Rockwell Automation Allen-Bradley DriveGuard 20D-P2-DG01, User Manual

Page 1: ...User Manual Safe Torque Off Option for PowerFlex 700S Phase II AC Drives and PowerFlex 700L Liquid Cooled AC Drives Catalog Number 20D P2 DG01 Original Instructions ...

Page 2: ...uits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations Labels may also be on or inside the equipment to provide specific precautions WARNING Identifies information about practic...

Page 3: ... and PFH Data 12 PFDavg and PFH for 20 year Proof Test Interval 12 Functional Proof Tests 13 Contact Information if Safety Option Failure Occurs 13 Chapter 2 Installation and Wiring Pre Installation Instructions 15 Option Board Installation 16 PowerFlex 700S Frames 1 6 and PowerFlex 700L Frames 2 3A and 3B 16 PowerFlex 700S Frames 9 14 17 PowerFlex 700S All Frames and PowerFlex 700L All Frames 18 ...

Page 4: ...4 Rockwell Automation Publication 20D UM007H EN P August 2019 Table of Contents Notes ...

Page 5: ...rds 8 Updated the certification classifications in Evaluation Certification by TUV Rheinland Group 9 Updated link to certification data 9 Expanded Important Safety Considerations 10 Updated definition of PFH 12 Updated Functional Proof Test to include link to Verify Operations 13 Added introduction to Chapter 2 for user care and additional resources 15 Added PowerFlex 700L Frames 2 drive 16 Added ...

Page 6: ...6 Rockwell Automation Publication 20D UM007H EN P August 2019 Summary of Changes Notes ...

Page 7: ...Off option Is designed to help safely remove power from the gate firing circuits of the drive s output power devices IGBTs This helps prevent the drive s output power devices from switching in the pattern necessary to generate rotation at the motor Can be used in combination with other safety devices to satisfy the Safe Torque Off requirements of SIL CL2 according to EN 61800 5 2 IEC 61508 and EN ...

Page 8: ...y related systems ATTENTION Electrical Shock Hazard Verify that all sources of AC and DC power are de energized and locked out or tagged out in accordance with the requirements of ANSI NFPA 70E Part II ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged before performing any work on the drive Measure the DC bus voltage at the DC and DC terminals...

Page 9: ...TÜV Rheinland Group Certifications Online CE Declarations of Conformity Certificates and other certifications details are available online at the Product Certifications website https rok auto certifications Drive Rating 1 1 All voltages are listed in AC these values are also relevant to their corresponding DC input voltage ratings TUV Report on Safety Function TUV Certification PowerFlex 700S Phas...

Page 10: ...in accordance with the information in this manual access control to the system including password handling analyzing all configuration settings and choosing the proper setting to achieve the required safety rating 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 IMP...

Page 11: ...e external wiring of the safety inputs is not one of the faults that can be detected by the system therefore according to DIN EN ISO 13549 2 these cables must be installed so as to be protected against external damage by cable ducting or armor Stop Category Definitions The selection of a stop category for each stop function must be determined by a risk assessment Stop Category 0 is achieved with i...

Page 12: ...h Demand Continuous mode where the frequency of demands for operation made on a safety related system is greater than once per year or greater than twice the proof test interval The SIL value for a Low Demand safety related system is directly related to order of magnitude ranges of its average probability of failure to satisfactorily perform its safety function on demand or simply average probabil...

Page 13: ... on page 28 for additional information 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 analy...

Page 14: ...14 Rockwell Automation Publication 20D UM007H EN P August 2019 Chapter 1 General Description Notes ...

Page 15: ...e DriveGuard Safe Torque Off option is intended to be part of the safety related 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 A safety analysis of the machine section controlled by th...

Page 16: ... PowerFlex 700S Frames 1 6 and PowerFlex 700L Frames 2 3A and 3B 1 Remove the I O Control Cassette from the drive Task Description Open the door of the power structure and disconnect the cables that connect to the main board Loosen the screws on the face of the cassette Remove the cassette A B C B C A PowerFlex 700S shown ...

Page 17: ...m the drive Task Description Open the door of the power structure and carefully disconnect the three cables that connect to the main board Loosen the thumb screw that holds the metal flange in place Swing the flange and cassette away from the control frame Loosen the screws on the face of the cassette Remove the cassette A B C D E B A Typical Frames 10 14 C E D ...

Page 18: ...s and PowerFlex 700L All Frames 2 Remove the screws securing the interior cassette cover to gain access to the Main board 3 Remove the 2 pin shunt jumper from the 16 15 pin position 16 15 IMPORTANT If the DriveGuard Safe Torque Off option is removed from the drive this jumper must be reinstalled or the drive will not run ...

Page 19: ...Rockwell Automation Publication 20D UM007H EN P August 2019 19 Installation and Wiring Chapter 2 4 Remove the exterior cassette covers to access the grounding plate ...

Page 20: ...20D UM007H EN P August 2019 Chapter 2 Installation and Wiring 5 Install the 16 pin stacker connector 6 Plug the DriveGuard Safe Torque Off option into the 16 pin connector 7 Install and tighten mounting screws 0 8 1 1 N m 7 0 10 0 lb in ...

Page 21: ...Rockwell Automation Publication 20D UM007H EN P August 2019 21 Installation and Wiring Chapter 2 8 Install the exterior cassette covers 0 8 1 1 N m 7 0 10 0 lb in ...

Page 22: ...cation 20D UM007H EN P August 2019 Chapter 2 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 0 8 1 1 N m 7 0 10 0 lb in ...

Page 23: ...ONS Firmware Date Firmware 20 HIM 28 IO 20 COMM 20B_ DB1 HIM I O COM Module Internal Dynamic Brake Date Use marker to note addition of DriveGuard Safe Torque Off option FIELD INSTALLED OPTIONS Firmware Date Firmware 20 HIM 28 IO 20 COMM 20B_ DB1 HIM I O COM Module Internal Dynamic Brake Date Frame 10 shown Use marker to note addition of DriveGuard Safe Torque Off option ...

Page 24: ...s 3A and 3B Input Filter Bay Power Module Bay Power Module Front Bottom Covers Removed Power Module Bay Door Cutaway DANGER DANGER FIELD INSTALLED OPTIONS Firmware Date Firmware 20 HIM 28 IO 20 COMM 20B_ DB1 HIM I O COM Module Internal Dynamic Brake Date Use marker to note addition of DriveGuard Safe Torque Off option ...

Page 25: ...ck 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 Minimum Insulation Rating Unshielded Per US NEC or applicable national or local code NOT RECOMMENDED 300V 60 degrees C 140 degrees F Shielded Multi conductor shielded cable such as Belden 8770 or equiv 0 750 mm2 18AWG 3...

Page 26: ... 4 HW Enable No HW Enable Jumper P22 1 2 3 4 1 2 3 4 IMPORTANT In addition to the correct jumper setting enable circuitry must be connected to I O Terminals 13 and 16 For wiring examples refer to the following publications PowerFlex 700S Phase II Drive Frames 1 6 Installation Instructions publication 20D IN024 PowerFlex 700H and 700S Drive Frames 9 14 Installation Instructions publication PFLEX IN...

Page 27: ...r 855 Rly Out3 Sel to option 0 User Select 3 Link Par 846 Dig Out1 Data Par 851 Dig Out2 Data or Par 856 Rly Out3 Data to Par 324 Fault Status 2 See Linking Parameters below 4 Set Par 847 Dig Out1 Bit Par 852 Dig Out2 Bit or Par 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 Out1 Data Par 851 Dig Out2...

Page 28: ...ion for proper operation after initial installation of the DriveGuard Safe Torque Off option Retest the safety function at the intervals determined by the safety analysis described on page 15 Verify that both safety channels are functioning according to Table 4 below Table 4 Channel Operation and Verification Safety Function Status Drive In Safe State Drive In Stopped State Drive In Stopped State ...

Page 29: ...e Torque Off relay is de energized parameter 156 Start Inhibits bit 16 GateShutDown is set to 1 If both inputs are de energized only bit 1 No Enable will be set to 1 because it takes precedence To meet EN ISO 13849 1 PL d Category 3 operation both safety channel inputs to the drive must be de energized to safely turn off output to the motor Refer to the following examples for details IMPORTANT The...

Page 30: ... Description of Operation Figure 1 Drive Safe Torque Off Circuitry 24V DC PowerFlex 700S 700L Stop Start Start Stop Common 24V DC Common 3 4 1 2 Safe Off Option AC Line Input Power Common Enable M Gate Control Power Supply Gate Control Circuit Safety Channel Safety Channel ...

Page 31: ...oring safety relay unit The output circuits 13 14 23 24 will cause the Safe Torque Off option and drive Enable circuit to trip and the 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...

Page 32: ...able circuit to trip and the motor will coast to stop After the programmed delay the timed output circuits 57 58 will cause the Safe Torque Off option circuit to trip To restart the drive the Minotaur safety relay must first be reset followed by a valid start command to the drive Application Considerations When the hazard analysis for the overall machine determines the need for external mechanical...

Page 33: ...with Controlled Stop Action Dual Channel Figure 4 Stop Category 1 Controlled Circuit Status Circuit shown with guard door closed and system ready for normal operation 24V DC Common 24V DC GuardMaster Trojan Stop Start A1 S21S11S52S12 A2 X1 X2 13 23 14 24 S33 Y2 S34 Y1 X3 37 47 57 38 48 58 X4 S22 Y39Y40 Minotaur MSR138DP Gate 24V DC PowerFlex 700S 700L Stop Start Start Stop Common 24V DC Common 3 4...

Page 34: ...l 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 due to the...

Page 35: ...Rockwell Automation Publication 20D UM007H EN P August 2019 35 Description of Operation Chapter 3 Notes ...

Page 36: ...36 Rockwell Automation Publication 20D UM007H EN P August 2019 Chapter 3 Description of Operation ...

Page 37: ... operation 29 F functional proof tests 13 H hardware enable configuration 26 I important safety considerations 10 L linking parameters 27 M machine safety standards 8 O option board pre installation instructions 15 terminal block specifications 25 wiring 25 P performance level 12 PFDavg data 12 definition 12 PFH data 12 definition 12 S safety category 3 definition 11 safety certifications 9 safety...

Page 38: ...40 Rockwell Automation Publication 20D UM007H EN P August 2019 Notes ...

Page 39: ...hs_bkcvr fm Page 41 Tuesday October 8 2019 3 28 PM ...

Page 40: ...ct dial page Literature Library Installation Instructions Manuals Brochures and Technical Data http www rockwellautomation com global literature library overview page Product Compatibility and Download Center PCDC Get help determining how products interact check features and capabilities and find associated firmware http www rockwellautomation com global support pcdc page Publication20D UM007H EN ...