PFLEX-UM003.
PFLEX-UM003.fm Page 2 Wednesday, July 18, 2012 8:26 AM General Description General Description The DriveGuard Safe Torque Off option, when used with PowerFlex 40P or PowerFlex 70 drives together with other safety components, provides a safety function which inhibits torque generation in the motor(s) powered by the drive.
PFLEX-UM003.fm Page 3 Wednesday, July 18, 2012 8:26 AM General Description ATTENTION: Electrical Shock Hazard. Verify that all sources of AC and DC power are de-energized and locked out or tagged out in accordance with the requirements of ANSI/NFPA 70E, Part II. ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged before performing any work on the drive.
PFLEX-UM003.fm Page 4 Wednesday, July 18, 2012 8:26 AM General Description CE Certification LV Directive 2006/95/EC Rockwell Automation declares the PF40P and PF70 drives compliant with the CE LV Directive as demonstrated by compliance with the requirements of EN 50178 Electronic equipment for use in power installations. The DriveGuard Safe Torque Off Option Kit is not within the scope of the Low Voltage Directive.
PFLEX-UM003.fm Page 5 Wednesday, July 18, 2012 8:26 AM General Description Certified Equipment Drive Rating PowerFlex 40P 240V 480V PowerFlex 70 Enhanced 240V Control 400V 480V TUV Certified ✔ ✔ ✔ ✔ ✔ DriveGuard Safe Torque Off Function Series B or greater Series B or greater Series A or greater Series A or greater Series A or greater ATTENTION: Hazard of injury exists due to electric shock. Only install a Series B or greater DriveGuard Safe Torque Off option in a PowerFlex 40P Drive.
PFLEX-UM003.fm Page 6 Wednesday, July 18, 2012 8:26 AM General Description Safe State The DriveGuard Safe Torque Off option is intended for use in safety-related applications where the de-energized state is the safe state. All of the examples in the Description of Operation section are based on achieving the de-energization as the safe state.
PFLEX-UM003.fm Page 7 Wednesday, July 18, 2012 8:26 AM General Description Stop Category Definitions The selection of a stop category for each stop function must be determined by a risk assessment. • Stop Category 0 is achieved with immediate removal of power to the actuator, resulting in an uncontrolled coast to stop. See “Description of Operation” Example 1 on page 20. • Stop Category 1 is achieved with power available to the machine actuators to achieve the stop.
PFLEX-UM003.fm Page 8 Wednesday, July 18, 2012 8:26 AM General Description The SIL value for a low demand safety-related system is directly related to order-of-magnitude ranges of its average probability of failure to satisfactorily perform its safety function on demand or, simply, average probability of failure on demand (PFD). The SIL value for a High Demand/Continuous mode safety-related system is directly related to the probability of a dangerous failure occurring per hour (PFH).
PFLEX-UM003.fm Page 9 Wednesday, July 18, 2012 8:26 AM General Description Functional Proof Tests The functional safety standards require that functional proof tests be performed on the equipment used in the system. Proof tests are performed at user-defined intervals and are dependent upon PFD and PFH values. IMPORTANT Your specific application determines the time frame for the proof test interval.
PFLEX-UM003.fm Page 10 Wednesday, July 18, 2012 8:26 AM Installation and Wiring Installation and Wiring Pre-Installation Instructions Installation must be in accordance with the following steps and must be carried out by competent personnel. The DriveGuard Safe Torque Off option is intended to be part of the safety related control system of a machine.
PFLEX-UM003.fm Page 11 Wednesday, July 18, 2012 8:26 AM Installation and Wiring EMC Considerations The DriveGuard Safe Torque Off option and PF40P and PF70 drives may be installed in an industrial electromagnetic environment which is consistent with the “Second Environment” described in IEC 61800-3 and where the EMC requirements documented in the PF40P and PF70 Installation manuals have been satisfied.
PFLEX-UM003.fm Page 12 Wednesday, July 18, 2012 8:26 AM Installation and Wiring 2. Remove the protective plug covering the PowerFlex 40P Safe Torque Off connector shown in Figure 1. Figure 1 - PowerFlex 40P Protective Plug 3. Remove the PowerFlex 40P Safe Torque Off connection jumper shown in Figure 2.
PFLEX-UM003.fm Page 13 Wednesday, July 18, 2012 8:26 AM Installation and Wiring 4. Remove the PowerFlex 40P Hardware Enable jumper shown in Figure 3. Figure 3 - PowerFlex 40P Hardware Enable Jumper Location 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 command is issued. 5.
PFLEX-UM003.fm Page 14 Wednesday, July 18, 2012 8:26 AM Installation and Wiring Figure 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 is issued. 3.
PFLEX-UM003.fm Page 15 Wednesday, July 18, 2012 8:26 AM Installation and Wiring Figure 7 - PowerFlex 70 Safe Torque Off Connector 0.8…1.1 N•m (7…10 lb•in) 4. Tighten screw to 0.8…1.1 N•m (7…10 lb•in). Wiring Important points to remember about wiring: • Always use copper wire. • Wire with an insulation rating of 600V or greater is recommended. • Control wires should be separated from power wires by at least 0.3 meters (1 foot).
PFLEX-UM003.fm Page 16 Wednesday, July 18, 2012 8:26 AM Installation and Wiring DriveGuard Safe Torque Off Option Terminal Description No. Signal 1 Monitor - N.C. 2 4 3 21 Description Normally closed contacts for monitoring relay status. Common - N.C. Maximum Resistive Load: 250V AC / 30V DC / 50 VA / 60 Watts Maximum Inductive Load: 250V AC / 30V DC / 25 VA / 30 Watts 3 +24V DC 4 24V Common Connections for user supplied power to energize coil. 33.3 mA typical, 55 mA maximum.
PFLEX-UM003.fm Page 17 Wednesday, July 18, 2012 8:26 AM Installation and Wiring PowerFlex 40P Channel Operation and Verification Safety Function Status Drive In Safe State Safe Torque Off Option Terminals 3 & 4 PowerFlex 40P Enable Input Safe Torque Off Option Monitor Contact Terminals 1 & 2 PowerFlex 40P [Control In Status] Param. 13, Bit 2 PowerFlex 40P Comms Status Word 8448, Bit 0 Safe Torque Off Output(1) Relay N.O.
PFLEX-UM003.fm Page 18 Wednesday, July 18, 2012 8:26 AM Description of Operation Description of Operation PowerFlex 40P Safe Torque Off Operation The DriveGuard Safe Torque Off option for PowerFlex 40P (see Figure 8) disables the drive’s output IGBT’s by breaking the link with the drive microcontroller. When used in combination with a second safety channel (the Enable input), the system satisfies the requirements of EN ISO 13849-1, Category 3 / PL (d) for Safe Torque Off and helps protect against restart.
PFLEX-UM003.fm Page 19 Wednesday, July 18, 2012 8:26 AM Description of Operation PowerFlex 70 Safe Torque Off Operation The PowerFlex 70 DriveGuard Safe Torque Off option (see Figure 9) 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 ISO 13849-1, Category 3 / PL (d) for Safe Torque Off and helps protect against restart.
PFLEX-UM003.fm Page 20 Wednesday, July 18, 2012 8:26 AM Description of Operation Connection Examples Example 1 - Safe Torque Off Connection with Coast-to-Stop Action, Dual Channel Figure 10 - Stop Category 0 – Coast AC Line Input Power PowerFlex AC Drive +24V DC +24V DC Gate GuardMaster Trojan Stop Stop A1 S21 S13 31 13 23 X1 Minotaur MSR9T A2 S22 S14 Start Start Safe Off Option 32 14 24 X2 4 3 2 +24V DC Common 1 Common *Important: The drive Enable digital input is a solid state circuit.
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PFLEX-UM003.fm Page 24 Wednesday, July 18, 2012 8:26 AM *PN-163523* PN-163523 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 www.rockwellautomation.com Power, Control and Information Solutions Headquarters Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.
