Safe Off Manual
Contents
1. Allen Bradley ji DriveGuard Safe Off Option for PowerFlex 700S Phase II AC Drives User Manual Automation Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment Safety Guidelines for the Application Installation and Maintenance of Solid State Controls Publication SGI 1 1 available from your local Rockwell Automation sales office or online at http www ab com manuals gi describes some important differences between solid state equipment and hard wired electromechanical devices Because of this difference and also because of the wide variety of uses for solid state equipment all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable In no event will Rockwell Automation Inc be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation Rockwell Automation Inc cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Rockwell Automation Inc with respect to use of information circuits equipment or software described in this manual Reproduction of the conte2. ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged before performing any work on the drive Measure the DC bus voltage at the DC and DC terminals or test points refer to your drive s User Manual for locations The voltage must be zero ATTENTION In safe off mode hazardous voltages may still be present at the motor To avoid an electric shock hazard disconnect power to the motor and verify that the voltage is zero before performing any work on the motor General Description 3 Safety of Machinery Standards The Safe Off with Second Encoder option meets the following safety standards e EN 60204 1 Safety of machinery Electrical equipment of machines Part 1 General Requirements e EN 954 1 1997 Category 3 Safety related parts of control systems CE Conformity Conformity with the Low Voltage LV Directive and Electromagnetic Compatibility EMC Directive has been demonstrated using harmonized European Norm EN standards published in the Official Journal of the European Communities PowerFlex Drives comply with the EN standards listed below when installed according to the User and Reference Manuals CE Declarations of Conformity are available online at http Avww ab com certification ce docs Low Voltage Directive 73 23 EEC e ENS50178 Electronic equipment for use in power installations EMC Directive 89 336 EEC e EN61800 3 Adjustable speed electrical p
3. amp S21 S22 to the Minotaur monitoring safety relay unit The output circuits 13 14 amp 23 24 will cause the Safe Off option and drive Enable circuit to go immediately to a safe state off and the motor will coast to stop To restart the drive the Minotaur safety relay inputs S13 S14 S21 S22 must first be ready for normal drive operation 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 to a safe state off at the next operation and will not cause loss of the safety function If the Safe Off option sticks ON the motor will stop on command due to the enable input The system cannot be reset and thereby reveals the fault condition to the operator Application Considerations When the hazard analysis for the overall machine determines the need for external mechanical brakes or other stopping means the external means shall be activated after the removal of power for Stop Category 0 2 DC Description of Operation 17 Example 2 Safe Off Connection with Controlled Stop Action Dual Channel Figure 3 Stop Category 1 Controlled AC Line Input Power Al A2 X T 24V DC Common PowerFlex 700S AC Drive 24V DC Stop O Start Start r S
4. 4 Common N c Monitoring relay status Maximum Resistive Load 250V AC 30V DC 50 VA 60 Watts Maximum Inductive Load 250V AC 30V DC 25 VA 30 Watts 12 Installation and Wiring Configure Hardware Enable Ensure that Jumper P22 on the Main Control Board is set to HW Enable Pins 2 and 4 HW Enable No HW Enable m zt a EEz 5o G o TI 1 R Important In addition to the correct jumper setting Enable circuitry must be connected to I O Terminals 13 and 16 Refer to the PowerFlex 700S Phase II Control User Manual publication 20D UMO086 for wiring examples Installation and Wiring 13 Configure Digital Outputs Digital Output 1 and 2 TB2 Terminals 3 4 and 5 and Relay Output 3 TB2 Terminals 6 7 and 8 can be configured to activate external logic in the event the safety enable diagnostic routine results in an F45 Enable Health fault 1 2 Set Par 147 FW Functions En Bit 14 Digital Outs to 1 True Set Par 845 Dig Outl Sel 850 Dig Out2 Sel or 855 Rly Out3 Sel to option 0 User Select Link Par 846 Dig Outl Data 851 Dig Out2 Data or 856 Rly Out3 Data
5. be verified using the table below How frequently the safety function is checked is dependent on the safety analysis of the machine section controlled by the drive Safety Function Drive In Drive In Drive In Drive Able Status Safe State Safe State Safe State To Run Safety Channel Operation Safe Off Option No Power Power Applied No Power Power Applied Terminals 1 amp 2 Applied Applied PowerFlex 700S No Power No Power Power Applied Power Applied Enable Input Applied Applied Description For Verification Safe Off Option Closed Open Closed Open Monitor Contact Terminals 3 amp 4 PowerFlex 700S Bit 16 0 Bit 16 0 Bit 16 1 Bit 16 0 Drive Inhibits Bit 1 1 Bit1 1 Bit 1 0 Bit 1 0 Param 156 Bits 1 amp 16 Description of Operation 15 Description of Operation The PowerFlex 700S Safe Off option see Figure 1 disables the drive s output IGBT s by disconnecting the gate control power supply When used in combination with a second safety channel the Enable input the system satisfies the requirements of EN 954 1 Category 3 for safe off and protection against restart Under normal drive operation the Safe Off relay is energized 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 954 1 Category 3 operation both safety channel inputs to the drive must be controlled de
6. energized to safely turn off output to the motor Refer to the following examples for details Important By itself the Safe Off option initiates a coast to stop action If coasting to a stop is not desired additional protective measures should be taken Figure 1 Safe Off Drive Circuitry AC Line Input Power PowerFlex 700S AC Drive 24V DC Stop Star Start Stop Common 24V DC Common Gate Control Power Supply Safe Safety Channel Ta Gate Control Circuit A Common Safety Channel Enable 16 Description of Operation Example 1 Safe Off Connection with Coast to Stop Action Dual Channel Figure 2 Stop Category 0 Coast AC Line Input Power PowerFlex 700S AC Drive 24V DC Stop 5 O Start GuardMaster tart Trojan Start Stop Common iz DC Common 13 23 Gate Control Power Supply Safe i 1424 24V DC 2 Common Gate Control Circuit 4 amp Common Enable Circuit Status Circuit shown with guard door closed and system ready for normal drive operation Operating Principle This is a dual channel system with monitoring of the safe off circuit and drive Opening the guard door will switch the input circuits S13 S14
7. responsibility for the compliance or the noncompliance to any code national local or otherwise for the proper installation of this equipment A hazard of personal injury and or equipment damage exists if codes are ignored during installation Installation and Wiring Open the door of the power structure and disconnect the cables that connect to the main board Remove the cassette e Loosen screws on face of cassette Q 1 Remove the I O Control Cassette from the drive Option Board Installation Task Description 222 2 222222 2 2222224 Ez J Annn w Installation and Wiring 2 Remove the screws securing the interior cassette cover to gain access to the Main board 15 pin position 3 Remove the 2 pin shunt jumper from the 16 Important If the Safe Off option is removed from the drive this jumper must be reinstalled or the drive will not run Installation and Wiring 4 Remove the exterior cassette covers to access the grounding plate 00900900990 0949049990990900999 N Installation and Wiring 5 Install the 16 pin stacker connector 000000080 20000000 0 8 1 1 Nem 7 0 10 0 Ib in 7 Install and tighten mounting screws Installation and Wiring 700099990 ar ULL LLL o pee A J ES L di r jf Te 8 Install the
8. to Par 324 Fault Status 2 See Linking Parameters below Set Par 847 Dig Outl Bit 852 Dig Out2 Bit or 857 Rly Out3 Bit to 12 Par 324 Bit 12 EnableHealth status Linking Parameters Use the following procedure to establish a link between Par 846 Dig Outl Data 851 Dig Out2 Data or 856 Rly Out3 Data and Par 324 Fault Status 2 1 Using the drive s Human Interface Module HIM select Parameter from the Main Menu and press the Enter key Using the HIM keypad enter 846 850 or 856 and press the Enter key The parameter value screen will appear Press ALT and then View Sel Next press the Up or Down Arrow to change Present Value to Defined Link Press the Enter key Press the Enter key to select the Link field Using the HIM keypad enter 324 as the Source Parameter Number and press the Enter key The linked parameter can now be viewed two different ways by repeating the steps above and selecting Preset Value or Define Link If an attempt is made to edit the value of a linked parameter Parameter is Linked will be displayed indicating that the value is coming from a source parameter and can not be edited To remove a link repeat the steps above and change the source parameter to zero 0 14 Installation and Wiring Verify Operation At regular intervals during the life of the machine check the safety function for proper operation Both safety channels shall
9. eals the fault condition to the operator 18 Supplemental Information Supplemental Information Certification TUV T V Rheinland Group T V Industrie Service GmbH Automation Software und Informationstechnologie ZE RTI F KAT Nr No 968 EZ 189 00 05 CERTIFICATE Pr fgegenstand Adjustable Frequency AC Drive Zertifikatsinhaber Rockwell Automation Product tested License holder 6400 West Enterprise Drive Hersteller USA Mequon WI 53092 Manufacture United States of America Typbezeichnung Verwendungszweck Safety relevant applications Type designation Intended application Safety Function Safe stand still according to EN 954 1 Allen Bradley PowerFlex 700S AC Drive category 3 Frame 1 2 3 4 5 6 240 V 400 V 480 V and corresponding DC input voltage ratings Frame 5 6 600 V 690 V and corresponding DC input voltage ratings Pr fgrundlagen EN 954 1 1996 Codes and standards forming EN ISO 13849 2 2003 the basis of testing EN 60204 1 1997 EN 50178 1997 EN 61800 3 1996 amp A11 2000 Pr fungsergebnis The safety function Safe standstill meets the requirements for Test results category 3 according EN 954 1 Besondere Bedingungen Fault exclusion for the external wiring has to be made according to Specific requirements EN ISO 13849 2 The user manual Safe Off Option for PowerFlex 700S AC Drive has to be considered Der Pr fbericht Nr 968 EZ 189 00 05 vom 2005 02 25 ist Be
10. exterior cassette covers 10 o 2 P P 2 2 2 P Installation and Wiring 9 Install the inside front cover 10 Reinstall the cassette in the drive 11 Record the modification on the Field Installed Option label Installation and Wiring 11 Wiring Important points to remember about wiring e Always use copper wire e Wire with an insulation rating of 600V or greater is recommended e Control wires should be separated from power wires by at least 0 3 meters 1 foot Safe Off with Second Encoder Terminal Block Specifications Wire Size Range Torque Maximum Minimum Maximum Recommended 1 5 mm 0 14 mm 0 25 N m 0 22 N m 16 AWG 26 AWG 2 2 Ib in 1 9 Ib in 1 Maximum minimum that the terminal block will accept these are not recommendations Wire Types Minimum Wire Type s Description Insulation Rating Unshielded Per US NEC or applicable _ 300V national or local code 60 degrees C Shielded Multi conductor shielded cable 0 750 mm2 18AWG 140 degrees F such as Belden 8770 or equiv 3 conductor shielded Safe Off Terminals Description No Signal Description 1 24V DC Connections for user supplied power 2 T24V Common to energize coil 33 3 mA typical 55 mA maximum ASSEMBLY cd m ID LABEL BAR CODE LABEL 3 Monitor N C Normally closed contacts for
11. l Automation 6040 Ponders Court Greenville SC 29615 4617 USA Tel 1 864 297 4800 Fax 1 864 281 2433 Europe Middle East Africa Rockwell Automation Br hlstra e 22 D 74834 Elztal Dallau Germany Tel 49 6261 9410 Fax 49 6261 17741 Asia Pacific Rockwell Automation 55 Newton Road 11 01 02 Revenue House Singapore 307987 Tel 65 6356 9077 Fax 65 6356 9011 U S Allen Bradley Drives Technical Support Tel 1 262 512 8176 Fax 1 262 512 2222 Email support drives ra rockwell com Online www ab com support abdrives Publication 20D UM007A EN P March 2005 363068 P01 Copyright 2005 Rockwell Automation Inc All rights reserved Printed in USA
12. nts of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations that can cause an explosion in a hazardous environment which may WARNING Identifies information about practices or circumstances lead to personal injury or death property damage or economic loss Important Identifies information that is critical for successful application and understanding of the product ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you e identify a hazard e avoid the hazard e recognize the consequences drive or motor to alert people that dangerous voltage may be present Burn Hazard labels may be located on or inside the equipment e g drive or motor to alert people that surfaces may be at dangerous temperatures Shock Hazard labels may be located on or inside the equipment e g PowerFlex is a registered trademark of Rockwell Automation Inc DriveExplorer DriveExecutive and SCANport are trademarks of Rockwell Automation Inc PLC is a registered trademark of Rockwell Automation Inc Table of Contents Section General Description r g Q oO What Is the PowerFlex Safe Off Option Safety of Machinery Standards CE Conformity Approved Equi
13. ower drive systems Part 3 EMC product standard including specific test methods Approved Equipment The following PowerFlex 700S Phase II AC Drives are certified to EN 954 1 Category 3 208 240V Frames 1 6 400 480V Frames 1 6 600 690V Frames 5 amp 6 The safety function for the following PowerFlex 700S Phase II AC Drives are approved to EN 954 1 Category 3 600V Frames 1 4 Installation and Wiring Installation and Wiring Installation must be in accordance with the following steps and must be carried out by suitably competent personnel This device is intended to be part of the safety related control system of a machine Before installation a risk assessment should be performed to determine whether the specifications of this device are suitable for all foreseeable operational and environmental characteristics of the machine to which it is to be fitted At regular intervals during the life of the machine check the safety function for proper operation How frequently the safety function is checked is dependent on the safety analysis of the machine section controlled by the drive Rockwell Automation Inc cannot accept responsibility for a failure of this device if the procedures given in this publication are not implemented or if it is used outside the recommended specifications in this publication ATTENTION The following information is merely a guide for proper installation Rockwell Automation Inc cannot assume
14. pment Installation and Wiring Option Board Installation Wiring Configure Hardware Enable Configure Digital Outputs 5 URS ion fi feo fic fico ino fino Linking Parameters ia Ico Verify Operation Description of Operation Supplemental Information amp amp S Certification ICO General Description General Description When used with suitable safety components the PowerFlex 700S Safe Off with Second Encoder option provides protection according to EN 954 1 1997 Category 3 for safe off and protection against restart The PowerFlex Safe Off option is just one safety control system All components in the system must be chosen and applied correctly to achieve the desired level of operator safeguarding What Is the PowerFlex Safe Off Option The PowerFlex Safe Off option e Is designed to safely remove power from the gate firing circuits of the Drive s output power devices IGBT s This prevents them from switching in the sequence necessary to generate torque in the motor e Can be used in combination with other safety devices to provide Category 0 Coast stop according to EN 60204 1 and NFPA 79 e The Safe Off option in the PowerFlex 700S provides Category 3 performance according to EN 954 1 Important The option is suitable for performing mechanical work on the drive system or affected area of a machine only It does not provide electrical safety
15. standteil dieses Zertifikates n Der Inhaber eines f r den Pr fgegenstand g ltigen Genehmigungs m n Ausweises ist berechtigt die mit dem Pr fgegenstand bereinstimmen den Erzeugnisse mit dem abgebildeten Pr fzeichen zu versehen The test report no 968 EZ 189 00 05 dated 2005 02 25 is an integral part of this certificate The holder of a valid licence certificate for the product tested is authorized to affix the test mark shown opposite to products which are identical with the product tested T V Rheinland V Industrie Service GmbH ftsfeld ASI AZ 4 2005 02 25 K Datum Date Firmenstempel Company seal Unterschrift Signature o www rockwellautomation com Corporate Headquarters Rockwell Automation 777 East Wisconsin Avenue Suite 1400 Milwaukee WI 53202 5302 USA Tel 1 414 212 5200 Fax 1 414 212 5201 Headquarters for Allen Bradley Products Rockwell Software Products and Global Manufacturing Solutions Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation SA NV Vorstlaan Boulevard du Souverain 36 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation 27 F Citicorp Centre 18 Whitfield Road Causeway Bay Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Headquarters for Dodge and Reliance Electric Products Americas Rockwel
16. tart Stop Common DI 24V DC Common Gate Control i BBB je Minotaur Power Supply MSR138DP Toy Safe Off Option X2 X3 X4 Y39 Y40 38 48 58 3 4 2 Gate Control 4 Circuit Common Enable Circuit Status Circuit shown with guard door closed and system ready for normal operation Operating Principle This is a dual channel system with monitoring of the safe off circuit and drive Opening the guard door will switch the input circuits S11 S12 amp S21 S22 to the Minotaur monitoring safety relay unit The immediate output circuits 13 14 will issue a Stop command to the drive and cause a controlled deceleration After the programmed delay the timed output circuits 47 48 amp 57 58 will cause the Safe Off option and the drive Enable circuit to go to a safe state off If the motor has not stopped rotating it will coast to stop To restart the drive the Minotaur safety relay inputs S11 S12 S21 S22 must first be ready for normal drive operation 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 to a safe state off at the next operation and will not cause loss of the safety function If the Safe Off option sticks ON the motor will stop on command due to the enable input The system cannot be reset and thereby rev
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