Group
Drive Rating
PowerFlex 700S
Phase II
PowerFlex 700L
Liquid-Cooled
208/240V and 400/480V
Frames 1…6
600/690V Frames 5 and 6
400/480V and 600/690V
Frames 9…14
400/480V and 600/690V
Frames 3A and 3B
TUV Report on Safety Function & TUV
Certification
TUV Certificate No. 01/205/5195/12
TUV Report No. 968/EZ 189.01/09
TUV Certificate No. 01/205/5195/12
TUV Report No. 968/EZ 189.02/12
TUV Report and Certificate No.
968/EZ 230.00/06
TUV Certificate No. 01/205/0667/09
TUV Report No. 968/EZ 230.02/09
Certifications Online
See the Product Certifications link at http://ab.com for Declarations of
Conformity, Certificates, and other certifications details.
Rockwell Automation Publication 20D-UM007G-EN-P - March 2012 9
Chapter 1 General Description
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.
10 Rockwell Automation Publication 20D-UM007G-EN-P - March 2012
General Description Chapter 1
Safety Category 3 Performance Definition
To achieve Safety Category 3 according to EN ISO 13849-1:2008, the
safety-related parts have to be designed such that:
• the safety-related parts of machine control systems and/or their protective
equipment, as well as their components, shall be designed, constructed,
selected, assembled, and combined in accordance with relevant standards
so that they can withstand expected conditions.
• well tried safety principles shall be applied.
• a single fault in any of its parts does not lead to a loss of safety function.
• some but not all faults will be detected.
• the accumulation of undetected faults can lead to loss of safety function.
• short circuits in the external wiring of the safety inputs is not one of the
faults that can be detected by the system, therefore, according to DIN EN
ISO 13549-2, these cables must be installed so as to be protected against
external damage by cable ducting or armor.
Stop Category Definitions
The selection of a stop category for each stop function must be determined by
a risk assessment.
• Stop Category 0 is achieved with immediate removal of power to the
actuator, resulting in an uncontrolled coast to stop. See “Description of
Operation” Example 1 on page 31
• Stop Category 1 is achieved with power available to the machine actuators
to achieve the stop. Power is removed from the actuators when the stop is
achieved. See “Description of Operation” Example 3 on page 33
IMPORTANT
Rockwell Automation Publication 20D-UM007G-EN-P - March 2012 11
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.
and Example 2 on page 32.
.
Chapter 1 General Description
Performance Level and Safety Integrity Level (SIL) CL2
For safety-related control systems, Performance Level (PL), according to
EN ISO 13849-1, and SIL levels, according to IEC 61508 and EN 62061,
include a rating of the system’s ability to perform its safety functions. All of
the safety-related components of the control system must be included in both
a risk assessment and the determination of the achieved levels.
Refer to the EN ISO 13849-1, IEC 61508, and EN 62061 standards for
complete information on requirements for PL and SIL determination.
PFD and PFH Definitions
Safety-related systems can be classified as operating in either a Low Demand
mode, or in a High Demand/Continuous mode.
• 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.
• High Demand/Continuous mode: where the frequency of demands for
operation made on a safety-related system is greater than once per year or
greater than twice the proof test interval.
The SIL value for a Low Demand safety-related system is directly related to
order-of-magnitude ranges of its average probability of failure to satisfactorily
perform its safety function on demand or, simply, average probability of
failure on demand (PFD). The SIL value for a High Demand/Continuous
mode safety-related system is directly related to the probability of a dangerous
failure occurring per hour (PFH).
PFD and PFH Data
These PFD and PFH calculations are based on the equations from Part 6 of
IEC 61508 and show worst-case values.
This table provides data for a 20-year proof test interval and demonstrates the
worst-case effect of various configuration changes on the data.
PFD and PFH for 20-year Proof Test Interval
Attribute Test Result Frames 1…6 Test Result Frames 9…14
PFD
av
PFH 6.00 x 10
MTTF
D
DC
av
12 Rockwell Automation Publication 20D-UM007G-EN-P - March 2012
-5
5.28 x 10
-10
(calculated according to IEC 61508)
High (4023 years) High (11415 years)
low (69%) low (80%)
1/h
-4
2.14 x 10
2.64 x 10-9 1/h
(calculated according to IEC 61508)
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