Allen-Bradley PowerFlex 40P User manual

Safe-Off Option (Series B)
for PowerFlex®40P and
PowerFlex®70 AC Drives
User Manual
www.abpowerflex.com

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.rockwellautomation.com/literature) 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 contents of this manual, in whole or in part, without written
permission of Rockwell Automation, Inc. is prohibited.
Throughout this manual we use notes to make you aware of safety considerations.
Attentions help you:
•identify a hazard
•avoid the hazard
•recognize the consequences
Important: Identifies information that is especially important for successful
application and understanding of the product.
DriveExplorer, DriveTools32, and SCANport are trademarks of Rockwell Automation.
PLC is a registered trademark of Rockwell Automation.
ControlNet is a trademark of ControlNet International, Ltd.
DeviceNet is a trademark of the Open DeviceNet Vendor Association.
!
ATTENTION: Identifies information about practices or circumstances
that can lead to personal injury or death, property damage, or economic
loss.
Shock Hazard labels may be located on or inside the drive to alert
people that dangerous voltage may be present.

Table of Contents
Summary of Changes
This is the initial release of the DriveGuard Safe-Off Option (Series B)
User Manual.
Section Page
General Description 2
What Is the DriveGuard Safe-Off Option? 2
Safety of Machinery Standards 3
EMC Instructions 3
Approved/Certified Equipment 3
Installation and Wiring 4
DriveGuard Safe-Off Option Installation 5
Wiring 9
Verify Operation 10
Description of Operation 11
PowerFlex 40P Safe-Off Operation 11
PowerFlex 70 Safe-Off Operation 12
Connection Examples 13
Supplemental Information 15
PowerFlex 40P Certification 15
PowerFlex 70 Enhanced Control Certification 16

English-2 General Description
General Description
The DriveGuard Safe-Off option, when used with other safety
components, helps provide protection according to EN 954-1:1997;
Category 3 for safe-off and protection against restart. The DriveGuard
Safe-Off option is just one component in a safety control system.
Components in the system must be chosen and applied appropriately to
achieve the desired level of operator safeguarding.
The DriveGuard Safe-Off Option Board:
•Is designed to help safely remove power from the gate firing circuits
of the drive’s output power devices (IGBT’s). This helps prevent the
drive’s output power devices from switching in the pattern necessary
to generate AC power to the motor.
•Can be used in combination with other safety devices to satisfy the
requirements of EN 954-1, Category 3 for safe-off and help protect
against restart.
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.
What Is the DriveGuard Safe-Off Option?
!
ATTENTION: Electric Shock Hazard. Verify that all sources of AC
and DC power are deenergized 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 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 English-3
The DriveGuard Safe-Off option meets the following council directives:
•EN 60204-1 Safety of machinery – Electrical equipment of machines
– Part 1: General Requirements
•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://www.ab.com/certification/ce/docs.
Low Voltage Directive (73/23/EEC)
•EN50178 Electronic equipment for use in power installations
EMC Directive (89/336/EEC)
•EN61800-3 Adjustable speed electrical power drive systems Part 3:
EMC product standard including specific test methods.
Safety of Machinery Standards
EMC Instructions
Approved/Certified Equipment
Drive Rating TUV Certified
DriveGuard
Safe-Off Option
PowerFlex 40P 240V ✔Series B or greater
480V ✔Series B or greater
PowerFlex 70
Enhanced Control
240V ✔Series A or greater
400V ✔Series A or greater
480V ✔Series A or greater
!
ATTENTION: Hazard of injury exists due to electric shock. Only
install a Series B or greater DriveGuard Safe-Off option in a PowerFlex
40P Drive.

English-4 Installation and Wiring
Installation and Wiring
The DriveGuard Safe-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-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 the drive is
required to determine how often the safety function should be tested for
proper operation during the life of the machine.
!
ATTENTION: The following information is merely a guide for proper
installation. Rockwell Automation, Inc. cannot assume 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 English-5
PowerFlex 40P Drives
1. Remove all power to the drive.
2. Remove the protective plug covering the PowerFlex 40P Safe-Off
connector shown in Figure 1.
Figure 1 PowerFlex 40P Protective Plug
3. Remove the PowerFlex 40P Safe-Off connection jumper shown in
Figure 2.
Figure 2 PowerFlex 40P Safe-Off Connection Jumper Location
DriveGuard Safe-Off Option Installation
!
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.

English-6 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-Off option.
Failure to remove the jumper may cause the drive to fault.
5. Plug the DriveGuard Safe-Off option (Series B or greater) into the
PowerFlex 40P four pin safe-off connector as shown in Figure 4.
Figure 4 PowerFlex 40P Safe-Off Connector
6. Tighten screw to 0.8-1.1 N-m (7-10 lb.-in.).
0.8-1.1 N-m
(7-10 lb.-in.)

Installation and Wiring English-7
PowerFlex 70 Drives
1. Remove the PowerFlex 70 Safe-Off Connection jumper as shown in
Figure 5.
Figure 5 PowerFlex 70 Safe-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-Off option.
Failure to remove the jumper will cause the drive to fault
when a start command is issued.

English-8 Installation and Wiring
3. Plug the DriveGuard Safe-Off option (Series A or greater) into the
PowerFlex 70 four pin connector as shown in Figure 7.
Figure 7 PowerFlex 70 Safe-Off Connector
4. Tighten screw to 0.8-1.1 N-m (7-10 lb.-in.).
0.8-1.1 N-m
(7-10 lb.-in.)

Installation and Wiring English-9
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).
Table 1 DriveGuard Safe-Off Option Terminal Block Specifications
Table 2 Wire Types
Table 3 DriveGuard Safe-Off Option Terminal Description
Wiring
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
Minimum
Insulation Rating
Unshielded Per US NEC or applicable
national or local code
— 300V,
60 degrees C
(140 degrees F)
Shielded Multi-conductor shielded cable
such as Belden 8770(or equiv.)
0.750 mm2(18AWG),
3 conductor, shielded.
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 VA / 30 Watts
2 Common - N.C.
3 +24V DC Connections for user supplied power to
energize coil.
33.3 mA typical, 55 mA maximum.
4 24V Common
1234

English-10 Installation and Wiring
Test the safety function for proper operation after the initial installation
of the DriveGuard Safe-Off option. Retest the safety function at the
intervals determined by the safety analysis described on page 4.
Verify that both safety channels are functioning according to the
drive-specific tables below.
Table 4 PowerFlex 40P Channel Operation and Verification
Table 5 PowerFlex 70 Channel Operation and Verification
Verify Operation
Safety Function
Status
Drive In
Safe State
Drive In
Stopped State
Drive In
Stopped State
Drive Able
To Run
Safety Channel Operation
Safe-Off Option
Terminals 3 & 4
No Power
Applied
Power Applied No Power
Applied
Power Applied
PowerFlex 40P
Enable Input
No Power
Applied
No Power
Applied
Power Applied Power Applied
Description For Verification
Safe-Off Option
Monitor Contact
Terminals 1 & 2
Closed Open Closed Open
PowerFlex 40P
[Control In Status]
Param. 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-Off Output(1)
Relay N.O.
Dig Output States
(1) Must set A055 [Relay Out Sel], A058 or A061 [Opto Outx Sel] to option 25 “Safe-Off”.
Closed Open Open Open
Safety Function
Status
Drive In
Safe State
Drive In
Stopped State
Drive In(1)
Stopped State
(1) A Start/Run command will cause an F111 “Enable Hardware” fault.
Drive Able
To Run
Safety Channel Operation
Safe-Off Option
Terminals 3 & 4
No Power
Applied
Power Applied No Power
Applied
Power Applied
PowerFlex 70
Enable Input
No Power
Applied
No Power
Applied
Power Applied Power Applied
Description For Verification
Safe-Off Option
Monitor Contact
Terminals 1 & 2
Closed Open Closed Open
PowerFlex 70
Drive Inhibits
Param. 214, Bit 2
Value = 1 Value = 1 Value = 0 Value = 0

Description of Operation English-11
Description of Operation
The DriveGuard Safe-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 954-1,
Category 3 for safe-off and helps protect against restart.
Under normal drive operation, the Safe-Off relay is energized, the enable
input is energized, and the drive is able to run. If either input is
de-energized, the gate control circuit becomes disabled. To meet EN
954-1, Category 3 operation, both safety channels must be de-energized.
Refer to the following examples for details.
Important: By itself, the Safe-Off option initiates a coast-to-stop
action. Additional protective measures will need to be
applied when an application requires a change to the stop
action.
Figure 8 PowerFlex 40P Drive Safe-Off Circuitry
PowerFlex 40P Safe-Off Operation
+24V DC
PowerFlex 40P
AC Drive
Stop
Start
1
2
3
4
Safe Off Option
AC Line
Input Power
Common
Enable
M
Gate Control
From Microcontroller
Gate Control
Circuit
Safety
Channel
Safety
Channel

English-12 Description of Operation
The PowerFlex 70 Safe-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 954-1, Category 3 for safe-off
and helps protect 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 channels
must be de-energized. Refer to the following examples for details.
Important: By itself, the Safe-Off option initiates a coast-to-stop
action. Additional protective measures will need to be
applied when an application requires a change to the stop
action.
Figure 9 PowerFlex 70 Drive Safe-Off Circuitry
PowerFlex 70 Safe-Off Operation
+24V DC
PowerFlex 70
AC Drive
Stop
Start
1
2
3
4
Safe Off Option
AC Line
Input Power
Common
Enable
M
Gate Control
Power Supply
Gate Control
Circuit
Safety
Channel
Safety
Channel

Description of Operation English-13
Example 1
Safe-Off Connection with Coast-to-Stop Action, Dual Channel
Figure 10 Stop Category 0 – Coast
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 &
S21-S22) to the Minotaur monitoring safety relay unit. The output
circuits (13-14 & 23-24) will cause the Safe-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 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 when this fault condition
exists.
Connection Examples
Stop
Start
A1 S21 S13 31 13 23 X1
A2
+24V DC
Common
+24V DC
S22 S14 32 14 24 X2
Minotaur
MSR9T
GuardMaster
Trojan
Gate
+24V DC
PowerFlex
AC Drive
Stop
Start
1
2
3
4
Safe Off Option
AC Line
Input Power
Common
Enable
M

English-14 Description of Operation
Example 2
Safe-Off Connection with Controlled Stop Action, Dual Channel
Figure 11 Stop Category 1 – Controlled
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 (S11-S12 &
S21-S22) to the Minotaur monitoring safety relay unit. The 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 & 57-58) will cause the Safe-Off option and the drive
Enable circuit to trip. If the motor is rotating when the trip occurs, it 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-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.
+24V DC
Common
+24V DC
GuardMaster
Trojan
Stop
Start
A1 S21 S11 S52 S12
A2 X1 X2
13 23
14 24
S33
Y2
S34
Y1X3
37 47 57
38 48 58X4
S22
Y39 Y40
Minotaur
MSR138DP
Gate
+24V DC
PowerFlex
AC Drive
Stop
Start
1
2
3
4
Safe Off Option
AC Line
Input Power
Common
Enable
M

Supplemental Information English-15
Supplemental Information
PowerFlex 40P Certification

English-16 Supplemental Information
PowerFlex 70 Enhanced Control Certification

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Publication PFLEX-UM003A-EN-P – June 2006 329055-P01
Copyright © 2006 Rockwell Automation, Inc. All rights reserved. Printed in USA.