Rockwell Automation Allen-Bradley 35E User Manual Download Page 28

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Rockwell Automation Publication 35-UM001A-EN-P - May 2022

Chapter 1 Armor PowerFlex Variable Frequency Drives Overview

Typical Configurations

Armor PowerFlex drives can be configured for standard or safety applications.

Standard Configuration

The Armor PowerFlex standard drive (35E) can be applied in systems where
safety functions are not required.

Figure 6 - Standard Drives Configuration

Configurable I/O - 0,1

Input - 0,1

Input - 2,3

Configurable I/O - 0,1

Input - 0,1

Input - 2,3

Main Power

Circuit

Protection

EtherNet/IP (supports DLR)

120V AC

24V DC

Encoder

24V DC Power Supply

3-phase Power

Armor PowerFlex Drive (35E)

Ethernet cable

Ethernet

Management

Switch

Programmable

Controller

Note

: Adapter cables are available to connect the Armor PowerFlex X-code Ethernet port to a

D-code 10/100 Ethernet port. For cable selection, see the On-Machine Media for Armor
PowerFlex, ArmorStart, and ArmorConnect Products Selection Guide, publication

280PWR-SG001

Summary of Contents for Allen-Bradley 35E

Page 1: ...ves Bulletins 35E 35S This manual links to Armor PowerFlex AC Drive Fault Codes Reference Data publication 35 RD002 and to Armor PowerFlex AC Drive CIP Objects and Attributes Reference Data publication 35 RD001 download the spreadsheet now for offline access ...

Page 2: ...u aware of safety considerations These labels may also be on or inside the equipment to provide specific precautions The following icon may appear in the text of this document Rockwell Automation recognizes that some of the terms that are currently used in our industry and in this publication are not in alignment with the movement toward inclusive language in technology We are proactively collabor...

Page 3: ...nd Outputs 15 Frame Size 16 Safety Functions 16 Location of Features 17 Catalog Number Explanation 18 Required Software 18 Motor Control 19 Control Modes 19 Volts Hertz 19 Sensorless Vector 20 Velocity Vector 20 Velocity Control 20 Flying Start 21 Load Monitor 21 Motor Thermal Overload 22 Velocity Skip Band 22 Fault Auto Reset 23 Safe Torque Off and Safe Monitor Functions 23 Hardwired Safe Torque ...

Page 4: ...iderations 43 Unshielded Motor Cable 44 Power Considerations 44 Branch Circuit Protection Requirements 44 Group Motor Installations for USA and Canada Markets 45 Auxiliary Power Connections 45 Power Supply Requirements 46 Internal Power Supply Wiring and Local Disconnect Behavior 47 Single External Power Supply Wiring and Local Disconnect Behavior 47 Multiple External Power Supply Wiring and Local...

Page 5: ...ndard Input Internal Wiring Diagram 78 Standard Input Wiring Examples 78 Configurable I O Operation 79 Configured Fault Actions 79 Configurable I O Internal Wiring Diagram Output 79 Standard Output Wiring Examples 80 Standard I O Wiring Example 80 Chapter 6 Safety Functions Safety Considerations 82 Stop Category Definitions 83 Performance Level PL and Safety Integrity Level SIL 83 Proof Tests 83 P...

Page 6: ...med Safe Stop 1 102 Timed Safe Stop 1 Operation 102 Monitored Safe Stop 1 103 Monitored Safe Stop 1 Operation 103 Safe Brake Control Function 105 Safe Brake Control Activation 105 Safe Brake Control Reset 106 Safe Brake Control Modes 107 Not Used 107 Used No Test Pulses 107 Used Test Pulses 107 STO Activates SBC Operation 108 SBC Safety Fault 109 Connecting a Safety Brake 110 Safety Feedback 111 S...

Page 7: ...put Status Data 126 Safety Input Status 127 Safety Input Value 127 Safety Input Valid 128 Safety Input Alarms 129 Configuration Error 129 Circuit Error 129 Discrepancy and Dual Channel Errors 129 Determining Safety Input Alarm Type 130 Safety Input Alarm Recovery 130 Safety Output Operation 130 Safety Output Features 131 Dual channel Mode Safety Outputs 131 Safety Output with Test Pulse 132 Safety...

Page 8: ...re Advanced Motor Protection 155 Configure Autotune 156 Configure Flying Start 159 Configure Auto Restart 159 Configure Encoder Feedback 160 Configure Velocity Control 161 Velocity Limits 162 Dynamic Acceleration Control 162 Preset Velocity Acceleration Time Deceleration Time S Curve 163 Output Frequency 164 Configure Stop Control 164 Configure DC Brake 165 Configure Dynamic Brake 166 Light Duty D...

Page 9: ...rs 199 Power Status Indicators 200 Keypad Status Indicators 201 Safety Function Status Indicator 202 Monitor Faults Alarms and Events 203 Access Fault Alarm and Event Codes 203 Condition Monitoring 204 Power Supply 204 Temperature Sensor 204 Chapter 10 Maintenance and Repair Remove Power Before Servicing the Armor PowerFlex Drive 205 Test for Hazardous Voltage 206 Fuse Replacement 208 3 phase AC P...

Page 10: ...10 Rockwell Automation Publication 35 UM001A EN P May 2022 Table of Contents Index 223 ...

Page 11: ...ownload firmware associated files such as AOP EDS and DTM and access product release notes from the Product Compatibility and Download Center at rok auto pcdc Terminology This table defines the abbreviations that are used in this manual This manual links to Armor PowerFlex AC Drive Fault Codes Reference Data publication 35 RD002 and to Armor PowerFlex AC Drive CIP Objects and Attributes Reference ...

Page 12: ...al conditions and under single fault conditions except earth faults in other circuits PFD Average Probability of a Dangerous Failure on Demand The average probability of a system to fail to perform its design function on demand PFH Average Frequency of a Dangerous Failure per hour The average frequency of a system to have a dangerous failure per hour PL Performance Level EN ISO 13849 1 safety rati...

Page 13: ...ference Manual publication 1756 RM099 Provides information on safety application requirements for GuardLogix 5570 and Compact GuardLogix 5370 controllers in Studio 5000 Logix Designer applications GuardLogix 5580 and Compact GuardLogix 5380 Controller Systems Safety Reference publication 1756 RM012 Provides information on safety application requirements for GuardLogix 5580 and Compact GuardLogix 5...

Page 14: ...8 Part 1 7 Functional safety of electrical electronic programmable electronic safety related systems EMC Directive 2014 30 EU EN 61800 3 Adjustable speed electric power drive systems Part 3 EMC requirements and specific test methods LVD Directive 2014 35 EU EN 61800 5 1 Adjustable speed electrical power drive systems Part 5 1 Safety requirements Electrical thermal and energy LVD RoHS Directive 201...

Page 15: ...d Outputs All Armor PowerFlex drives include four standard inputs and two standard configurable I Os The Armor PowerFlex safety drive includes two test outputs four safety inputs and one bipolar safety output IMPORTANT The Armor PowerFlex drive ships with a rubber sealing boot which is required to be installed when the power OUT connection is not in use This scenario could apply when daisy chainin...

Page 16: ...x safety version 35S is capable of hard wired and integrated safety In hardwired mode Safe Torque Off STO can be used Integrated safety supports Safe Torque Off STO integrated drive based Safe Stop functions and integrated controller based Safe Monitor functions See Chapter 6 for details Table 2 Frame Sizes Frame Output Current Input Voltage Dimensions approx Size Rating Diagram Width max Depth ma...

Page 17: ...s Gigabit Ethernet Port Status Indicators 3 phase Power IN 3 phase Power OUT Encoder Local Disconnect Configurable I O Jog and Direction Dynamic Brake Connection Gigabit Ethernet Port Motor and Electromechanical Brake Connection Safety I Os With internal power supply Without internal power supply Standard I Os Status Indicators 24V DC Auxiliary Power OUT 24V DC Auxiliary Power IN 3 phase Power IN ...

Page 18: ...ion Code Description Code Description 35 Armor PowerFlex Drive S Integrated Safety version 6 IP54 66 Type 1 4 12 NEMA Type 1 4 12 D 480Y 277V AC 50 60 Hz E EtherNet IP e f g h i Motor Power Output Rating 24V DC Auxiliary Power Source Power in Gland EM Brake EMI Filter Code Description Code Description Code Description Code Description Code Description 1 1 Hp 0 75 kW 2 3 A L External 0 Cord conduit...

Page 19: ...r Volts Hertz Volts Hz control is a simple low cost method for controlling variable frequency drives VFD and is generally regarded as the most common VFD control scheme It s suitable for both constant torque and variable torque applications and can provide up to 150 of the rated torque at zero speed for startup and peak loads The magnetic field strength is proportional to the ratio of voltage V to...

Page 20: ...e nuisance trips due to shock loads and will continuously adapt to changes in the motor and load characteristics A separate adaptive controller uses information gained during auto tuning actual reference information and motor feedback information to give independent torque and flux control This allows continuous regulation of the motor speed and improved overall control For the Armor PowerFlex dri...

Page 21: ...the drive synchronizes with the motor at its rotating speed and ramps to the proper speed little or no mechanical stress is present When flying start is disabled and the drive receives a start command while the motor is in motion the drive performs a ramp from zero speed no output frequency to the commanded speed Performing this ramp from zero on a running motor can cause an overcurrent condition ...

Page 22: ...ed The protection feature lets the motor operate at a power level above its overload rating for short periods of time while starting or accelerating to help prevent faults from occurring When excessive current flows through the motor circuit there is increased motor temperature sensed which will result in a Drive fault after a specified delay defined as Class 10 This overheating generally occurs w...

Page 23: ...TO mode The STO function is controlled by either dual channel safety input either safety input 0 S0 and safety input 1 S1 or safety input 2 S2 and safety input 3 S3 Use only the S0 and S1 connector when the hardwired safety device that controls when safety is demanded requires pulse testing per the risk assessment If pulse testing is not required then either the S2 and S3 connector or the S0 and S...

Page 24: ...indication of the actual speed of the motor load Supported standard encoder types Digital Incremental Single Channel Single Ended Digital Incremental Single Channel Differential Digital Incremental Dual Channel Single Ended Digital Incremental Dual Channel Differential The encoder signals are connected in parallel for both safety and standard drive control Standard control can use single ended enc...

Page 25: ...of the unit The local disconnect removes power from the motor terminals and outputs when in the Off position The local disconnect does not remove safety output power A lock can be applied to the local disconnect when in the Off position For additional information see Local Disconnect Behavior on page 58 If a motor over current fault should occur the integrated branch protection may trip This may c...

Page 26: ... brake IGBT In this case external resistor packages must be protected from over temperature condition using a protective circuit or equivalent as the example shown The Armor PowerFlex drive has the internal ability to detect a thermal event on the dynamic brake resistor and shut down the Electronic Motor Disconnect which eliminates the need for the upstream control devices See Electronic Motor Dis...

Page 27: ... and cost The internal power supply IPS connects to the line side of the local disconnect This means that when the local disconnect is Off the IPS will continue to provide 24V DC to the Armor PowerFlex Only when the machine level main disconnect is Off removing all three phase power does the IPS shutdown and the Armor PowerFlex drive turns Off Electromechanical Brake EM Brake or EMB The Armor Powe...

Page 28: ...rable I O 0 1 Input 0 1 Input 2 3 Configurable I O 0 1 Input 0 1 Input 2 3 Main Power Circuit Protection EtherNet IP supports DLR 120V AC 24V DC Encoder 24V DC Power Supply 3 phase Power Armor PowerFlex Drive 35E Armor PowerFlex Drive 35E Ethernet cable Ethernet cable Ethernet cable Ethernet Management Switch Programmable Controller Note Adapter cables are available to connect the Armor PowerFlex ...

Page 29: ...nputs 0 and 1 support safety pulse test in hardwired safety operation Safety inputs 2 and 3 do NOT support pulse test in hardwired mode IMPORTANT In hardwired safety mode only one of the two safety input connectors can be used either safety input 0 and 1 or safety input 2 and 3 Connecting a cable and safety device to both safety inputs connectors in hardwired safety mode will cause a safety fault ...

Page 30: ...separate Armor PowerFlex safety drive 35S makes the safety only I O connection Figure 8 Integrated Safe Torque Off STO or timed Safe Stop SS1 Safety Inputs Safety Bipolar Output EtherNet IP with CIP Safety supports DLR Ethernet cable Ethernet cable Ethernet cable Ethernet cable Main Power Circuit Protection EtherNet IP DLR 120V AC 24V DC Encoder Auxiliary Control Power 3 phase Power Armor PowerFle...

Page 31: ...ntegrated Safe Speed Monitored Safety Inputs Configurable I O 0 1 Input 0 1 Input 2 3 Configurable I O 0 1 Input 0 1 Input 2 3 Main Power Circuit Protection 120V AC 24V DC Encoder Auxiliary Control Power 3 phase Power Safety Inputs Armor PowerFlex Drive with Integrated Safety 35S Ethernet cable Ethernet cable Ethernet cable Ethernet cable Safety Bipolar Output Safety Bipolar Output Armor PowerFlex...

Page 32: ...32 Rockwell Automation Publication 35 UM001A EN P May 2022 Chapter 1 Armor PowerFlex Variable Frequency Drives Overview Notes ...

Page 33: ...evice or devices Check the items nameplate numbers against the purchase order See Catalog Number Explanation on page 18 and for an explanation of the catalog number system that aids in nameplate interpretation Contact your local Allen Bradley distributor if any items are missing Storage The drive must remain in its shipping container before installation If the equipment will not be used for some t...

Page 34: ...pair Do not dismantle the module ATTENTION The National Electrical Code NEC NFPA 79 and any other governing regional or local code overrules the information in this manual Rockwell Automation cannot assume responsibility for the compliance or proper installation of the Armor PowerFlex drive or associated equipment A hazard of personal injury and or equipment damage exists if codes are ignored duri...

Page 35: ...f Solid state Controls publication SGI 1 1 available from your local Rockwell Automation sales office or online at rok auto literature describes some important differences between solid state equipment and hard wired electromechanical devices ATTENTION To make sure that the cables and the Armor PowerFlex connection points are at the same temperature within specifications at the time of installatio...

Page 36: ...gh voltage connectors pointing toward the earth Acceptable limits of deviation from the standard orientation are as follows Up to 60 tilt about the vertical axis forward or back 90 rotation with local disconnect pointing up 180 rotation with high voltage connectors pointing up These deviations from the standard orientation may result in thermal or power derating For additional details see Configur...

Page 37: ... 10 Mount Positions with Mounting Feet Shown Standard Mount 180 Rotation Mount Up to 60 Tilt Mount Front Back Front Back 90 Rotation Mount Front Back 60 60 Standard Mount with adjusted feet positions ATTENTION For proper heat dissipation and product operation mount in one of the orientations shown in Figure 10 ...

Page 38: ...ensions are not intended to be used for manufacturing purposes All dimensions are subject to change Figure 11 Armor PowerFlex Frame Size A Standard Mounting Position 143 8 5 66 365 14 37 203 7 99 6 5 0 26 406 15 98 68 3 2 69 71 2 8 23 3 0 92 55 2 17 75 5 2 97 29 5 1 16 248 9 76 227 8 94 6 5 0 26 203 7 99 162 6 38 425 14 37 406 15 98 441 17 36 Alternate mounting bracket orientation ...

Page 39: ... are shown in millimeters inches Dimensions are not intended to be used for manufacturing purposes All dimensions are subject to change Figure 12 Armor PowerFlex Frame Size A 180 Mount Position 143 8 5 66 203 7 99 68 3 2 69 71 2 8 23 3 0 92 55 2 17 75 5 2 97 29 5 1 16 248 9 76 227 8 94 365 14 37 6 5 0 26 406 15 98 ...

Page 40: ...are shown in millimeters inches Dimensions are not intended to be used for manufacturing purposes All dimensions are subject to change Figure 13 Armor PowerFlex Frame Size A 90 Mount Position 143 8 5 66 162 6 38 203 7 99 6 5 0 26 430 16 93 451 17 76 406 15 98 71 2 8 103 3 4 06 58 3 2 29 55 2 17 105 5 4 15 59 5 2 34 ...

Page 41: ...ables that include control voltage cables for example 24V DC and communications are not to be exposed to operator or building traffic on a continuous basis Location of the Armor PowerFlex drive to minimize exposure to continual traffic is recommended If location to minimize traffic flow is unavoidable other barriers to minimize inadvertent exposure to the cabling must be considered Cables must be ...

Page 42: ...fferent requirements The objective of grounding is to verify that all metal work is at the same ground or Earth potential at power frequencies Impedance between the drive and the building scheme ground must conform to the requirements of national and local industrial safety regulations or electrical codes These requirements vary based on country type of distribution system and other factors Period...

Page 43: ...nection with a separate ground conductor We recommend that each motor frame is grounded to building ground at the motor Motor Cable Considerations Most recommendations about motor cable address issues come from the nature of the drive output A PWM drive creates AC motor current by sending DC voltage pulses to the motor in a specific pattern These pulses affect the wire insulation and can be a sour...

Page 44: ...s When using ArmorConnect three phase power media or fixed wire such as cord or conduit with the Armor PowerFlex drive protective devices that meet local applicable electrical codes can be used for the feeder branch circuit protection The Armor PowerFlex drive is self protected therefore the feeder protective device is only intended to protect the line side power conductors ATTENTION Shielded moto...

Page 45: ...ckwell Automation offers a wide range of branch circuit protection that will protect your branch circuit conductors that feed power to your Armor PowerFlex drive group Our molded case circuit breakers have multiple frame sizes to accommodate your required current ratings and breaking capabilities These breakers provide protection of circuits against overload short circuit and ground fault For more...

Page 46: ...S output power the main disconnect must be set to the Off position to remove all three phase power coming into the Armor PowerFlex drive You can install configure and operate the I O without three phase power connected if you order an Armor PowerFlex drive with the external power supply configuration and if you provide external unswitched 24V DC to the product IMPORTANT There is an instantaneous i...

Page 47: ... EMD Output Power to Motor Invertor Convertor Off On Manual Switch Three phase Power Motor Comm Safety Bipolar Output Input Config I O Encoder Safety Output Safety Input Motor En Unswitched Power 24V DC Internal Power Supply Switched Power EMD Aux Line Input Power Disconnect EMD Output Power to Motor Invertor Convertor Off On Manual Switch Three phase Power Motor Unswitched Power User Supplied Ext...

Page 48: ...ure 17 Multiple External Power Supplies Line Input Power Disconnect EMD Output Power to Motor Invertor Convertor Off On Manual Switch Three phase Power Motor Unswitched Power Switched Power Comm Safety Bipolar Output Input Config I O Encoder Safety Output Safety Input Motor En User Supplied External Power Supply 1 24V DC External Power Supply 2 24V DC User Supplied EMD Aux ...

Page 49: ...Supply INT_24V SW_24V UNSW_24V SW_24V UNSW_24V Control Section Standard Inputs Safety Inputs Conũgurable I O Safety Output Ethernet IP Switches Push Buttons LEDs Encoder PS Selector Customer replaceable fuses SW_24V UNSW_24V External Auxiliary 24V Supply PELV SELV rated Optional SW_24V UNSW_24V UNSW_24V Voltage 50V Voltage 50V UNSW_24V Motor U V W PE Armor PowerFlex Safety Drive 1 2 3 4 5 Chassis ...

Page 50: ...pply INT_24V SW_24V UNSW_24V SW_24V UNSW_24V Control Section Standard Inputs Conũgurable I O Ethernet IP Switches Push Buttons LEDs Encoder PS Selector Customer replaceable fuses SW_24V UNSW_24V External Auxiliary 24V Supply PELV SELV rated Optional SW_24V UNSW_24V UNSW_24V Voltage 50V Voltage 50V UNSW_24V Motor U V W PE Armor PowerFlex Drive 1 2 3 4 5 Chassis DC Bus Chopper IGBT BR DC Bus P Therm...

Page 51: ...1 24V unswitched power sensor power brown Pin 2 Switched power ground white Pin 3 Unswitched power ground blue Pin 4 24V switched power black FE FE pass through jumper gray Pin 1 DB temp SW Pin 2 DB resistor T1 Pin 3 Chassis PE Pin 4 DB resistor T2 Pin 5 DB temp SW 5 1 4 3 2 Cable Connector Torque 1 69 N m 15 lb in Pin 1 Motor T1 black Pin 2 Motor T2 white Pin 3 Motor T3 red Pin 4 Ground green yel...

Page 52: ...e input connectors there is no fuse protection on the 24V supply and an input power overcurrent fault will occur that cannot be cleared Pin 1 Line input 1 Pin 2 Line input 2 Pin 3 Line input 3 Pin 4 not used Pin 11 not used Pin 12 not used Center Pin Chassis PE Use when application requires CE compliance as standard 11 4 PE 3 1 2 12 Cable Connector Torque Snap in place no torque Pin 1 Line input 1...

Page 53: ... not both to enable torque in hardwired mode Ethernet Connections and Cable Torque The Armor PowerFlex drive uses a sealed X coded M12 micro style Ethernet connector EtherNet 1 GB M12 Socket View Pin 1 Test Output 1 Pin 2 Safety Input n 1 Pin 3 Common Pin 4 Safety Input n Pin 5 Test Output 0 2 3 5 4 1 Cable Connector Torque 0 5 0 6 N m 4 4 5 3 lb in hand tight Pin 1 NC no connection Pin 2 Output n...

Page 54: ...hite Pin 2 Output A SIN brown Pin 3 Output B COS green Pin 4 Output B COS yellow Pin 5 not used grey Pin 6 not used pink Pin 7 Encoder supply ground blue Pin 8 Encoder supply power 5V or 12V red 1 8 7 6 5 4 3 2 Cable Connector Torque 0 5 0 6 N m 4 4 5 3 lb in hand tight Sin Sin Cos Cos Outer Shield C C DATA DATA DGND UB EK8S Encoder Incremental Motor Side Drive Side Encoder Connector 1 A_Sin 2 A_S...

Page 55: ...low repeatable consistent connection of the three phase and auxiliary power to the Armor PowerFlex drive and motor by providing a plug and play environment that also avoids system mis wiring Outer Shield C C DGND UB EK8R Encoder Incremental Motor Side Drive Side Encoder Connector 1 A_Sin 2 A_Sin 4 B_Cos 3 B_Cos 0 Shield 8 Power 7 COM 6 NC 5 NC M12 8 pin A code Plug B B A A 3 REFSIN 7 SIN 8 COS 4 R...

Page 56: ...r operation of the Armor PowerFlex drive the maximum total cable length for 24V Auxiliary Power IN is 20 m 65 6 ft SHOCK HAZARD Risk of electrical shock Do not disconnect or connect power cables under load ATTENTION ArmorConnect cables are not intended to be connected or disconnected under load Connecting or disconnecting ArmorConnect cables under load can result in physical injury or equipment da...

Page 57: ...fies the available cable lengths 2 Three phase power cable round or Three phase power cable square 280 PWRM35A Mxx 1 or HARTING 61 04 202 2953 Lxxx 1 3 Three phase power t port round or Three phase power t port square 280 T35 or HARTING 09 12 008 4720 4 5 6 Auxiliary Control power cable 4 pin Auxiliary Control power cable 4 to 5 pin Auxiliary Control power cable 5 pin 889N F4AFNM xx 1 889L R5JFN4M...

Page 58: ... for the safety inputs but it does remove output power for the bi polar safety output When the disconnect switch is in the On position and a short circuit or ground fault event occurs the Armor PowerFlex drive will fault but the switch handle will NOT change state to a fault position In this case you need to manually turn the disconnect switch to the Off position When the switch is in the Off posi...

Page 59: ... PowerFlex drive from three phase power The relays are controlled by the Driver Control block Driver Circuit that controls the Mechanical Relays of each phase independently to open or close The Drive Control Block commands come from the Disconnect Override Control block Disconnect Override This circuit controls the Driver Block which commands the relays to open or close The Disconnect Override Con...

Page 60: ...drive is faulted When this occurs the EMD will open So if the drive sensed a DB Resistor Thermal event a fault will be created and the EMD will open which is what an isolating contactor would be used for On Off Disconnect Detection Circuit that monitors the state of each of the contacts of the DPST Disconnect Switch Each contact is monitored independently by the On Off Disconnect Detection Block t...

Page 61: ...P Address using Rotary Switches Use this procedure if you cannot or do not want to use the BOOTP DHCP tool There are four rotary switches that are used to set the IP address one Mode switch and three address switches The Mode switch is used to set one of the five predefined private IP addresses except for the last octet The last octet is set by the three address switches The Armor PowerFlex drive ...

Page 62: ...switch changes to be recognized The Mode switch setting is ignored if the rotary switches address is not within the range of 1 254 Table 5 describes the Mode switch settings when the rotary address switches are set to 1 254 Set the Mode switch to one of the predefined IP Address types and then set the rotary address switches to a value that completes the IP address This example shows the rotary ad...

Page 63: ... See Figure 26 5 Replace the Armor PowerFlex drive s logic cover See Figure 27 6 Re apply unswitched auxiliary power to the Armor PowerFlex drive After the Armor PowerFlex drive goes through its boot up sequence the IP address is set to 192 168 1 123 2 Class A private IP address 10 0 11 x 1 255 255 255 0 1 0 0 0 0 2 254 10 0 11 1 3 IP address 136 129 6 x 1 255 255 0 0 100 0 0 0 0 2 99 or 101 254 1...

Page 64: ...device Desired IP address for the Armor PowerFlex drive To configure the Armor PowerFlex IP Address using the BOOTP DHCP utility after you install and power up the drive perform the following steps 1 Run the BOOTP DHCP software In the BOOTP DHCP Request History panel the hardware MAC ID addresses of the devices that are issuing BOOTP DHCP requests are shown Figure 28 BOOTP DHCP Request History Pan...

Page 65: ...ddress assignment has been made 5 To assign this configuration to the device highlight the device in the Relation List panel and click the Disable BOOTP DHCP button When power is cycled to the Armor PowerFlex it uses the IP Address assigned and will not issue a DHCP request anymore 6 If desired DHCP can be enabled using the BOOTP DHCP Server Utility To enable DHCP for a device with DHCP disabled h...

Page 66: ...fault setting and does not have an IP address set the IP address to 192 168 1 123 by following the steps in Example of How to Set the IP Address Switches on page 63 before proceeding If the Armor PowerFlex drive already has an IP address set perform the following steps 1 Launch FactoryTalk Linx and make sure that the IP Address of the Armor PowerFlex drive can be seen The proper EtherNet driver mu...

Page 67: ...ay 2022 67 Chapter 3 EtherNet IP Operation 4 In Advanced Settings check Enable Device Configuration under the General tab and click OK This allows changing the IP address using FactoryTalk Linx 5 Right click the device and choose Device Configuration ...

Page 68: ...t Protocol tab 7 Click Manually Configure IP Settings if not already checked and change the appropriate fields to configure the new IP address 8 Click Apply to make the changes For more information on how to configure the adapter with the BOOTP DHCP and FactoryTalk Linx tools see online help or the EtherNet IP Network Devices User Manual publication ENET UM006 ...

Page 69: ...ion Ring supervisor A ring supervisor provides these functions Manages traffic on the DLR network Collects diagnostic information for the network A DLR network requires at least one node to be configured as ring supervisor By default the supervisor function is disabled on supervisor capable devices Ring participants Ring participants provide these functions Process data that is transmitted over th...

Page 70: ...ed I O 1756 EN2T 1756 I O Modules 1794 AENT 1794 I O 1769 L23Ex 1769 L3xE 1734 AENT Workstation PowerFlex Drive Armor PowerFlex Drive 1783 ETAP Workstation 1783 ETAP 1783 ETAP PanelView Terminal 1738 AENTR 1738 I O Modules 1734 AENTR 1734 I O Modules 1756 EN2TR 1756 I O Modules Device Level Ring It is recommended that no more than 50 nodes are on a single DLR If your application requires more than...

Page 71: ...tion of safety parameters Safety configurations are allowed when there is a standard I O connection to support commissioning efforts If an attempt is made a device state conflict error is reported Ethernet Communication Troubleshooting The EtherNet IP communication module can experience intermittent network connectivity due to these conditions Duplex mismatch Electrical noise that is induced into ...

Page 72: ...maximum data rate that is needed is typically 100 200 MB s Therefore a 10 port switch that is rated at least 1 GB s is adequate for an EtherNet IP application Table 7 Resources for EtherNet IP Network Information Publication Description Troubleshoot EtherNet IP Networks Application Technique publication ENET AT003 Describes troubleshooting techniques for Integrated Architecture products on EtherNe...

Page 73: ...ide mode that provides local control via the Forward Reverse and Jog keypad buttons Auto is for control of the drive where all reference and sequencing commands come from a network connection When in Auto mode the Forward Reverse and Jog keypad buttons are not operational HAND AUTO Red Hand HAND AUTO Green Auto Forward Reverse When in Hand mode press this button to toggle between forward and rever...

Page 74: ...he current mode hand is default The drive must not be running to use the button to switch modes in Auto mode the Forward Reverse and Jog buttons don t do anything Forward Reverse toggles between directions in Hand mode The indicator displays the current direction forward is default At power up the keypad direction is set to forward The direction is maintained when switching between HAND AUTO mode ...

Page 75: ... disable the keypad motor control operation a MSG instruction targeting attribute 2 Inhibit of the Motor Control Source object can be used Set this attribute to 1 true to disable keypad motor control operation Table 9 shows the message instruction parameter needed to temporarily disable the keypad control Table 9 Keypad Control MSG This configuration allows you to temporarily use Hand mode of the ...

Page 76: ...based on selected direction color F0 LED Amber LED Off Amber LED Off F1 LED Amber LED Off Amber LED Off F2 LED Amber LED Off Amber LED Off Table 11 Keypad Mode Keypad Actions KEYPAD mode HAND AUTO F0 Button Fwd Rev F1 Button JOG F2 Button F0 selected F0 unselected F1 selected F1 unselected F2 selected F2 unselected Mode LEDs Top Off Bottom Amber Network reads F0 state 1 All reference and commands ...

Page 77: ...or and sourced from control power The inputs use two M12 connectors Each input has an light emitting diode LED status indication See I O Status Indicators on page 198 for details They are configurable as sinking or sourcing See Configure Safety Inputs on page 178 for configuration details Short circuit protection The maximum sourcing sensor power is 300 mA for all discrete inputs Therefore if all ...

Page 78: ...nection In1 Circuitry In0 Circuitry Connected Devices Connection Schematic Diagram Reset switch Connect the reset switch between 24V Unswitched Sensor Power and Input 1 Dual input configuration Connect the LED between 24V and Input 1 and connect the reset switch between 24V and Input 0 1 1 2 2 4 4 3 3 5 5 1 2 4 3 5 Pin 1 24V unswitched sensor power Pin 2 Input 1 Pin 3 Input Common Pin 4 Input 0 Pi...

Page 79: ...ut device You must confirm that the Discrete Output Point output value is not accidentally set to 1 if the point is being used as an input If an I O point is to be an output dedicate that point as an output with a wired load and energize it through a control program Energized outputs show an associated active input that can be used as a feedback mechanism to verify that the output is on If an I O ...

Page 80: ...nput Output 0 and Common Pin 1 24V unswitched sensor power Pin 2 Input Output 1 Pin 3 Input Common Pin 4 Input Output 0 Pin 5 Chassis PE 1 1 2 2 4 4 3 3 5 5 Pin 1 24V unswitched sensor power Pin 2 Input Output 1 Pin 3 Input Common Pin 4 Input Output 0 Pin 5 Chassis PE 1 1 2 2 4 4 3 3 5 5 Connected Devices Connection Schematic Diagram Output drives LED and Input as reset switch Output Connect the L...

Page 81: ...580 Compact GuardLogix 5380 Controller based stop functions Monitored Safe Stop 1 SS1 1 Safe Brake Control SBC Controller based monitor functions Safely Limited Speed SLS 1 Safely Limited Position SLP 1 Safe Direction SDI 1 Safety feedback function Safety Feedback Interface SFX 1 Integrated STO mode Safe Torque Off STO Table 13 Hardwired Safety Functions and Compatible Controllers Hardwired Safety...

Page 82: ...ty checks ATTENTION The drive is suitable for performing mechanical work on the drive train or affected area of a machine only It does not provide electrical safety ATTENTION The drive does not remove dangerous voltages at the drive output Before performing any electrical work on the drive or motor turn off the input power to the drive and follow all safety procedures ATTENTION Failure to maintain...

Page 83: ... year once every 15 years or whatever time frame is appropriate The Armor PowerFlex drive has a useful life of 20 years no proof test is required Other components of the system such as safety I O devices sensors and actuators can have different useful life times PFD and PFH Definitions Safety related systems can be classified as operating in either a Low Demand mode or in a High Demand Continuous ...

Page 84: ...lations are based on the equations from Part 6 of EN 61508 and show worst case values Table 16 PFD and PFH for Armor PowerFlex Drives Integrated STO and Timed SS1 Table 14 Maximum Diagnostic Test Intervals To achieve the listed safety rating Maximum STO demand interval SIL 3 Category 4 PLe one STO operation per day SIL 3 Category 3 PLe one STO operation per three months SIL 2 Category 3 PLd one ST...

Page 85: ...ety Instance is set to Single Feedback Monitoring Table 18 PFD or PFH to Add When Safety Functions Use Safety Feedback Attribute Single Channel Safety I O Dual Channel Safety I O PFD average 6 64 E 4 1 12 E 4 PFH 1 hour 7 58 E 9 1 28 E 9 SIL 2 3 PL d e Category 2 4 MTTFd years 760 3 757 6 DCavg 95 95 HFT 0 1 Mission time 20 years 20 years IMPORTANT Single channel safety I O is only certified for u...

Page 86: ...k Period and Watchdog settings Produced and consumed safety Connection Reaction Time Limit settings Safety Output Connection Reaction Time Limit settings See Safety Input and Output Connection Settings safety variants only on page 169 for information on how to configure these settings For details on reaction time calculation of your safety system see Reaction Times in the GuardLogix Controller Sys...

Page 87: ...top Category 0 stop as described in Stop Category Definition for STO on page 88 and protection against restart as specified in IEC 60204 1 The Safe Torque Off feature provides a method with sufficiently low probability of failure to force the power transistor control signals to a disabled state When disabled or anytime power is removed from the safety enable inputs all drive output power transisto...

Page 88: ...configuration settings including standard and safety I O configurations are returned to their out of box settings Resetting Ownership using the AOP requires that the Module Connection is inhibited Follow these steps to inhibit the module 1 Right click the device and choose Properties 2 Choose Connection 3 Check the Inhibit Module checkbox 4 Click Apply and then OK Follow these steps to reset the d...

Page 89: ...ddress switches to 888 using the following procedure a Remove power from the product Wait for it to power down b Set the network address switches to 888 See Set the IP Address on page 61 for instructions on how to set the IP address c Apply power to the product d Wait for 60 seconds e Remove power from the product Wait for it to power down f Set the network address switches to 1 to 254 or 999 g Ap...

Page 90: ...Instance 1 Revision Attribute 0x0B 11 decimal Device status DataType SINT Short integer Value DisplayText Definition 1 Testing Device is performing test diagnostics 2 Idle No active connections 3 Test Flt A fault has occurred while executing test diagnostics 4 Executing Normal running state 5 Abort A major recoverable fault has occurred 6 Critical Flt A critical fault has occurred 7 Configuring Tr...

Page 91: ...Output Solid State Devices OSSD Only one pair of inputs can be used at a time See Safety I O Operation on page 120 for additional information If either pair of safety inputs are energized SI0 and SI1 or SI2 and SI3 the output power transistors will turn on If either of the safety enable inputs are de energized then all output power transistors turn off The hardwired Safe Torque Off response time i...

Page 92: ...t pairs become energized SI0 or SI1 and SI2 or SI3 a Both Pairs Active 105 STO Fault type will occur All inputs must be set to zero for 1 ms for the fault to be cleared Letter Description A Set Safety Input SI0 0 volts B Set Safety Input SI1 0 volts within 0 9 seconds C Set Safety Input SI0 24 volts D Set Safety Input SI1 24 volts within 0 9 seconds 2 3 5 4 1 OSSD1 OSSD2 24V DC Pin 1 Test Output 1...

Page 93: ...I0 0 volts B Discrepancy fault after 0 9 seconds C Set Safety Input SI1 0 volts D Discrepancy fault cleared after 1 0 seconds E Set Safety Input SI0 24 volts F Set Safety Input SI1 24 volts G Clear Armor PowerFlex Fault ATTENTION The STO fault is detected upon demand of the STO function After troubleshooting a safety function must be executed to verify correct operation 0 9 A C D B G E F 0 9 1 0 S...

Page 94: ... Monitored Safe Stop 1 and Safe Brake Control stop functions Controller based safety functions operate in GuardLogix 5580 or Compact GuardLogix 5380 controllers and use the EtherNet IP network to communicate with the safety I O Drive Safety instructions use safety feedback provided by the Armor PowerFlex drive to the safety task of the controller to perform safe monitor functions The supported Dri...

Page 95: ...lt into the drive Detailed information for each function follows this topic Safe Torque Off page 96 Timed Safe Stop 1 page 102 Monitored Safe Stop 1 page 103 Safe Brake Control page 105 Safety Output Assembly Safe Stop Function Tags The safety output assembly for Integrated Safe Speed consists of different Logix tags Pass thru status and faults Safety stop function commands Safety I O commands See...

Page 96: ...te the STO function is received by the Armor PowerFlex drive the output power device transitions to an Off state which results in a condition where the motor is coasting The Integrated Safe Torque Off response time is less than 10 ms You can use the STO circuit in combination with other safety devices to achieve the stop and protection against restart as specified in IEC 60204 1 These conditions m...

Page 97: ...MSG Instruction see attribute 265 in Armor PowerFlex AC Drives CIP Objects and Attributes Reference Data publication 35 RD001 Figure 39 Safe Torque Off Activation Safe Torque Off Reset After torque is disabled due to a STO activation the STO function must be reset to enable torque When the STO function must be reset the following attribute values are set devicename SI STOActive 1 devicename SI Res...

Page 98: ...t the STO Delay to zero The STO Delay must be a positive integer value If Safe Brake Control is being used the STO delay must be zero If an STO delay is desired with the use of the Safe Brake Control function see Safe Brake Control Function on page 105 for information on how to configure STO to SBC delay If STO is activated by a safety fault any configured delay is ignored and torque is disabled i...

Page 99: ...ue Off Safety Fault When the Armor PowerFlex drive experiences a STO Fault the Armor PowerFlex drive is placed in the safe state and the cause of the fault is recorded If the STO function detects a fault it sets the following attributes devicename SI SafetyFault 1 devicename SI RestartRequired 1 STO Fault Type see Safe Torque Off Fault on page 117 For more information on STO Fault Types and troubl...

Page 100: ...e or more sources SS1 Request Setting the Safety Output Assembly Tag devicename SO SS1Request1 1 Limit Active Reserved for future use Connection Loss Loss of connection to the safety controller Connection Idle Safety controller in program mode When SS1 is activated all sources of activation are stored in an attribute as a bit mask and the attribute can then be read to determine the causes of an SS...

Page 101: ...me SO SS1Request1 tag Manual Cold Start Restart Type Operation If there are no Safety Faults in the module the SS1 function can be reset by a 1 to 0 transition on the devicename SO SS1Request1 tag then a 0 to 1 transition on devicename SO ResetRequest tag SS1 Safety Fault When an SS1 Safety Fault occurs the STO function is activated immediately and torque is disabled Figure 44 describes the operat...

Page 102: ...vation attribute which sets STO Active to Disable Torque In Timed Safe Stop 1 mode speed and deceleration are not monitored so this mode does not require Safety Feedback Figure 45 shows the timing of SS1 status and torque attributes in response to an SS1 activation along with the restart type behavior 0x00 0x01 SS1 Request SS1 Active 3 Deceleration Rate Torque Disabled Restart Required Safety Faul...

Page 103: ...SS1 Active bit is set the configured SS1 Decel Monitor Delay timer begins After the configured Decel Monitor Delay expires an internal speed ramp value is computed every time that the encoder is sampled If the magnitude of devicename SI FeedbackVelocity exceeds the sum of the internal ramp plus Decel Speed Tolerance the SS1 Fault Type attribute is set to Deceleration Rate and the SS1 Fault attribu...

Page 104: ... positive and SBC Mode Not Used or if STO to SBC Delay is negative and STO Activates SBC Linked then the Torque Disabled attribute is set after the configured time delay Otherwise the Torque Disabled attribute is set immediately A Configured Decel Reference Rate of 0 disables the ramp check SS1 faults if the drive does not slow to less than the Standstill Speed SS1 Decel Ref Rate Decel Reference R...

Page 105: ... Tag devicename SO SBCOutput1 0 0x00 0x01 SS1 Request SS1 Active Disable Torque Torque Disabled Restart Required 0x02 SS1 Complete SS1 Decel Ref Rate Velocity SI RestartRequired 3 SI STOActive 3 SI SS1Active 3 SO SS1Request 1 SS1 Activation 2 SI TorqueDisabled 3 STO Activation 2 0x00 Required if Restart Type Manual SI RequestReset 1 0x00 0x00 Standstill Speed SS1 Request SS1 Decel Monitor Delay SS...

Page 106: ...ctive 1 devicename SI RestartRequired 1 The steps to reset the SBC function depend on the cause of SBC activation and the Restart Cold Start Type configured in the module Safety Fault SBC Activation Reset Once the fault is removed a 0 to 1 transition on devicename SO ResetRequest tag resets the SBC function to the Brake Released state Automatic Cold Start Restart Type Operation If there are no Saf...

Page 107: ...ety Discrete Output Point Object Instance 4 Safety Dual Channel Output Object Instance 2 Used Test Pulses In the Used Test Pulses mode the safety outputs are under SBC control and cannot be configured independently The safety outputs are mapped to the same CIP objects as the Used No Test Pulses mode There is no difference in implementation of Safety Outputs pulse testing in SBC control versus dire...

Page 108: ...n when torque is disabled by the STO function If the SBC function is configured to link STO activation to SBC activation you can configure an STO to SBC Delay time where STO to SBC Delay 0 configures a delay between when STO is activated and the brake is engaged Figure 51 describes this operation STO to SBC Delay 0 configures the brake to engage when STO is activated and delays disabling torque Fi...

Page 109: ...ctive 1 Safety Output Assembly 2 Safe Stop Function Attribute 3 24V DC Safety Output 4 Safety Output Assembly Restart Type Automatic Restart Type Manual SI BrakeEngaged 1 SI SBCActive 1 SI TorqueDisabled 1 SI STO Active 1 STO to SBC Delay 0 SBC Activation 2 Brake Engaged 0x00 So0 and So1 3 SO RequestReset 4 Brake Engaged Disable Torque Torque Disabled Engage Brake Required If Restart Type Manual 0...

Page 110: ...utputs can directly control To support brakes with that require higher voltage and higher current an interposing safety relay such as the 700S CF Safety Control Relay is required Safety brakes typically require a voltage suppression device Most safety brakes provide a suppression device as an option or they specify a diode or MOV to use Use the recommended suppression devices The drive based SBC f...

Page 111: ...ance reports a voltage monitoring fault and causes the module to enter the safe state IMPORTANT For fault free operation of the encoder the cable shield of the connecting cable must be grounded on both sides encoder and control using large area connections On the encoder side this is typically done in the plug connector or via the connecting cable IMPORTANT Achievable safety rating depends on each...

Page 112: ... being used specifies a maximum acceleration set the maximum acceleration configuration value to this value or lower If the maximum acceleration is configured as 0 this diagnostic is not performed Maximum Encoder Input Frequency The maximum encoder input frequency diagnostic confirms that the safety feedback signals do not exceed the maximum frequency encoder counts per second supported by the mod...

Page 113: ...ctor length monitoring diagnostic confirms that the sine and cosine signals are sinusoidal and 90 apart This diagnostic is meant to detect errors in the wiring of the encoder and problems within the encoder itself Table 25 describes the tolerance of encoder output signal amplitudes for this diagnostic Table 26 describes the phase tolerance of the diagnostic If the module detects that the amplitude...

Page 114: ...Safety Instructions Table 27 Signal Offset Tolerance Maximum Minimum 3 0V 2 0V Table 28 Safety Instructions Safety Instruction Description Safety Feedback Interface SFX The SFX function scales feedback position into position units and feedback velocity into position units per time unit SFX is used with other Drive Safety instructions SFX also provides unwind for rotary applications and position ho...

Page 115: ...uction Information Description Configurable Inputs Safety function parameters that are used to define how the safety function operates Inputs Feedback SFX is the link to the SFX instruction for a safety drive Request initiates the safe monitoring function Reset initiates a safety instruction reset Pass Through Safety Output Assembly Object tags pass safety function status information from the Safe...

Page 116: ...nstruction Monitor Safety Status and Faults via a Message Instruction To obtain more detailed information about any faults that are detected in the drive most faults have a corresponding fault type attribute Use an MSG instruction in the ladder program to read the specific attribute information Details of the various fault type attributes are described in the following sections See Example Read SS...

Page 117: ...has occurred 7 Transition state configuring 8 Out of box state waiting 51 Out of box state waiting with torque permitted 52 STO bypass state executing with torque permitted Table 32 Safe Torque Off Fault Type MSG Parameter Value Description Service Code 0x0E Get attribute single Class 0x5A Safety stop functions Instance 1 Drive module safety instance Attribute 0x108 STO fault type DataType SINT Sh...

Page 118: ...ribute single Class 0x5A Safety stop functions Instance 1 Drive module safety instance Attribute 0x11c 284 decimal SS1 fault type Data Type SINT Short integer Table 35 SS1 Fault Types SS1 Fault Type Value SS1 Fault Type Name Description 1 No Fault No Fault is present 2 Invalid Configuration The drive based SS1 function has been requested when it has been configured as not used 3 Deceleration Rate ...

Page 119: ...put assembly tag device SI SafetyFault is set to one A Safety Fault can result from the SS1 stopping function STO function safety feedback SBC function or other safety diagnostics To acknowledge or clear this fault remove the source of the safety fault and send a fault reset to the safety logic See Figure 57 on page 120 for more information about the Integrated Safety Functions option module state...

Page 120: ...rformed through safety connections that support CIP Safety protocol over an EtherNet IP network There are status indicators for each I O point see View Status Indicators on page 197 B D E C F A Disable Torque Permit Torque No Fault No Fault Reset Request Torque Disabled Faulted Reset Required Faulted Reset Request Reset Required Disable Torque Torque Disabled Faulted Safety Status Safety Fault STO...

Page 121: ...ol how long two channels are allowed to be discrepant before a fault is declared An external wiring short circuit check is possible when inputs are wired in combination with test outputs The drive must be wired in combination with test outputs when this function is used Independently adjustable on and off delays are available per channel Separate test outputs are provided for short circuit detecti...

Page 122: ...ancy occurs If the second channel transitions to the appropriate state before the discrepancy time elapses the inputs are considered equivalent If the second transition does not occur before the discrepancy time elapses the channels transition to the alarm state In the fault state the input and status for both channels are set low Off When configured as an equivalent dual pair the data bits for bo...

Page 123: ...fore the discrepancy time elapses the channels transition to the alarm state The alarm state of complementary inputs is the even numbered input that is turned Off and the odd numbered input turned On Note that if faulted both channel status bits are set low When configured as a complementary dual channel pair the data bits for both channels are sent to the controller in complementary or opposite s...

Page 124: ...of the input contact The input turns on only if the input contact remains on after the on delay time has elapsed This setting helps prevent rapid changes of the input data due to contact bounce Figure 61 On delay ON OFF Safety Input 0 Terminal Normal Operation ON OFF Safety Input 1 Terminal ON OFF Safety Input 0 Value ON OFF Safety Input 1 Value OK ALARM Dual Channel Status ON OFF Safety Input 0 T...

Page 125: ...rcuit fault detection Configure the test output as a pulse test source and associate it to a specific safety input Figure 63 Test Output Wiring Example Figure 64 Test Pulse in a Cycle The pulse width X is typically 500 μs The pulse period Y is typically 300 ms The relation between pulse period and width is fixed When the external input contact is closed a test pulse is output from the test output ...

Page 126: ...utes IMPORTANT Depending on the targeted SIL Category PL and the safety application fault exclusions for short circuits between any two conductors cables may be necessary See ISO 13849 2 Annex D for additional information IMPORTANT Only the Safety Input Value and Status in the Safety Input Assembly can be considered safety data Input values that are read through CIP messages are not safety data Do...

Page 127: ...ut 0 Data Safety Input 1 Data Safety Input 0 Status Safety Input 1 Status Dual channels Equivalent OFF OFF OFF OFF ON ON OFF Normal OFF ON OFF OFF OFF OFF OFF Alarm ON OFF OFF OFF OFF OFF OFF Alarm ON ON ON ON ON ON ON Normal Dual channels Complementary OFF OFF OFF OFF OFF OFF OFF Alarm OFF ON OFF ON ON ON ON Normal ON OFF ON OFF ON ON ON Normal ON ON OFF OFF OFF OFF OFF Alarm Table 40 Safety Inpu...

Page 128: ... In00Data 0 Value of Safety Input 0 0 OFF 1 ON devicename SI In01Data 1 Value of Safety Input 1 0 OFF 1 ON devicename SI In02Data 2 Value of Safety Input 2 0 OFF 1 ON devicename SI In03Data 3 Value of Safety Input 3 0 OFF 1 ON Table 43 MSG Configuration for Safety Input Value Service Code 0x0E Get attribute single Class 0x3D Safety Discrete Input Point Object Instance i 1 Where i is the number of ...

Page 129: ...cuitry inside the module has failed An internal circuit error may not be recoverable replacing the module may be required An external circuit error occurs when pulse testing by the safety input s associated test output fails This error indicates the input circuitry external to the card has failed Discrepancy and Dual Channel Errors The discrepancy and dual channel errors are related as a discrepan...

Page 130: ...ut status turns on alarm cleared after the input error latch time has elapsed Safety Output Operation The safety outputs can operate only in dual channel bipolar mode The safety output can also be configured to run pulse test diagnostics The safety output assembly controls the bipolar output only when the drive is not using the SBC function If the SBC function is used it controls the output Table ...

Page 131: ...vidual safety output status turn off for both channels Figure 66 shows the operation of dual channel outputs under normal and alarm conditions Figure 66 Dual channel Setting Not to Scale In dual channel mode the output latch error time describes the period between when the alarm condition is removed and when the dual channel safety output stops reporting the alarm Figure 67 shows the normal operat...

Page 132: ...output to remove power from the output terminals of the module If an error is detected the safety output data and individual safety output status turn Off Figure 69 Test Pulse in a Cycle OK ALARM Safety Output 1 Status Output Latch Error Time Alarm Detected Alarm Condition Removed and Output Values in Safe State Alarm Cleared ON OFF Safety Output 0 Value ON OFF Safety Output 1 Value OK ALARM Safet...

Page 133: ... messaging Table 50 Safety Output Specifications IMPORTANT To help prevent the test pulse from causing the connected device to malfunction pay careful attention to the input response time of the output device Table 48 Safety Input Assembly Tags for Safety Output Status Safety Input Assembly Tag Name safety controller Type bit Description devicename SI OutputStatus SINT A collection of safety outpu...

Page 134: ... Table 51 Safety Input Assembly Tags for Safety Output Ready Safety Input Assembly Tag Name safety controller Type bit Description devicename SI IOSupport SINT A collection of bits describing safety IO functionality devicename SI Out00Ready 4 Safety Output 0 Ready 0 Not Ready 1 Ready devicename SI Out01Ready 5 Safety Output 1 Ready 0 Not Ready 1 Ready Table 52 MSG Configuration for Safety Output R...

Page 135: ... turn on if they configured for either Pulse Test or Power Supply These configured functions are independent of the I O connections to the module ATTENTION If a module with Test Outputs configured as Pulse Test or Power Supply is incorrectly installed in an application where actuators are connected to these Test Output points the actuators are activated as soon as the firmware boots and power is s...

Page 136: ...ernal Wiring Diagram IMPORTANT Stuck high faults on safety outputs require a power reset to clear the error IMPORTANT The wiring examples that are shown here are not a guarantee of Safety Category and Performance Level ratings You must perform your own risk assessment to validate the requirements of your system Test Output 1 Safety Input 1 Input Common Safety Input 0 Test Output 0 M12 5 Pin Connec...

Page 137: ...point has a status LED see I O Status Indicators on page 198 for details Safety Source Out 0 Safety Sink Out 0 Output Common M12 5 Pin Connector Out 1 Safety μC B Safety μC A Armor PowerFlex Drive Internal Circuitry Safety 24V DC Safety VCC_3V3 Safety VCC_3V3 Safety 24V DC Out 1 Monitor Out 0 Out 0 Monitor Safety Out 0 Sink Circuit Safety Out 0 Source Circuit ...

Page 138: ...n 4 Input 0 Pin 5 Test Out 0 1 1 2 2 4 4 3 3 5 5 1 2 4 3 5 Pin 1 Test Out 1 Pin 2 Input 1 Pin 3 Input Common Pin 4 Input 0 Pin 5 Test Out 0 1 1 2 2 4 4 3 3 5 5 Connected Devices Output Pulse from Output Test Connection Schematic Diagram Up to Safety Category Up to Performance Level Drive inductive load No Connect the switch between Output 0 sink and Output 0 source 4 PLe Pin 1 No connection Pin 2 ...

Page 139: ...ity on the initial download to the device Replace an Armor PowerFlex drive in a GuardLogix System When you replace an Armor PowerFlex drive the replacement device must be configured properly and the replacement Armor PowerFlex drive s operation be user verified Two options for Armor PowerFlex drive replacement are available on the Safety page of the Controller Properties dialog box in the Logix De...

Page 140: ...eplacement Armor PowerFlex drive that meets the following requirements The controller has configuration data for a compatible Armor PowerFlex drive at that network address The Armor PowerFlex drive is in out of box condition mode or has an SNN that matches the configuration ATTENTION Enable the Configure Always feature only if the entire integrated safety control system is not being relied on to m...

Page 141: ...d Center PCDC website at rok auto pcdc Create a Logix Designer Project Before you can add the Armor PowerFlex drive you must create a Logix Designer project that includes a Logix 5000 controller with a connection to the EtherNet IP network The Armor PowerFlex has an embedded dual port EtherNet module so there is no need for an optional EtherNet communication module If you are using integrated Safe...

Page 142: ... Connection Input Output Configuration Standard and Safety Overview Date and Time Faults and Alarms Safety Configuration Safety Feedback Scaling Safe Torque Off STO Safe Brake Control SBC Safe Stop 1 SS1 Test Output Input Configuration Output Configuration Actions Motor Control Flying Start Auto Restart Encoder Feedback Velocity Control Stop Control Connection Input Output Configuration Safety Onl...

Page 143: ...he appropriate option and click Create Configure the Device Definition When the Armor PowerFlex module is first created the software automatically launches the Device Definition window since the Name and IP Address of the module is the minimal configuration that is needed to create the module To make any changes to the Device Definition at a later time you will need to launch Device Definition fro...

Page 144: ... Disable Keying If you use Disable Keying you must take full responsibility for understanding whether the device being used can fulfill the functional requirements of the application IMPORTANT Changing Electronic Keying parameters online interrupts connections to the device and any devices that are connected through the device Connections from other controllers can also be broken If an I O connect...

Page 145: ...g the power supply for the auxiliary control power EM Brake No EM Brake The drive does not have a mechanical brake option EM Brake The drive has the mechanical brake control option IMPORTANT For an Armor PowerFlex drive with safety 35S the safety and standard connections can both be managed by one Safety controller or the safety connection can be managed by a Safety controller and the standard con...

Page 146: ...box If needed the Device Definition dialog box can be reaccessed via the Overview page QuickStart QuickStart is an optional wizard that allows you to quickly set up the drive and test the motor QuickStart is only available if a connection between the Armor PowerFlex drive and the programmable controller is inhibited The QuickStart will launch automatically after the OK button is pressed in the Dev...

Page 147: ...ompted jog to confirm that the motor is moving in the correct direction Adjust if necessary 4 Adjust the Motor Polarity field or swap two of the motor cables to change the motor rotation direction 5 Once the motor is rotating in the correct direction click Next to access the Autotune page Autotune Page See Configure Autotune on page 156 WARNING Before swapping motor cables take appropriate precaut...

Page 148: ...ate of a connected motor The state can either be stopped no power applied to motor or running power applied to motor Basic motor control also allows the direction of motion of the motor to be controlled When the Armor PowerFlex drive is configured for standard and safety or standard only connections the following categories are available in the Module Properties window for motor configuring operat...

Page 149: ...al current is the vector sum of the torque and flux producing components In this mode you cannot adjust the Frequency Control settings See Configure Advanced Motor Control for the next steps Velocity Vector Control VVC A high speed bandwidth regulator and adaptive controller are used to provide continuous regulation of the motor speed and improved overall control It is recommended to use an encode...

Page 150: ...trol parameters that are configurable depend upon which Boost Select method that you choose See Table 57 on page 151 to help you set the frequency control values Voltage Frequency Hz Frequency max Base Frequency nameplate BaseVoltage nameplate Start Boost Voltage max Frequency Voltage Break Frequency Rated Frequency Maximum Freq Start Boost Rated Voltage Maximum Voltage Break Voltage Minimum Freq ...

Page 151: ...ata can also be entered manually with values that are available from the motor manufacturer Frequency Control Value Description Configurable in this Boost Select method Custom V Hz Variable Constant Start Boost This setting redefines the Volts Hz curve It is used to create additional torque for breakaway from zero speed and acceleration of heavy loads at lower speeds The boost voltage is only appl...

Page 152: ...vanced Motor Control dialog box Attribute Range Description Full Load Slip Droop 600 600 RPM This setting compensates for the inherent slip in an induction motor This speed is added to the commanded output frequency based on motor current Positive values indicate slip compensation negative values indicate droop compensation Maximum PWM Frequency 2000 16 000 Hz This setting limits the carrier frequ...

Page 153: ... Size 1 Hp 35S 6D1 35E 6D1 Motor Nameplate Minimum Maximum Default Voltage 20V AC 460V AC 460V AC Frequency 0 Hz 500 Hz 60 Hz Rated Speed 0 RPM 24 000 RPM 1750 RPM Rated Power 0 kW 0 75 kW 0 75 kW Pole Count 2 N A 4 Full Load Amps rms 0 0652 A 2 3 A 2 3 A Size 2 Hp 35S 6D2 35E 6D2 Motor Nameplate Minimum Maximum Default Voltage 20V AC 460V AC 460V AC Frequency 0 Hz 500 Hz 60 Hz Rated Speed 0 RPM 2...

Page 154: ...ble 58 Attribute Range Description Overload Current 0 4 6 A Set the overload current to the maximum allowable current Current Limit 0 00 4 14 A Configure the Current Limit which sets the maximum motor output current that is allowed before current limiting occurs Derate Frequency 0 60 Hz Set the Derate Frequency which lets the thermal capacity be reduced when the frequency being output to the motor...

Page 155: ...tection dialog box Attribute Range Description Motor Overload Enabled Disabled This defines the behavior of the motor thermal overload feature when the device powers up Enabled toggle switch left The value of the Thermal Capacity Utilized attribute is reset to 0 on power up This assumes that the motor is fully cool Disabled toggle switch right The value of the Thermal Capacity Utilized attribute i...

Page 156: ...een established and the Run Autotune button will be grayed out Online Connection Error The software will check if the drive is ready to run before allowing the Autotune step If torque is disabled the drive is not ready to run and this will result in an error IMPORTANT For systems with an EM brake you must release the motor EM brake manually before performing the tune procedure The EM brake state i...

Page 157: ...e the Armor PowerFlex Drive 1 Click Run Autotune Autotune page ATTENTION Rotation of the motor in an undesired direction can occur during this procedure To guard against possible injury and or equipment damage we recommend disconnecting the motor from the load before you continue ...

Page 158: ...ic tune are limited For induction motors the following are measured during a static Autotune Induction Motor Stator Resistance Induction Motor Rotor Resistance Use this Autotune operation when no motor movement is allowed or when the motor cannot be uncoupled from the load 2 Rotate Tune A rotate Autotune operation performs measurements of physical attributes of the attached motor while the motor i...

Page 159: ... number of times the drive attempts to reset a fault and restart 3 Choose an Auto Restart Delay time up to 120 s which defines the time between restart attempts if Auto Restart Tries is set to a value greater than zero IMPORTANT The Auto Restart feature only clears a limited number of the following motor control related faults Any other faults will not be cleared and the drive will not restart The...

Page 160: ...u are using an encoder click Encoder Feedback 2 Choose the Electrical Interface Type Digital Incremental Single Channel Single Ended Digital Incremental Single Channel Differential Digital Incremental Dual Channel Single Ended Digital Incremental Dual Channel Differential Generic Sine Cosine 3 From the Encoder Feedback page select the encoder parameters See Table 62 on page 161 Type Incremental Su...

Page 161: ... between Normal default or Inverted as appropriate for your application This is based on encoder rotation and evaluation requirements Cycle Resolution 1 20 000 cycles rev This setting is used in the Effective Resolution calculation The actual motor encoder cycle resolution This is the raw encoder cycle resolution of the motor or encoder device type Cycle Interpolation 4 default This is used in the...

Page 162: ...n Control See Table 64 Table 64 Dynamic Acceleration Control Attribute Range Description Minimum Velocity 0 400 Rev s Sets the minimum velocity for the drive Maximum Velocity 0 400 Rev s Sets the maximum velocity for the drive IMPORTANT Stop the drive before changing this setting Attribute Description Enabled You can change the values of Acceleration and Deceleration Times currently being used and...

Page 163: ...ty Output Tag the CommandVelocity output tag is used Table 66 Preset Acceleration Deceleration S Curve Output Tag Bit Configuration AccelRefSelect_2 AccelRefSelect_1 AccelRefSelect_0 Preset Acceleration Time Deceleration Time S Curve to be used 0 0 0 Preset 1 0 0 1 Preset 1 0 1 0 Preset 2 0 1 1 Preset 3 1 0 0 Preset 4 IMPORTANT If an illegal value a value that is not defined in the table is entere...

Page 164: ...minimum and maximum Output Frequency settings Configure Stop Control The Stop Control page includes attributes related to the stop control of the motor 1 Click Stop Control S Curve Time Total Time to Accelerate Accel Time S Curve Time 50 S Curve Target vel Target vel 2 S Curve Time Accel Time Total Time to Accelerate Accel Time S Curve Time 100 S Curve Target vel ...

Page 165: ...tiated power to the motor is not interrupted but the velocity is reduced to zero at a rate defined by the Deceleration Time Power to the motor is not removed until zero velocity is achieved This is a controlled stop DC Brake When a stop is initiated power to the motor is not interrupted but a user configured amount of DC current is injected into the motor to produce a more rapid stop After either ...

Page 166: ...lue Description DynamicBrake Resistor Not Specified Not used no dynamic brake External Light Duty 3 duty cycle for details see Light Duty Dynamic Brake Resistor Operation on page 167 External Normal Duty 5 duty cycle for details see Standard Duty Dynamic Brake Resistor Operation on page 167 DC Bus Voltage Threshold 77 850V DC If the DC bus voltage falls below the value set in this parameter the Dy...

Page 167: ...it in an I O assembly DeviceName 0 EMBrakeRelease is the output tag Choose a Release Mode for the EM Brake from the pull down menu If choosing Automatic also set the Off Delay and On Delay see Figure 80 Figure 80 EM Brake Delay Timer Example Click OK to exit the Stop Control page Equivalent to Equivalent to EM Brake Release Mode Description Always Engaged The integrated EM brake contactor does not...

Page 168: ...g Listen Only connections between an owner controller and a digital I O module without removing the module from the configuration This process lets you temporarily disable a module to perform maintenance 4 Configure whether a drive connection failure while the programmable controller is in Run mode causes a major fault in the controller Minor fault is the default The connection between the owner a...

Page 169: ...e RPI Requested Packet Interval for the Safety Input connection can be adjusted for the application See the following table for additional information The RPI for the Safety Output connection is a fixed value based on the period set for the safety task in the controller 2 The Reaction Time Limit for the Safety Input and the Safety Output can be adjusted for the application Click Edit to open the C...

Page 170: ...the Input Delay Time On Off 0 65 535 ms in increments of 6 ms The default value is zero Delay time is On to Off transition Input must be low after input delay has elapsed before it is set logic 0 This delay time is configured per channel with each channel tuned to match the characteristics of the field device for maximum performance If using the configurable I O points as inputs define an Off On a...

Page 171: ... variants Safety configuration includes the following pages Safety Feedback only available with an encoder Scaling only available with an encoder Safe Torque Off STO Safe Brake Control SBC Safe Stop 1 SS1 Test Output Input Configuration Output Configuration Actions Configure Safety Feedback Configure primary feedback if you intend to use any drive based or controller based safety function that mon...

Page 172: ... to power the feedback Not Monitored default 4 75 5 25V 11 4 12 6V Cycle Resolution Defines the number of Cycles per Unit The unit is typically meters for linear devices and revolutions for rotary devices cycles rev Cycle Interpolation Defines the number of position Counts per Cycle counts cycle Effective Resolution Defines the number of position Counts per Unit counts rev Velocity Average Time Sp...

Page 173: ...nter the safety scaling attributes per the following table Attribute Description Effective Resolution The number of counts per motor revolution which is determined by the Primary Feedback category Position Units The position units for this safety application Enter text for the name of your units Time Units The evaluation of position per unit of time for a velocity evaluation Choose between Seconds...

Page 174: ...ction Idle Action STO Drive based SS1 Function is Complete 1 Safety Stop Fault 1 Critical Safety fault occurs STO Output is a tag in the safety output assembly of the Armor PowerFlex drive that is used to activate the STO function for the drive When any source for STO is asserted the STO Active bit becomes high to indicate that the STO function is operating STO Delay follows this sequence of event...

Page 175: ...rol Function on page 105 See Table 68 for descriptions of the SBC attributes Table 68 SBC Attributes Attribute Description STO Activates SBC Determines if an STO event engages the brake If set to Not Linked an STO event does not engage the brake If set to Linked the brake is engaged during an STO event based on the STO to SBC Delay attribute This attribute is only valid when the Mode is set to one...

Page 176: ...stance in the Device Definition is configured for single feedback monitoring for more information on the drive based Safe Stop 1 function see Safe Stop 1 Function on page 100 Timed SS1 is a fixed time for the motor to stop before removing torque Motor feedback is not monitored Stop Delay is the only parameter that is used for Timed SS1 and determines the Max Stop Time Monitored SS1 is a ramped saf...

Page 177: ... is initiated by a stop type condition Max StopTime Displays the SS1 maximum stop time This value is the sum of Stop Delay and Stop Monitor Delay Decel Reference Speed Specifies the deceleration speed to monitor for SS1 This parameter is unavailable when Mode is Timed SS1 Decel Reference Rate The minimum rate of deceleration while stopping This parameter is unavailable when Mode is Timed SS1 Decel...

Page 178: ...hannel Inputs are treated as single channels Dual channel safety inputs can be configuredas two individual single channels This configuration does not affect pulse tests because it is handled on an individual channel basis IMPORTANT Use single channel mode when you intend to use the GuardLogix safety application instructions Dual Channel Equivalent Inputsaretreatedasadual channelpair The channels ...

Page 179: ...t Error Latch Time field enter the time that the module holds an error to make sure that the controller can detect it 0 65 535 ms in increments of 1 ms default 1000 ms This setting provides more accurate diagnostics The purpose for latching input errors is to make sure that intermittent faults that can exist only for a few milliseconds are latched long enough for the controller to read The amount ...

Page 180: ... menu choose Output Configuration 2 Assign the Point Mode 3 Enter the Output Error Latch Time Point Mode Description Not Used The test output is disabled Test Pulse Output Used to test a safety input for short circuit detection Output configuration is not available when Safe Brake Control is enabled Point Mode Description Not Used The output is disabled Used withoutTest Pulses The output point is ...

Page 181: ... based Safe Stop 1 function is initiated and operates according to the SS1 configuration STO Torque is removed according to the STO configuration Connection Idle Action Connection idle is caused by the safety output task becoming disabled because the controller goes from run to Remote Program mode SS1 Drive based Safe Stop 1 function is initiated and operates according to the SS1 configuration STO...

Page 182: ... GuardLogix 5580 and Compact GuardLogix 5380 Controller Systems Safety Reference Manual publication 1756 RM012 for information on how to use the connection status tags Table 73 Standard Input Tags InputTag Function DeviceName I DriveStatus Bitmask of status bits below DeviceName I Ready 0 Motor control is not ready to run see run inhibits for details 1 Motor control is ready to run there is nothin...

Page 183: ...nect switch 0 open off 1 closed on DeviceName I EMBrakeReleased Set to 1 if the EM brake is released energized else 0 DeviceName I Alarm Set to 1 if there is an active alarm condition present DeviceName I OutputFrequency Frequency of the output to the motor in hertz DeviceName I OutputVoltage Voltage of the output to the motor in volts AC DeviceName I OutputCurrent Current being output to the moto...

Page 184: ...sing this I O point as an input this should remain 0 DeviceName O EMBrakeRelease 1 Manually release energize the EM brake This tag member is ignored on units without EM brake control circuitry DeviceName O CommandFrequency Dynamic velocity reference value used if DeviceName O VelocityRefSelect 0 0 0 Table 75 Safety Input Tags Safety InputTags Function DeviceName SI ConnectionStatus Reserved for fu...

Page 185: ...ety Output 0 0 OFF 1 ON DeviceName SI Out01Monitor Output Monitor Value of Safety Output 1 0 OFF 1 ON DeviceName SI Out00Status Status of Safety Output 0 0 Alarm 1 OK DeviceName SI Out01Status Status of Safety Output 1 0 Alarm 1 OK DeviceName SI Test00Status Status of Test Output 0 0 Alarm 1 OK DeviceName SI Test01Status Status of Test Output 1 0 Alarm 1 OK DeviceName SI InputStatus A collection o...

Page 186: ...quence to set the Safety Brake has started This function is only available as a controller based function 0 SBC Function is not Active 1 SBC Function is Active DeviceName SO SBCBrakeEngaged Indicates that the External Safety Brake is engaged by the controller based SBC function 0 Brake is Engaged 1 Brake is Released DeviceName SO SS1Active Indicates that the controller based SS1 function is active...

Page 187: ...its 1 axis position is outside of the limits DeviceName SO SFHomed Status of the controller based SFX position homing function 1 SFX Homed DeviceName SO PassThruStopFaults See the following descriptions of individual bits indicating the Safety Fault status of controller based safety functions DeviceName SO SFXFault Indicates that a fault occurred with the controller based SFX function 0 Normal Ope...

Page 188: ... Safe Stop 1 SS1 is configured 0 No Request 1 Request Safe Stop 1 If Safe Stop 1 is not configured this tag must be set to 0 If set to 1 will cause SS1 fault DeviceName SO ResetRequest A 0 to 1 transition is required to reset Safety Faults If Restart Type is Manual a 0 to 1 transition is required to restart a Safety Stop Functions DeviceName SO SafetyIOCommands See the following descriptions of in...

Page 189: ... auditable events Manage audit storage capacity Manage a diagnostics and health log Manage change detection and reporting Schedule backups Recover from disruptions if they occur MOD NET MOD NET MOD NET MOD NET 2 1 1 4 I O 2 1 2 1 2 1 UFB UFB A UFB B UFB A UFB B D D D D D D MF A MF B MF A MF B D D MBRK MOD NET 2 1 UFB A UFB B D D MF A MF B D D 1 I O 6 5 10 1 I O A 6 5 10 1 I O B 6 5 10 1 I O A 6 5 ...

Page 190: ...e information on CIP Security for example a list of CIP Security capable products and publications that describe how to use the products including limitations and considerations see the following https www rockwellautomation com en us capabilities industrial security security products cip security html CIP Security with Rockwell Automation Products Application Technique publication SECURE AT001 Fo...

Page 191: ...Box for Secure Erase A power up with rotary address switches set to 888 triggers a factory reset to out of box configuration A factory reset clears user configurable settings such that the data cannot be retrieved with commercially available tools It does not erase the following types of data Diagnostic data like power on time Security log data Elapsed and remaining life data for components that a...

Page 192: ...x drive using FactoryTalk Linx 1 Launch the FactoryTalk Linx and create the appropriate EtherNet driver if needed 2 Once you see the Armor PowerFlex IP Address listed under the EtherNet Driver go to the advance settings as shown IMPORTANT Once a port is disabled it cannot be used with FactoryTalk Linx So if both ports are disabled FactoryTalk Linx will not be able to communicate with the unit The ...

Page 193: ...2 193 Chapter 8 Develop Secure Applications 3 In Advanced Settings check Enable Device Configuration under the General tab and click OK This allows the IP Address to be changed using FactoryTalk Linx 4 Right click the device and choose Device Configuration ...

Page 194: ...tions 5 Click on the Port Configuration tab 6 Under the Enable column uncheck the check box of the port that you want to disable 7 Click Apply 8 The port unchecked port is now disabled 9 To re enable a port repeat steps 1 7 but in step 6 check the check box of the port that you want to enable ...

Page 195: ...arameters in Table 77 In this example the controller tag is named Port_Configuration Source Length 1 IMPORTANT You cannot add a MSG instruction to your program if the controller keyswitch is in Run mode or if the FactoryTalk Security settings deny this editing option Table 77 Port Configuration Tab MSG Parameter Value Description Service Code 0x10 Set Attribute Single Class 0x00F6 Motor Control So...

Page 196: ...used in the example 5 Before you enable the MSG instruction make sure that the Source Element tag value is 2 IMPORTANT Messages to THIS must be unconnected messages IMPORTANT You can re enable an Ethernet port after it is disabled To re enable the port complete the steps that are described in this section Before you enable the MSG instructions however make sure that the Source Element tag value is...

Page 197: ...stics during commissioning or troubleshooting Do not attempt to use status indicators to determine operational status Table 78 STATUS LED State LED Indicator Status Description Drive is ready to run Flashing green Drive is ready to run but is not running no faults or alarms Drive is running Steady green Drive is running no faults or alarms Drive is not ready to run Flashing amber Drive is not read...

Page 198: ...icator Status Description I O off Off Input or output is off no fault Input on Steady green Input is on no fault Output on Steady amber Output is on no fault I O fault Steady red I O point is faulted ATTENTION Do not use light emitting diode LED status indicators on the safety I O for safety operations Do not use the colors as indication of safe or unsafe states Table 81 Safety Input LEDs SAFETY I...

Page 199: ...he connections in which this device is the target has timed out the network status indicator is flashing red This indicator is turned Off only when all timeout connections are re established or if the device is reset Self test Flashing red green While the device is performing its power up test the network status indicator is flashing green red Table 85 Ethernet Module Status LED MOD State LED Indi...

Page 200: ... drive On Steady green 3 phase AC input power is present the local disconnect switch is On 3 phase input power present drive Off Flashing green 3 phase AC power is present and the local disconnect switch is Off Table 87 Module Sensor Actuator Switched Auxiliary Control 24V Power Output Power State LED Indicator Status Description Switched 24V power not present Off Switched 24V input power not pres...

Page 201: ...ad has been configured for user mode HAND AUTO keypad mode is available Steady green HAND AUTO keypad mode is available Table 90 HAND AUTO State LED Indicator Status Description Keypad is in another mode Off Keypad is in Function mode or it has been disabled Keypad is in auto mode Steady green Keypad is in auto mode Keypad is in hand mode Steady red Keypad is in hand mode Table 91 FWD REV State LE...

Page 202: ...us Description Torque disabled Off Torque is disabled STO active 1 Disable Torque Device may not be powered check Module Status LED Torque permitted Steady green The STO circuit is permitting torque Torque Disabled 0 Torque Permitted Torque inhibited Flashing green Torque is enabled but the STO circuit is not permitting torque STO Active 0 Permit Torque Torque Disabled 1 Torque Disabled Circuit fa...

Page 203: ...event occurs during normal operation of the product and can help you monitor status or troubleshoot problems The Armor PowerFlex drive s fault log accessible from the Faults and Alarms page displays the fault code name of the fault timestamp and type of fault Event Alarm Fault and details about the fault The log stores the 100 most recent entries in nonvolatile memory The Clear Faults button clear...

Page 204: ...n to get the status of the internal or external power supplies active or inactive the nominal and measured voltage and more For message instruction information see Armor PowerFlex AC Drives CIP Objects and Attributes Reference Data publication 35 RD001 You can also use a message instruction to get the state of the front panel disconnect switch on off used to interrupt 3 phase AC power to the drive...

Page 205: ...ty of maintenance personnel and others who can be exposed to electrical hazards associated with maintenance activities follow the local safety related work practices for example the NFPA 70E Part II in the United States Maintenance personnel must be trained in the safety practices procedures and requirements that pertain to their respective job assignments ATTENTION The drive contains high voltage...

Page 206: ...nd assemblies Static control precautions are required during installation test service or repair of this assembly Component damage can result if ESD control procedures are not followed If you are not familiar with static control procedures see Guarding against Electrostatic Damage publication 8000 4 5 2 or any other applicable ESD protection handbook ATTENTION An incorrectly applied or installed d...

Page 207: ... Loosen the screws and remove the internal power section cover 7 To verify that power has been removed and hazardous voltage is no longer present take measurements on the exposed terminal block Measure input power on L1 L2 and L3 line to line and line to ground 8 You can now proceed with Fuse Replacement or other service to the device Input Output Terminal Terminal R Terminal S Terminal T Terminal...

Page 208: ...ng We recommend using fuse puller FP 3 from Eaton Bussmann 4 Check each fuse with a multimeter to see if they are in good condition If damaged replaced the fuses Table 96 3 phase Input Power and EM Brake Fuse Specifications Specification 3 phase AC Line Power Fuses EM Brake Fuses Part No KTK 20 KTK 6 Description 20 A 600V AC UL Listed Class CC Std 248 14 6 A 600V AC UL Listed Class CC Std 248 14 C...

Page 209: ...5 UM001A EN P May 2022 209 Chapter 10 Maintenance and Repair 5 Replace the internal power section cover Tighten the screws 1 37 1 57 N m 12 1 13 9 lb in 6 Replace the power section door Tighten the screws 1 37 1 57 N m 12 1 13 9 lb in ...

Page 210: ...ition If damaged replaced the fuses 4 Replace the logic section door Tighten the screws 1 37 1 57 N m 12 1 13 9 lb in Table 97 24V Fuse Specifications Specification Unswitched Control 24V DC Power Fuses Switched Sensor 24V DC Power Fuses Part No 21502 5MXP 215004 MXP Description Fuse T C 2 5 A 250V H CLIP Fuse T C 4 A 250V H CLIP Current 2 5 A 4 A Interrupting Capacity 1500 A 250V AC 1500 A 250V A...

Page 211: ...1 Use the SS1 instruction checklist in Table 98 to verify normal operation and the abnormal operation scenarios IMPORTANT The validation tests in this appendix only apply to these integrated safety functions Monitored Safe Stop 1 SS1 Safely Limited Speed SLS Safely Limited Position SLP Safe Direction SDI Safety Feedback Interface SFX Safe Brake Control SBC IMPORTANT Perform I O verification and va...

Page 212: ... SFX_Name ActualSpeed SS1_Name SpeedLimit SS1_Name DecelerationRamp SS1_Name O1 Initiate SS1 demand Make sure that the instruction generates a deceleration fault and that the drive initiates an STO instruction Verify that the STO instruction de energizes the motor for a normal safe condition While the system is stopped with the sensor subsystems in a safe state initiate a Start command Verify that...

Page 213: ...h the sensor subsystems in a safe state remove the SLS demand Verify proper machine status and safety application program status Resume normal machine operation Verify proper machine status and safety application program status Abnormal Operation 1 Initiate a Start command Verify that the machine is in a normal machine run condition Verify proper machine status and safety application program statu...

Page 214: ...drive achieves and maintains a position between the SLP_Name PositiveTravelLimit and the SLP_Name NegativeTravelLimit without asserting the SLP_Name SLPLimit output While the system is in the SLP monitoring state initiate a motion command that violates the SLP_Name PositiveTravelLimit Verify that SLP_Name SLPLimit output is asserted and the programmed stop action is initiated While the system is s...

Page 215: ...ame SDILimit output is not asserted While the system is in SDI monitoring state and with the sensor subsystems in a safe state remove the SDI demand Verify proper machine status and safety application program status Resume normal machine operation Verify proper machine status and safety application program status Abnormal Operation 1 Initiate a Start command Verify that the machine is in a normal ...

Page 216: ...t command Initiate a Homing procedure Verify that the Home Position in the SFX instruction is set Set up a trend with the expected time scale and the following tags to graphically compare the motion position and speed from the Main task to the scaled position and speed in the Safety task Axis_Name ActualPosition SFX_Name ActualPosition Verify that the standard and safety position are correlated as...

Page 217: ...tion Axis_Name ActualSpeed SFX_Name ActualPosition SFX_Name ActualSpeed Verify that the standard and safety position and speed are correlated as expected Disconnect the Ethernet cable between the controller and the drive Verify the generation of a Fault Type 101 Connection Fault by checking the Device_Name SI ConnectionFaulted tag Verify that the system fault action takes place as configured While...

Page 218: ...chine status and safety application program status While the system is stopped initiate a Start command Verify that the system remains de energized for a normal safe condition Verify proper machine status and safety application program status While the system is stopped initiate a Reset command Verify that the system remains de energized for a normal safe condition Verify proper machine status and...

Page 219: ...ections and CIP encapsulation sessions For details on how to use MSG instructions see Logix 5000 Controllers Messages Programming Manual publication 1756 PM012 Message Process Figure 81 Message Process IMPORTANT A message instruction must not be used for any safety related function Box Description 1 Format the required data and configure the ladder logic program to send a Message Request to the sc...

Page 220: ...been selected In most cases this is a read only box If you select Custom in the Service Type box then you must specify a service code in this box for example 4B for a Get Attributes Scattered service or 4C for a Set Attributes Scattered service 4 Class The class is an EtherNet IP class 5 Instance The instance is an instance or object of an EtherNet IP class 6 Attribute The attribute is a class or ...

Page 221: ... or instances is controlled by a safety supervisor The supervisor status is read by the safety controller through the Safety Input Assembly or by an explicit message Table 104 Safe Stop 1 Fault Type MSG Parameter Value Description Service Code 0x0E Get attribute single Class 0x5A Safety Stop Functions Object Instance 1 Attribute 0x11C SS1 Fault Type Data Type USINT Unsigned short integer ...

Page 222: ...222 Rockwell Automation Publication 35 UM001A EN P May 2022 Appendix B Configure a Message Instruction Notes ...

Page 223: ...truction 195 discrepancy error 129 discrepancy time 122 123 drive safety instruction 114 dual channel error 129 mode 131 dual channel mode 122 131 E electromagnetic compatibility EMC general notes 41 wiring 42 Explicit Message configuration 219 F fault 119 detection 123 recovery 130 safety core 117 SS1 118 SS2 SOS SBC SLS SLP SDI 119 STO 117 fault detection 124 features DeviceLogix 25 gland plate ...

Page 224: ...applications disable the Ethernet port on port configuration tab 192 with a MSG instruction 195 SFX 216 validation checklist 216 shield and grounding of motors and motor cables 43 short circuit between input signal lines 126 single feedback monitoring 85 SLP 214 fault 119 validation checklist 214 SLS 213 example 115 fault 119 validation checklist 213 SOS fault 119 SS1 100 118 176 212 activation 10...

Page 225: ...Rockwell Automation Publication 35 UM001A EN P May 2022 225 Armor PowerFlex AC Drives User Manual ...

Page 226: ...irmware associated files such as AOP EDS and DTM and access product release notes rok auto pcdc At the end of life this equipment should be collected separately from any unsorted municipal waste Rockwell Otomasyon Ticaret A Ş Kar Plaza İş Merkezi E Blok Kat 6 34752 İçerenköy İstanbul Tel 90 216 5698400 EEE Yönetmeliğine Uygundur UNITED KINGDOM Rockwell Automation Ltd Pitfield Kiln Farm Milton Keyn...

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