Rockwell Automation 20A-DG01 User Manual Download

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User Manual

Original Instructions

Safe Torque Off Option (Series B)

for PowerFlex 40P and PowerFlex 70

Enhanced Control AC Drives

Catalog Number 20A-DG01

Topic

Page

Summary of Changes

General Description

What Is the DriveGuard Safe Torque Off Option?

Certifications and Compliance

CE Certification

Certified Equipment

Important Safety Considerations

Safe State

Safety Category 3 / PL (d) Performance Definition

Stop Category Definitions

Performance Level and Safety Integrity Level (SIL) CL2

PFDavg and PFH Definitions

PFDavg and PFH Data

Functional Proof Tests

Contact Information if Safety Option Failure Occurs

Installation and Wiring

Pre-Installation Instructions

EMC Considerations

DriveGuard Safe Torque Off Option Installation

Wiring

Verify Operation

Description of Operation

PowerFlex 40P Safe Torque Off Operation

PowerFlex 70 Safe Torque Off Operation

Connection Examples

Summary of Contents for 20A-DG01

Page 1: ...State 7 Safety Category 3 PL d Performance Definition 7 Stop Category Definitions 8 Performance Level and Safety Integrity Level SIL CL2 8 PFDavg and PFH Definitions 8 PFDavg and PFH Data 9 Functional Proof Tests 10 Contact Information if Safety Option Failure Occurs 10 Installation and Wiring 11 Pre Installation Instructions 11 EMC Considerations 12 DriveGuard Safe Torque Off Option Installation ...

Page 2: ...2 Rockwell Automation Publication PFLEX UM003D EN P June 2021 Summary of Changes Summary of Changes Change See Page Updated Certifications and Compliance sections 5 ...

Page 3: ... to achieve the desired level of safeguarding What Is the DriveGuard Safe Torque Off Option The DriveGuard Safe Torque Off option Provides the Safe torque off STO function defined in EN IEC 61800 5 2 Blocks gate firing signals from reaching the IGBT output power devices of the drive This prevents the IGBT s from switching in the sequence necessary to generate torque in the connected motor Can be u...

Page 4: ...UV also certifies that the DriveGuard Safe Torque Off option may be used in applications up to Category 3 PL d according to EN ISO 13849 1 and SIL 2 according to EN IEC 62061 IEC 61508 EN IEC 61800 5 2 TUV Rheinland certifications may be found at rok auto certifications ATTENTION Electrical Shock Hazard Verify that all sources of AC and DC power are de energized and locked out or tagged out in acc...

Page 5: ... Rockwell Automation declares the PowerFlex 40P and PowerFlex 70 drives compliant with the CE LV Directive as demonstrated by compliance with the requirements of EN 61800 5 1 Adjustable speed electrical power drive systems Part 5 1 Safety requirements Electrical thermal and energy The DriveGuard Safe Torque Off Option Kit is not within the scope of the Low Voltage Directive EMC Directive 2014 30 E...

Page 6: ...all configuration settings and choosing the proper setting to achieve the required safety rating In circumstances where external influences for example falling or suspended loads are present additional measures for example mechanical brakes can be necessary to prevent any hazard Drive Rating AC TUV Certified DriveGuard Safe Torque Off Function PowerFlex 40P 240V Yes Series B or greater 480V Yes Se...

Page 7: ...ned in accordance with relevant standards so that they can withstand expected conditions Well tried safety principles shall be applied A single fault in any of its parts does not lead to a loss of safety function Some but not all faults will be detected The accumulation of undetected faults can lead to loss of safety function Short circuits in the external wiring of the safety inputs is not one of...

Page 8: ... of the safety related components of the control system must be included in both a risk assessment and the determination of the achieved levels See the EN ISO 13849 1 IEC 61508 and EN IEC 62061 standards for complete information on requirements for PL and SIL determination PFDavg and PFH Definitions Safety related systems can be classified as operating in either a Low Demand mode or in a High Dema...

Page 9: ...ow worst case values This table provides data for a 20 year proof test interval and demonstrates the worst case effect of various configuration changes on the data PowerFlex 40P PFDavg and PFH for 20 year Proof Test Interval PowerFlex 70 PFDavg and PFH for 20 year Proof Test Interval Terminology Attribute Test Result PFDavg 1 74E 05 PFH 2 0E 10 SFF 81 Attribute Test Result PFDavg 3 4E 05 PFH 3 9E ...

Page 10: ...ues Contact Information if Safety Option Failure Occurs If you experience a failure with any safety certified device contact your local Rockwell Automation distributor With this contact you can Return the device to Rockwell Automation so the failure is appropriately logged for the catalog number affected and a record is made of the failure Request a failure analysis if necessary to determine the p...

Page 11: ...ed control system of a machine Before installation a risk assessment should be performed that compares the DriveGuard Safe Torque Off option specifications and all foreseeable operational and environmental characteristics of the machine to which it is to be fitted In no case should be DriveGuard Safe Torque Off option be used in a PowerFlex 40P or PowerFlex 70 drive where the maximum surrounding a...

Page 12: ...the EMC requirements documented in the PowerFlex 40P and PowerFlex 70 Installation manuals have been satisfied Important installation requirements include All motor output control I O and signal wiring for the drive and DriveGuard Safe Torque Off option must be shielded cable Grounding earthing must conform to the requirements described in the drive user manuals ATTENTION The following information...

Page 13: ... PowerFlex 40P Protective Plug 3 Remove the PowerFlex 40P Safe Torque Off connection jumper shown in Figure 2 Figure 2 PowerFlex 40P Safe Torque Off Connection Jumper Location ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged before performing any work on the drive Measure the DC bus voltage at the DC and DC terminals or test points the voltag...

Page 14: ... Torque Off option Series B or greater into the PowerFlex 40P four pin Safe Torque Off connector as shown in Figure 4 Figure 4 PowerFlex 40P Safe Torque Off Connector 6 Tighten screw to 0 8 1 1 N m 7 10 lb in IMPORTANT The PowerFlex 40P hardware enable jumper must be removed when using the DriveGuard Safe Torque Off option Failure to remove the jumper will cause the drive to fault when a start com...

Page 15: ...igure 5 PowerFlex 70 Safe Torque Off Connection Jumper Location Typical 2 Remove the PowerFlex 70 Hardware Enable jumper as shown in Figure 6 Figure 6 PowerFlex 70 Hardware Enable Jumper Location Typical IMPORTANT The PowerFlex 70 hardware enable jumper must be removed when using the DriveGuard Safe Torque Off option Failure to remove the jumper will cause the drive to fault when a start command i...

Page 16: ... recommended Control wires should be separated from power wires by at least 0 3 m 1 ft DriveGuard Safe Torque Off Option Terminal Block Specifications Wire Types Wire Size Range 1 1 Maximum minimum that the terminal block will accept these are not recommendations Torque Maximum Minimum Maximum Recommended 1 5 mm2 16 AWG 0 14 mm2 26 AWG 0 25 N m 2 2 lb in 0 22 N m 1 9 lb in Wire Type s Description ...

Page 17: ...he safety analysis described on page 11 Verify that both safety channels are functioning according to the PowerFlex 40P Channel Operation and Verification or PowerFlex 70 Channel Operation and Verification on page 18 No Signal Description 1 Monitor N C Normally closed contacts for monitoring relay status Maximum Resistive Load 250V AC 30V DC 50 VA 60 Watts Maximum Inductive Load 250V AC 30V DC 25 ...

Page 18: ...ameter 13 Bit 2 Value 0 Value 0 Value 1 Value 1 PowerFlex 40P Comms Status Word 8448 Bit 0 Value 0 Value 0 Value 0 Value 1 Safe Torque Off Output 1 Relay N O Dig Output States Closed Open Open Open 1 Must set A055 Relay Out Sel A058 or A061 Opto Outx Sel to option 25 Safe Off Safety Function Status Drive In Safe State Drive In Stopped State Drive In 1 Stopped State Drive Able To Run Safety Channel...

Page 19: ...on the Safe Torque Off relay is energized the enable input is energized and the drive is able to run If either inputs is de energized the gate control circuit is disabled To meet EN ISO 13849 1 Category 3 PL d operation both safety channels must be de energized See the following examples for details Figure 8 PowerFlex 40P Drive Safe Torque Off Circuitry IMPORTANT By itself the Safe Torque Off opti...

Page 20: ...rgized the enable input is energized and gate control power is available to the gate control circuit If either of these inputs is de energized the gate control circuit is disabled To meet EN ISO 13849 1 Category 3 PL d operation both safety channels must be de energized See the following examples for details Figure 9 PowerFlex 70 Drive Safe Torque Off Circuitry IMPORTANT By itself the Safe Torque ...

Page 21: ...e motor will coast to stop To restart the drive the Minotaur safety relay must first be reset followed by a valid start command to the drive Fault Detection A single fault detected on the Minotaur safety input circuits will result in the lock out of the system at the next operation and will not cause loss of the safety function If the Safe Torque Off option sticks On the motor will stop on command...

Page 22: ...d start command to the drive Fault Detection A single fault detected on the Minotaur safety input circuits will result in the lock out of the system at the next operation and will not cause loss of the safety function If the Safe Torque Off option sticks On the motor will stop on command due to the enable input The system cannot be reset when this fault condition exists The function is considered ...

Page 23: ...Rockwell Automation Publication PFLEX UM003D EN P June 2021 23 Description of Operation Notes ...

Page 24: ...ur comments help us serve your documentation needs better If you have any suggestions on how to improve our content complete the form at rok auto docfeedback For technical support visit rok auto support Rockwell Otomasyon Ticaret A Ş Kar Plaza İş Merkezi E Blok Kat 6 34752 İçerenköy İstanbul Tel 90 216 5698400 EEE Yönetmeliğine Uygundur Technical Support Center Find help with how to videos FAQs ch...

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